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Teledyne M300EM operation manual Zero/Span Point Calibration Procedure

Models: M300E M300EM

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9.3.3.2.Zero/Span Point Calibration Procedure

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

Calibration Procedures

9.3.3.2.Zero/Span Point Calibration Procedure

The zero and cal operations are initiated directly and independently with dedicated keys (CALZ & CALS).

04288D DCN5752

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Teledyne M300EM operation manual Zero/Span Point Calibration Procedure

Contents

Operation Manual TELEDYNE ADVANCED POLLUTION INSTRUMENTATION9480 CARROLL PARK DRIVE SAN DIEGO, CA USA MODEL 300E FAMILY CARBON MONOXIDE ANALYZERSPage SAFETY MESSAGES This page intentionally left blank Safety MessagesCOVERAGE WARRANTYWARRANTY POLICY 02024D CAUTION – Avoid Warranty Invalidation04288D DCN5752 This page intentionally left blankName/Description ABOUT THIS MANUALinstrument Part NoChange Summary REVISION HISTORY2010 June DocumentRevision 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 11. THEORY OF OPERATION 10. EPA CALIBRATION PROTOCOLPART III – TECHNICAL INFORMATION xiii13. 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 SPECIFICATIONS AND WARRANTY 1.2.1.USING THIS MANUALTABLE OF CONTENTS PART I – GENERAL INFORMATIONMAINTENANCE SCHEDULE AND PROCEDURES PART III – TECHNICAL INFORMATIONAPPENDICES ADVANCED FEATURES OF THE M300E/EM ANALYZER2.1.SPECIFICATIONS 2.SPECIFICATIONS AND APPROVALSTable 2-1:M 300E/300EM Basic Unit Specifications 2.2.EPA EQUIVALENCY DESIGNATION 2.4.1.EMISSIONS COMPLIANCE 2.4.2.SAFETY COMPLIANCE2.3.TUV DESIGNATION 2.4.CE MARK COMPLIANCEThis page intentionally left blank Specifications and ApprovalsFront Panel Layout 3.GETTING STARTED3.1.M300E/EM ANALYZER LAYOUT FigureSAMPLE Table 3-2:Inlet / Outlet Connector NomenclatureFigure Rear Panel LayoutFigure 3-3:Internal Layout – M300E Getting StartedGetting Started Figure 3-5:Optical Bench Layout Figure 3-6:M300E/EM Internal Gas Flow Basic Configuration ELECTRICAL SHOCK HAZARD 3.2.UNPACKING THE M300E/EM ANALYZERGENERAL SAFETY HAZARD power CAUTION – Avoid Warranty InvalidationDo not defeat the ground wire on power plug 3.3.1.POWER CONNECTION3.3.ELECTRICAL CONNECTIONS 3.2.1.VENTILATION CLEARANCEFigure 3.3.3.CONNECTING THE STATUS OUTPUTS3.3.2.ANALOG OUTPUT CONNECTIONS Analog Output ConnectorREAR PANEL Figure 3-8:Status Output ConnectorTable 3-5:Status Output Signals STATUSFigure 3.3.4.CONNECTING THE CONTROL INPUTSControl Input Connector Table 3-6:Control Input Signals3.4.PNEUMATIC CONNECTIONS 3.3.5.CONNECTING THE SERIAL PORTS3.3.6.CONNECTING TO A LAN OR THE INTERNET 3.3.7.CONNECTING TO A MULTIDROP NETWORK3.4.1.2.Span Gas area or shelter surrounding the instrument GENERAL SAFETY HAZARDexhaust and supply gas lines glass, stainless steel or brass3.4.2.2.Calibration Gas Sources 3.4.2.1.Sample Gas Sourceof the analyzer using the procedures defined in Section 3.5.INITIAL OPERATION3.4.2.3.Input Gas Venting 3.4.2.4.Exhaust Outletautomatically begins its initialization routine 3.5.1.STARTUPconfiguration and calibration data System waits 3 seconds then3.5.3.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 ENTR is set for SNGLIf it is not, press SINGL3.6.2.2.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 PPMTHANK YOU 3.6.3.O2 SENSOR CALIBRATION PROCEDURE3.6.4.CO2 SENSOR CALIBRATION PROCEDURE The M300E/EM Analyzer is now ready for operation4.1.