Zero/Span Point Calibration Procedure | Teledyne M300EM guide

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 Messages COVERAGE WARRANTYWARRANTY POLICY 02024D CAUTION – Avoid Warranty Invalidation 04288D DCN5752 This page intentionally left blank Name/Description ABOUT THIS MANUALinstrument Part No Change Summary REVISION HISTORY2010 June Document Revision History This page intentionally left blank Revision Historyviii Table of Contents TABLE OF CONTENTS 6. BASIC OPERATION PART II – OPERATING INSTRUCTIONS 8. REMOTE OPERATION 7. ADVANCED FEATURES 9. CALIBRATION PROCEDURES 11. THEORY OF OPERATION 10. EPA CALIBRATION PROTOCOLPART III – TECHNICAL INFORMATION xiii 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 Part PART - GENERAL INFORMATIONGENERAL INFORMATION GENERAL INFORMATION PartThis page intentionally left blank 1.1.M300E FAMILY OVERVIEW 1.INTRODUCTION 1.2.ADDITIONAL DOCUMENTATION SPECIFICATIONS AND WARRANTY 1.2.1.USING THIS MANUALTABLE OF CONTENTS PART I – GENERAL INFORMATION MAINTENANCE SCHEDULE AND PROCEDURES PART III – TECHNICAL INFORMATIONAPPENDICES ADVANCED FEATURES OF THE M300E/EM ANALYZER 2.1.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 COMPLIANCE This page intentionally left blank Specifications and Approvals Front Panel Layout 3.GETTING STARTED3.1.M300E/EM ANALYZER LAYOUT Figure SAMPLE Table 3-2:Inlet / Outlet Connector NomenclatureFigure Rear Panel Layout 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 ELECTRICAL SHOCK HAZARD 3.2.UNPACKING THE M300E/EM ANALYZERGENERAL SAFETY HAZARD power CAUTION – Avoid Warranty Invalidation Do not defeat the ground wire on power plug 3.3.1.POWER CONNECTION3.3.ELECTRICAL CONNECTIONS 3.2.1.VENTILATION CLEARANCE Figure 3.3.3.CONNECTING THE STATUS OUTPUTS3.3.2.ANALOG OUTPUT CONNECTIONS Analog Output Connector REAR PANEL Figure 3-8:Status Output ConnectorTable 3-5:Status Output Signals STATUS Figure 3.3.4.CONNECTING THE CONTROL INPUTSControl Input Connector Table 3-6:Control Input Signals 3.4.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 NETWORK 3.4.1.2.Span Gas area or shelter surrounding the instrument GENERAL SAFETY HAZARDexhaust and supply gas lines glass, stainless steel or brass 3.4.2.2.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 Outlet automatically begins its initialization routine 3.5.1.STARTUPconfiguration and calibration data System waits 3 seconds then 3.5.3.WARNING MESSAGES 3.5.2.WARM UP Table 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 SINGL 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 THANK YOU 3.6.3.O2 SENSOR CALIBRATION PROCEDURE3.6.4.CO2 SENSOR CALIBRATION PROCEDURE The M300E/EM Analyzer is now ready for operation 4.1.FAQ’S 4.FREQUENTLY ASKED QUESTIONS Term 4.2.GLOSSARYDescription/Definition Description/Definition Term Description/Definition Term 5.1.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 50A Figure 5.6.2.1.Internal Pneumatics OPT 50A SAMPLE GAS SOURCE 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.3.Input Gas Venting 5.6.2.4.Exhaust Outlet 5.6.3.1.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 GAS 5.6.4.1.Internal Pneumatics OPT 50H ZERO AIR 5.6.4.2.Pneumatic Set Up OPT 50HSAMPLE GAS SOURCE CALIBRATION GAS SOURCES SPAN GAS Scrubber 5.6.5.1.Internal Pneumatics OPT 50E ZERO AIR 5.6.5.2.Pneumatic Set Up OPT 50ESAMPLE GAS SOURCE CALIBRATION GAS SOURCES SPAN GAS Table 5-5:M300E/EM Modem Cable Options 5.7.COMMUNICATION OPTIONS5.7.1.RS-232MODEM CABLE OPTION 60A 5.7.2.RS-232MULTIDROP OPTION Figure 5-12:M300E/EM Ethernet Card 5.7.3.ETHERNET OPTION 63A 5.7.4.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 Analyzer 5.9.2.1.NDIR measurement of CO2 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS5.9.CARBON DIOXIDE SENSOR OPTION 67A 5.9.2.THEORY OF OPERATION 5.9.2.3.