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 5.6.1.1.Gas Flow Rate 5.5.EXPENDABLES AND SPARES KITS OPTIONS 42A,5.6.CALIBRATION VALVES OPTIONS 50A, 50B, 50E, 50H 5.6.2.ZERO/SPAN VALVE OPTION 50AFigure 5.6.2.1.Internal Pneumatics OPT 50ASAMPLE GAS SOURCE 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.3.Input Gas Venting 5.6.2.4.Exhaust Outlet5.6.3.1.Internal Pneumatics OPT 50B 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50BFigure ZERO AIR 5.6.3.2.Pneumatic Set Up OPT 50BSAMPLE GAS SOURCE CALIBRATION GAS SOURCES SPAN GAS5.6.4.1.Internal Pneumatics OPT 50H ZERO AIR 5.6.4.2.Pneumatic Set Up OPT 50HSAMPLE GAS SOURCE CALIBRATION GAS SOURCES SPAN GASScrubber 5.6.5.1.Internal Pneumatics OPT 50EZERO AIR 5.6.5.2.Pneumatic Set Up OPT 50ESAMPLE GAS SOURCE CALIBRATION GAS SOURCES SPAN GASTable 5-5:M300E/EM Modem Cable Options 5.7.COMMUNICATION OPTIONS5.7.1.RS-232MODEM CABLE OPTION 60A 5.7.2.RS-232MULTIDROP OPTIONFigure 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 Analyzer5.9.2.1.NDIR measurement of CO2 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS5.9.CARBON DIOXIDE SENSOR OPTION 67A 5.9.2.THEORY OF OPERATION5.9.2.3.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 5.11.1.DILUTION RATIO OPTION 5.11.SPECIAL FEATURES5.11.2.MAINTENANCE MODE SWITCH 5.11.3.SECOND LANGUAGE SWITCHOPERATING INSTRUCTIONS PART – OPERATING INSTRUCTIONSThis page intentionally left blank OPERATING INSTRUCTIONSEXPLANATION 6.BASIC OPERATION6.1.OVERVIEW OF OPERATING MODES MODEanalyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Test Functions Defined TableTable 6-3:List of Warning Messages 6.3.WARNING MESSAGESMEANING The IR source may be faultycurrently selected reporting range EXAMPLES 6.4.CALIBRATION MODEinstrument until the ENTR Key is pressed 6.5.SETUP MODEPrimary Setup Mode Features and Functions Secondary Setup Mode Features and Functions6.5.2.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 M300E Table 6-7:M300E Family Physical range by ModelMODEL RANGEFigure 6-4:Analog Output Connector Pin Out 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATIONANALOG OUT AUTO 6.6.3.REPORTING RANGE MODESSNGL DUALPage The two ranges must be independently calibrated concentrationsBasic Operation computing the CO concentration discards the new setting accepts the new settingToggle these keys to select the upper limit for the reporting rangesufficient Basic Operationreporting units Pressure STPUsing the dilution ratio option is a 4-stepprocess This page intentionally left blank Basic OperationIDAS STATUS 7.ADVANCED FEATURES7.1.1.IDAS STATUS LED STATE7.1.2.1.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 ALLOWED 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSDEFAULT Table 7-4:Variable Names VARSSETUP settingaccepts the new setting SETUPDIAG I/O Table 7-5:Diagnostic Mode DIAG FunctionsSIGNAL I/O CONFIGURATION7.3.1.ACCESSING THE DIAGNOSTIC FEATURES OUTPUT 7.4.USING THE M300E/EM ANALYZER’S ANALOG OUTPUTSTable 7-6:DIAG - Analog I/O Functions SUB MENUPage MINIMUM OUTPUT Table 7-7:Analog Output Voltage Range Min/MaxRANGE NAME RANGE SPAN04288D 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 Resistor for 4-20mA % FSVoltage across Resistor for 2-20mAPage Page FULL SCALE TEST CHANNELDESCRIPTION ZEROSETUP settingnew setting 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 1024 8.1.4.COMM PORT COMMUNICATION MODES8192 2048Remote 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 Table 8-3:Teledyne API’s Serial I/O Command Types 8.1.7.2.Command Syntax8.1.7.3.Data Types X ID COMMAND <CR>X DDD:HH:MM Id MESSAGE<CRLF> 8.1.7.4.Status ReportingV RS-232_PASS=NNNNNN 8.1.7.5.COMM Port Password Security940331 is the default password LOGON8.2.MULTIDROP RS-232SET UP Last INSTRUMENT HostCALIBRATOR TAPI AnalyzerFigure 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 ETHERNETPROPERTY Table 8-5:LAN/Internet Configuration PropertiesDEFAULT STATE See your network administratorRemote Operation ∙Your LAN is not running a DHCP software package SETUP ON/OFFSETUP PRIMARY SETUP MENUInserts a character before the cursor location FUNCTIONMoves the cursor one character to the left or rightEXIT 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEFUNCTION ENTRMinimum 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 TEXT 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODEMODE ID MODE DESCRIPTIONO2, 0, 312, REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESGAS TYPE,RANGE,GAS ID,REPORTED CO, 0, 310, REPORTED CO2, 0, 311, REPORTED8.6.6.2.Editing or Adding HESSEN Gas List Entries 8.6.6.3.Deleting HESSEN Gas List Entries STATUS FLAG NAME 8.6.7.SETTING HESSEN PROTOCOL STATUS FLAGSTable 8-8:Default Hessen Status Flag Assignments DEFAULT BIT8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS 9.CALIBRATION PROCEDURESCalibration Procedures SECTION 9.1 – BEFORE CALIBRATIONtroubleshooting tips 9.1.BEFORE CALIBRATION9.1.2.CALIBRATION GASES 9.1.2.1.Zero Aircalibration 9.1.3.DATA RECORDING DEVICES9.1.2.2.Span Gas 9.1.2.3.Traceabilityand 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 ACTION 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCALTable 9-2:AUTOCAL Modes MODE NAMEACTION Table 9-3:AutoCal Attribute Setup ParametersTIMER ENABLED ATTRIBUTEZERO-SPAN MODE ANDVALUE COMMENTfrom the display SETUP X.X STARTING DATE: 04–SEP–08 for each MINIMUM VALUE 9.5.CO CALIBRATION QUALITYTable 9-5:Calibration Data Quality Evaluation FUNCTIONDAS RNGE PASS CLK MORE 9.6.1.DARK CALIBRATION TESTSETUP SETUPatmospheric pressure 9.6.2.PRESSURE CALIBRATION9.6.3.FLOW CALIBRATION 9.6.4.ELECTRICAL TEST CALIBRATION Figure 9-7:O2 Sensor Calibration Set Up 9.7.1.O2 SENSOR CALIBRATION PROCEDURE9.7.1.1.O2 Calibration Setup 9.7.CALIBRATION OF OPTIONAL SENSORSSet 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 CALIBRATIONFigure 9-8:CO2 Sensor Calibration Set Up 9.7.2.CO2 SENSOR CALIBRATION PROCEDURE9.7.2.1.CO2 Calibration Setup 9.7.2.2.Set CO2 Span Gas Concentrationcomplete 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 10.4.2.DATA REDUCTION AUDIT 10.4.AUDITING PROCEDURE10.3.1.PRECISION CALIBRATION PROCEDURES 10.4.1.CALIBRATION 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 information11.1.1.BEER’S LAW 11.THEORY OF OPERATION11.1.MEASUREMENT METHOD 11.2.MEASUREMENT FUNDAMENTALSFigure 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 Rejectionover ambient pressure 11.3.PNEUMATIC OPERATIONGENERAL SAFETY HAZARD maintenance schedule, Table11.4.1.1.Critical Flow Orifice 11.4.FLOW RATE CONTROL11.4.3.2.Sample Flow Sensor 11.4.2.PARTICULATE FILTER11.4.3.PNEUMATIC SENSORS 11.4.3.1.Sample Pressure Sensor11.5.1.OVERVIEW 11.5.ELECTRONIC OPERATIONBOARD PC 104 BusFigure 11-9:M300E/EM Electronic Block Diagram MOTHERDISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.3.GFC Wheel 11.5.3.1.Temperature Control11.5.3.OPTICAL BENCH & GFC WHEEL 11.5.3.2.IR SourceSCHMIDT TRIGGERS Figure 11-10:GFC Light Mask M/R SENSORSEGMENT SENSOR Figure 11-11:Segment Sensor and M/R Sensor Output11.5.4.1.Overview 11.5.3.4.IR Photo-DetectorTable 11-2:Sync DEMOD Sample and Hold Circuits 11.5.4.2.Signal Synchronization and DemodulationM300E/EM Sync/Demod Block Diagram FigureFigure 11-13:Sample & Hold Timing 11.5.4.4.Photo-DetectorTemperature Control11.5.4.5.Dark Calibration Switch 11.5.4.3.Sync/Demod Status LED’s11.5.5.2.GFC Wheel Motor Control 11.5.4.6.Electric Test Switch11.5.5.RELAY BOARD 11.5.5.1.Heater ControlDC VOLTAGE TEST RELAY PCA PNSTATUS LED’s 11.5.5.5.Status LED’s11.5.6.3.Thermistor Interface 11.5.6.MOTHERBOARD11.5.6.1.A to D Conversion 11.5.6.2.Sensor InputsBENCH TEMPERATURE SENSOR 11.5.6.4.Analog Outputs11.5.6.5.Internal Digital I/O 11.5.6.6.External Digital I/OGENERAL SAFETY HAZARD 11.5.8.POWER SUPPLY/ CIRCUIT BREAKER11.5.7.I2C DATA BUS POWER UP