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 OPTION CO 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 SWITCH OPERATING INSTRUCTIONS PART – OPERATING INSTRUCTIONS This page intentionally left blank OPERATING INSTRUCTIONS EXPLANATION 6.BASIC OPERATION6.1.OVERVIEW OF OPERATING MODES MODE analyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Test Functions Defined Table Table 6-3:List of Warning Messages 6.3.WARNING MESSAGESMEANING The IR source may be faulty currently selected reporting range EXAMPLES 6.4.CALIBRATION MODE instrument until the ENTR Key is pressed 6.5.SETUP MODEPrimary Setup Mode Features and Functions Secondary Setup Mode Features and Functions 6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATION 6.5.1.SETUP  CFG: CONFIGURATION INFORMATION Password Levels 6.5.3.SETUP  PASS: PASSWORD FEATURETable 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 M300E Table 6-7:M300E Family Physical range by ModelMODEL RANGE Figure 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 concentrations Basic Operation computing the CO concentration discards the new setting accepts the new settingToggle these keys to select the upper limit for the reporting range sufficient Basic Operationreporting units Pressure STP Using the dilution ratio option is a 4-stepprocess This page intentionally left blank Basic Operation IDAS STATUS 7.ADVANCED FEATURES7.1.1.IDAS STATUS LED STATE 7.1.2.1.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 CONFIGURATION attempting any iDAS changes ALLOWED 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSDEFAULT Table 7-4:Variable Names VARS SETUP settingaccepts the new setting SETUP DIAG I/O Table 7-5:Diagnostic Mode DIAG FunctionsSIGNAL I/O CONFIGURATION 7.3.1.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 SPAN 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 Resistor for 4-20mA % FSVoltage across Resistor for 2-20mAPage Page FULL SCALE TEST CHANNELDESCRIPTION ZERO SETUP settingnew setting SETUP 7.4.7.AIN CALIBRATION STATUS ALARMLIMIT SET POINT1 This page intentionally left blank Advanced Features 8.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 2048 Remote 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 Reporting V RS-232 PASS=NNNNNN 8.1.7.5.COMM Port Password Security940331 is the default password LOGON 8.2.MULTIDROP RS-232SET UP Last INSTRUMENT HostCALIBRATOR TAPI Analyzer Figure 8-5:CPU RS-485Setup 8.3.RS-485CONFIGURATION OF COM2 Female 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 ETHERNET PROPERTY Table 8-5:LAN/Internet Configuration PropertiesDEFAULT STATE See your network administrator Remote Operation ∙Your LAN is not running a DHCP software package SETUP ON/OFFSETUP PRIMARY SETUP MENU Inserts a character before the cursor location FUNCTIONMoves the cursor one character to the left or right EXIT 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEFUNCTION ENTR Minimum 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 Operation 8.6.1.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 DESCRIPTION O2, 0, 312, REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESGAS TYPE,RANGE,GAS ID,REPORTED CO, 0, 310, REPORTED CO2, 0, 311, REPORTED 8.6.6.2.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 BIT 8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS 9.CALIBRATION PROCEDURESCalibration Procedures SECTION 9.1 – BEFORE CALIBRATION troubleshooting tips 9.1.BEFORE CALIBRATION9.1.2.CALIBRATION GASES 9.1.2.1.Zero Air calibration 9.1.3.DATA RECORDING DEVICES9.1.2.2.Span Gas 9.1.2.3.Traceability and 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 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 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 NAME ACTION Table 9-3:AutoCal Attribute Setup ParametersTIMER ENABLED ATTRIBUTE ZERO-SPAN MODE ANDVALUE COMMENT from 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 FUNCTION DAS RNGE PASS CLK MORE 9.6.1.DARK CALIBRATION TESTSETUP SETUP atmospheric pressure 9.6.2.PRESSURE CALIBRATION 9.6.3.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 SENSORS 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 Figure 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 Concentration 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 10.3.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 AUDIT 10.4.3.