CIRCUITTheory of Operation Figure 11-15:Power Distribution Block DiagramBoard 11.5.9.COMMUNICATION INTERFACEFigure 11-16:Interface Block Diagram MotherFigure 11-17:M300E/EM Front Panel Layout 11.5.10.FRONT PANEL INTERFACE11.5.10.1.Analyzer Status LED’s 11.5.10.2.Keyboard2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY 11.5.10.3.Display11.5.10.4.Keyboard/Display Interface Electronics I2C InterfaceKEY-DEPRESS-DETECTCIRCUIT KEYPAD DECODERDISPLAY CONTROLLER DISPLAY POWER WATCH DOGI2C INTERFACE CHIP DISPLAY DATA DECODER11.5.12.ADAPTIVE FILTER 11.5.11.SOFTWARE OPERATIONFigure 11-19:Basic Software Operation 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDAS 11.5.15.TEMPERATURE AND PRESSURE COMPENSATION11.5.13.CALIBRATION - SLOPE AND OFFSET 11.5.14.MEASUREMENT ALGORITHMThis page intentionally left blank Theory of OperationQUALIFIED PERSONNEL 12.MAINTENANCE SCHEDULE & PROCEDURES12.1.MAINTENANCE SCHEDULE GENERAL SAFETY HAZARDMaintenance Schedule & Procedures CAL CHECK MANUAL REQ’D ITEMACTION FREQMaintenance Schedule & Procedures CONDITION 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSTable 12-3:Predictive uses for Test Functions FUNCTIONFigure 12-1:Sample Particulate Filter Assembly 12.3.MAINTENANCE PROCEDURES12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER 12.3.2.REBUILDING THE SAMPLE PUMPGENERAL SAFETY HAZARD 12.3.3.PERFORMING LEAK CHECKS12.3.3.1.Vacuum Leak Check and Pump Check 12.3.3.2.Pressure Leak CheckGENERAL SAFETY HAZARD 12.3.5.CLEANING THE OPTICAL BENCH12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM 12.3.4.PERFORMING A SAMPLE FLOW CHECKQUALIFIED PERSONNEL 13.TROUBLESHOOTING & REPAIR13.1.GENERAL TROUBLESHOOTING GENERAL SAFETY HAZARDBENCH TEMP WARNING 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESCLR SETUP SAMPLETable 13-1:Warning Messages - Indicated Failures 13.1.2.FAULT DIAGNOSIS WITH TEST FUNCTIONS Table 13-2:Test Functions - Indicated Failures INDICATED FAILURESPRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMP BOX TEMPPHT DRIVE SLOPE OFFSET INDICATED FAILURESFigure 13-2:Example of Signal I/O Function CPU Status LED Figure 13-3:CPU Status Indicator 13.1.4.1.CPU Status Indicator13.1.4.INTERNAL ELECTRONIC STATUS LED’S Motherboard P/NBoard JP4 Connector to Opto-Pickup13.1.4.2.Sync Demodulator Status LED’s D1 – M/R Sensor StatusPOINTS RELAY PCA PNSTATUS LED’s DC VOLTAGE TESTRelay 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 13.2.2.3.High Flow 13.2.2.TYPICAL SAMPLE GAS FLOW PROBLEMS13.2.2.1.Flow is Zero 13.2.2.2.Low Flow13.2.2.6.Sample Pump 13.3.CALIBRATION PROBLEMS13.3.1.MISCALIBRATED 13.2.2.4.Displayed Flow = “Warnings”13.3.3.INABILITY TO SPAN – NO SPAN KEY 13.3.2.NON-REPEATABLEZERO AND SPAN13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.4.1.2.Bench Temperature 13.4.OTHER PERFORMANCE PROBLEMS13.4.1.TEMPERATURE PROBLEMS 13.4.1.1.Box or Sample TemperatureHazardous Voltages are present during this test 13.4.1.3.GFC Wheel Temperature13.4.1.4.IR Photo-DetectorTEC Temperature ELECTRICAL SHOCK HAZARD13.4.2.EXCESSIVE NOISE DC Power Test Point and Wiring Color Codes 13.5.1.AC MAINS CONFIGURATION13.5.2.DC POWER SUPPLY 13.5.SUBSYSTEM CHECKOUTTable 13.5.3.I2C BUS13.5.4.KEYBOARD/DISPLAY INTERFACE DC Power Supply Acceptable LevelsCONTROL 13.5.5.RELAY BOARDTable 13-8:Relay Board Control Devices FUNCTION13.5.6.1.Sync/Demodulator Assembly 13.5.6.SENSOR ASSEMBLY13.5.6.2.Electrical Test Table 13.5.6.3.Opto Pickup Assembly13.5.6.4.GFC Wheel Drive 13.5.6.5.IR Source13.5.6.6.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 Outputs13.5.7.5.Control Inputs – Remote Zero, Span 13.5.9.1.General RS-232Troubleshooting13.5.8.CPU 13.5.9.RS-232COMMUNICATIONS13.5.10.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 9480 Carroll Park Drive 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURE13.7.TECHNICAL ASSISTANCE Teledyne API, Customer Service14.1.HOW STATIC CHARGES ARE CREATED 14.A PRIMER ON ELECTRO-STATICDISCHARGEFigure 14-1:Triboelectric Charging 14.2.HOW ELECTRO-STATICCHARGES CAUSE DAMAGE Figure 14-2:Basic anti-ESDWorkbench 14.3.COMMON MYTHS ABOUT ESD DAMAGE14.4.BASIC PRINCIPLES OF STATIC CONTROL 14.4.1.GENERAL RULESAlways 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 <TST TST> SAMPLE SETUPRNGE PASS CLK MOREAPPENDIX 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-7Value Range Setup VariableDefault Value Numeric UnitsUnits DefaultNumeric ValueNumeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/OValue Setup VariableDefault NumericNumeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/OValue Setup VariableDefault NumericNumeric Setup VariableDefault Same settings asValue Setup VariableDefault NumericNumeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/OValue Setup VariableDefault NumericNumeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/OValue Setup VariableDefault NumericNumeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/OAPPENDIX A-3:Warnings and Test Functions NameMessage Text DescriptionA-22 NameMessage Text DescriptionDESCRIPTION A-23TEST FUNCTION NAME MESSAGE TEXTAPPENDIX A-3:Warnings and Test Functions A-24STABIL_SAMPLES DESCRIPTION A-25TEST FUNCTION NAME MESSAGE TEXTAPPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number APPENDIX A-4:Signal I/O DefinitionsA-27 Signal NameBit or Channel Number DescriptionDescription Bit or ChannelNumber Signal NameDescription Signal NameRear board temperature MUX analog inputs Bit or Channel NumberDescription Signal NameAPPENDIX A-4:Signal I/O Definitions Bit or Channel NumberA-31 NameDescription APPENDIX A-5:DAS Triggers and ParametersA-32 NameDescription UnitsA-33 NameDescription UnitsCOMMAND APPENDIX A-6:Terminal Command DesignatorsTable A-7:Terminal Command Designators APPENDIX A-6:Terminal Command DesignatorsMODBUS Floating Point Input Registers MODBUSRegister Address dec., 0-basedUnits MODBUS Floating Point Holding RegistersMODBUS DescriptionDescription MODBUS Discrete Input Registerssingle-bit; read-only MODBUSDescription MODBUS Coil Registerssingle-bit;read/write MODBUS04288D DCN5752 APPENDIX B - Spare PartsThis page intentionally left blank Part Number M300E Spare Parts ListDescription Description M300E Spare Parts ListReference: 05362J DCN5494 Part NumberPart Number M300EM Spare Parts ListDescription Description M300EM Spare Parts ListReference: 05424H DCN5494 Part Number21-30 M300EM Recommended Spare Parts Stocking Levels6-10 11-20Reference: 0096004C M300E/EX Expendables KitASSY, SOURCE 000941000ORIFICE, 13 MIL SAMPLE FLOW 009550500009560301 Please complete the following table APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM Email: api-customerservice@teledyne.com2v/DIV APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com T300/T300M and M300E/EM04288D 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 3 03297k_3.sch D C B ASync Demod Page 1 03297k_1.sch Sync Demod Page 2 03297k_2.schproper authorization 1. This schematics is for PCASchematics for PCA 03296, Sync Demod SignalSYNC_10 Schematics for PCA 03296, Sync DemodPREAMP_ENAB TV_ENAB17-Sep-2008 Schematics for PCA 03296, Sync Demodproper authorization BIAS SUPPLY1 of PCA 03631, Isolated 0-20ma,E Series03632 19-Jul-2002PCA PN, 1. This schematic is based on theNOTES PWB PN, 03974 and applies to+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 NOTE: 1. Use PWB Schematic, PCA 04135 Revision A, M300E Relay PCABENCH SPAREthe PWB PN, 03974 and 1. This schematic is based onNOTES applies to PCA PN,Not Used SCH, E-SeriesAnalog Output Isolator, PCA04468 1 A B C D 1