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 information 11.1.1.BEER’S LAW 11.THEORY OF OPERATION11.1.MEASUREMENT METHOD 11.2.MEASUREMENT FUNDAMENTALS Figure 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 Rejection over ambient pressure 11.3.PNEUMATIC OPERATIONGENERAL SAFETY HAZARD maintenance schedule, Table 11.4.1.1.Critical Flow Orifice 11.4.FLOW RATE CONTROL 11.4.3.2.Sample Flow Sensor 11.4.2.PARTICULATE FILTER11.4.3.PNEUMATIC SENSORS 11.4.3.1.Sample Pressure Sensor 11.5.1.OVERVIEW 11.5.ELECTRONIC OPERATION BOARD PC 104 BusFigure 11-9:M300E/EM Electronic Block Diagram MOTHER DISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.3.GFC Wheel 11.5.3.OPTICAL BENCH & GFC WHEEL11.5.3.1.Temperature Control 11.5.3.2.IR Source SCHMIDT TRIGGERS Figure 11-10:GFC Light Mask M/R SENSORSEGMENT SENSOR Figure 11-11:Segment Sensor and M/R Sensor Output 11.5.4.1.Overview 11.5.3.4.IR Photo-Detector Table 11-2:Sync DEMOD Sample and Hold Circuits 11.5.4.2.Signal Synchronization and DemodulationM300E/EM Sync/Demod Block Diagram Figure Figure 11-13:Sample & Hold Timing 11.5.4.5.Dark Calibration Switch11.5.4.3.Sync/Demod Status LED’s 11.5.4.4.Photo-DetectorTemperature Control 11.5.5.2.GFC Wheel Motor Control 11.5.4.6.Electric Test Switch11.5.5.RELAY BOARD 11.5.5.1.Heater Control DC VOLTAGE TEST RELAY PCA PNSTATUS LED’s 11.5.5.5.Status LED’s 11.5.6.3.Thermistor Interface 11.5.6.MOTHERBOARD11.5.6.1.A to D Conversion 11.5.6.2.Sensor Inputs BENCH TEMPERATURE SENSOR 11.5.6.4.Analog Outputs11.5.6.5.Internal Digital I/O 11.5.6.6.External Digital I/O GENERAL SAFETY HAZARD 11.5.8.POWER SUPPLY/ CIRCUIT BREAKER11.5.7.I2C DATA BUS POWER UP CIRCUIT Theory of Operation Figure 11-15:Power Distribution Block Diagram Board 11.5.9.COMMUNICATION INTERFACEFigure 11-16:Interface Block Diagram Mother Figure 11-17:M300E/EM Front Panel Layout 11.5.10.FRONT PANEL INTERFACE11.5.10.1.Analyzer Status LED’s 11.5.10.2.Keyboard 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY 11.5.10.3.Display11.5.10.4.Keyboard/Display Interface Electronics I2C Interface KEY-DEPRESS-DETECTCIRCUIT KEYPAD DECODER DISPLAY CONTROLLER DISPLAY POWER WATCH DOGI2C INTERFACE CHIP DISPLAY DATA DECODER 11.5.12.ADAPTIVE FILTER 11.5.11.SOFTWARE OPERATIONFigure 11-19:Basic Software Operation 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDAS 11.5.13.CALIBRATION - SLOPE AND OFFSET11.5.14.MEASUREMENT ALGORITHM 11.5.15.TEMPERATURE AND PRESSURE COMPENSATION This page intentionally left blank Theory of Operation QUALIFIED PERSONNEL 12.MAINTENANCE SCHEDULE & PROCEDURES12.1.MAINTENANCE SCHEDULE GENERAL SAFETY HAZARD Maintenance Schedule & Procedures CAL CHECK MANUAL REQ’D ITEMACTION FREQ Maintenance Schedule & Procedures CONDITION 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSTable 12-3:Predictive uses for Test Functions FUNCTION Figure 12-1:Sample Particulate Filter Assembly 12.3.MAINTENANCE PROCEDURES12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER 12.3.2.REBUILDING THE SAMPLE PUMP GENERAL SAFETY HAZARD 12.3.3.PERFORMING LEAK CHECKS12.3.3.1.Vacuum Leak Check and Pump Check 12.3.3.2.Pressure Leak Check GENERAL 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 CHECK QUALIFIED PERSONNEL 13.TROUBLESHOOTING & REPAIR13.1.GENERAL TROUBLESHOOTING GENERAL SAFETY HAZARD BENCH TEMP WARNING 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESCLR SETUP SAMPLE Table 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 TEMP PHT DRIVE SLOPE OFFSET INDICATED FAILURES Figure 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/N Board JP4 Connector to Opto-Pickup13.1.4.2.Sync Demodulator Status LED’s D1 – M/R Sensor Status POINTS RELAY PCA PNSTATUS LED’s DC VOLTAGE TEST Relay Board Status LED Failure Indications Table 13.2.1.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 Flow 13.2.2.6.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 Temperature Hazardous Voltages are present during this test 13.4.1.3.GFC Wheel Temperature13.4.1.4.IR Photo-DetectorTEC Temperature ELECTRICAL SHOCK HAZARD 13.4.2.EXCESSIVE NOISE DC Power Test Point and Wiring Color Codes 13.5.1.AC MAINS CONFIGURATION13.5.2.DC POWER SUPPLY 13.5.SUBSYSTEM CHECKOUT Table 13.5.3.I2C BUS13.5.4.KEYBOARD/DISPLAY INTERFACE DC Power Supply Acceptable Levels CONTROL 13.5.5.RELAY BOARDTable 13-8:Relay Board Control Devices FUNCTION 13.5.6.1.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 Source 13.5.6.6.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 Outputs 13.5.7.5.Control Inputs – Remote Zero, Span 13.5.9.1.General RS-232Troubleshooting13.5.8.CPU 13.5.9.RS-232COMMUNICATIONS 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 Figure 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 Service 14.1.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 RULES 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 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 Analyzers APPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 TEST1 SAMPLEMSG1 <TST TST> SAMPLE SETUPRNGE PASS CLK MORE 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-7 Value Range Setup VariableDefault Value Numeric Units Units DefaultNumeric Value Numeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/O Value Setup VariableDefault Numeric Numeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/O Value Setup VariableDefault Numeric Numeric Setup VariableDefault Same settings as Value Setup VariableDefault Numeric Numeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/O Value Setup VariableDefault Numeric Numeric Setup VariableDefault APPENDIX A-2:Setup Variables For Serial I/O Value Setup VariableDefault Numeric Numeric Setup VariableDefault APPENDIX A-2 Setup Variables For Serial I/O APPENDIX A-3:Warnings and Test Functions NameMessage Text Description A-22 NameMessage Text Description DESCRIPTION A-23TEST FUNCTION NAME MESSAGE TEXT APPENDIX A-3 Warnings and Test Functions A-24STABIL_SAMPLES DESCRIPTION A-25TEST FUNCTION NAME MESSAGE TEXT APPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number APPENDIX A-4:Signal I/O Definitions A-27 Signal NameBit or Channel Number Description Description Bit or ChannelNumber Signal Name A-29 Signal NameBit or Channel Number Description Description Signal NameAPPENDIX A-4:Signal I/O Definitions Bit or Channel Number A-31 NameDescription APPENDIX A-5:DAS Triggers and Parameters A-32 NameDescription Units A-33 NameDescription Units COMMAND APPENDIX A-6:Terminal Command DesignatorsTable A-7:Terminal Command Designators APPENDIX A-6:Terminal Command Designators MODBUS Floating Point Input Registers MODBUSRegister Address dec., 0-based Units MODBUS Floating Point Holding RegistersMODBUS Description Description MODBUS Discrete Input Registerssingle-bit; read-only MODBUS Description MODBUS Coil Registerssingle-bit;read/write MODBUS 04288D DCN5752 APPENDIX B - Spare Parts This page intentionally left blank Part Number M300E Spare Parts ListDescription Description M300E Spare Parts ListReference: 05362J DCN5494 Part Number Part Number M300EM Spare Parts ListDescription Description M300EM Spare Parts ListReference: 05424H DCN5494 Part Number 21-30 M300EM Recommended Spare Parts Stocking Levels6-10 11-20 Reference: 0096004C M300E/EX Expendables Kit ASSY, SOURCE 000941000ORIFICE, 13 MIL SAMPLE FLOW 009550500 009560301 Please complete the following table APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM Email: api-customerservice@teledyne.com 2v/DIV APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com T300/T300M and M300E/EM 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 3 03297k_3.sch D C B ASync Demod Page 1 03297k_1.sch Sync Demod Page 2 03297k_2.sch proper authorization 1. This schematics is for PCASchematics for PCA 03296, Sync Demod Signal SYNC_10 Schematics for PCA 03296, Sync DemodPREAMP_ENAB TV_ENAB 17-Sep-2008 Schematics for PCA 03296, Sync Demodproper authorization BIAS SUPPLY 1 of PCA 03631, Isolated 0-20ma,E Series03632 19-Jul-2002 PCA PN, 1. This schematic is based on theNOTES PWB PN, 03974 and applies to +15V +15V+15V +15V Schematic 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 SPARE the 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