9.7.1.4.O2ZERO/SPAN CALIBRATION | Teledyne M300EM guide

9.7.1.4.O2ZERO/SPAN CALIBRATION

Calibration Procedures

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

9.7.1.4.O2ZERO/SPAN CALIBRATION

To perform the zero/span calibration procedure:

212	04288D DCN5752

Image 214

Teledyne M300EM operation manual 9.7.1.4.O2ZERO/SPAN CALIBRATION, To perform the zero/span calibration procedure

Contents

MODEL 300E FAMILY CARBON MONOXIDE ANALYZERS TELEDYNE ADVANCED POLLUTION INSTRUMENTATION9480 CARROLL PARK DRIVE SAN DIEGO, CA USA Operation ManualPage SAFETY MESSAGES Safety Messages This page intentionally left blank CAUTION – Avoid Warranty Invalidation WARRANTYWARRANTY POLICY 02024D COVERAGE This page intentionally left blank 04288D DCN5752 Part No ABOUT THIS MANUALinstrument Name/Description Document REVISION HISTORY2010 June Change Summary Revision History This page intentionally left blank Revision Historyviii TABLE OF CONTENTS Table of Contents PART II – OPERATING INSTRUCTIONS 6. BASIC OPERATION 7. ADVANCED FEATURES 8. REMOTE OPERATION 9. CALIBRATION PROCEDURES xiii 10. EPA CALIBRATION PROTOCOLPART III – TECHNICAL INFORMATION 11. THEORY OF OPERATION 12. MAINTENANCE SCHEDULE & PROCEDURES 13. TROUBLESHOOTING & REPAIR 14. A PRIMER ON ELECTRO-STATICDISCHARGE LIST OF APPENDICES LIST OF FIGURES TABLE OF CONTENTS LIST OF TABLES xviii Table TABLE OF CONTENTS This page intentionally left blank Part PART - GENERAL INFORMATIONGENERAL INFORMATION GENERAL INFORMATION PartThis page intentionally left blank 1.INTRODUCTION 1.1.M300E FAMILY OVERVIEW 1.2.ADDITIONAL DOCUMENTATION PART I – GENERAL INFORMATION 1.2.1.USING THIS MANUALTABLE OF CONTENTS SPECIFICATIONS AND WARRANTY ADVANCED FEATURES OF THE M300E/EM ANALYZER PART III – TECHNICAL INFORMATIONAPPENDICES MAINTENANCE SCHEDULE AND PROCEDURES 2.1.SPECIFICATIONS 2.SPECIFICATIONS AND APPROVALSTable 2-1:M 300E/300EM Basic Unit Specifications 2.2.EPA EQUIVALENCY DESIGNATION 2.4.CE MARK COMPLIANCE 2.4.2.SAFETY COMPLIANCE2.3.TUV DESIGNATION 2.4.1.EMISSIONS COMPLIANCE Specifications and Approvals This page intentionally left blank Figure 3.GETTING STARTED3.1.M300E/EM ANALYZER LAYOUT Front Panel Layout Rear Panel Layout Table 3-2:Inlet / Outlet Connector NomenclatureFigure SAMPLE Getting Started Figure 3-3:Internal Layout – M300E Getting Started Figure 3-5:Optical Bench Layout Figure 3-6:M300E/EM Internal Gas Flow Basic Configuration power CAUTION – Avoid Warranty Invalidation 3.2.UNPACKING THE M300E/EM ANALYZERGENERAL SAFETY HAZARD ELECTRICAL SHOCK HAZARD 3.2.1.VENTILATION CLEARANCE 3.3.1.POWER CONNECTION3.3.ELECTRICAL CONNECTIONS Do not defeat the ground wire on power plug Analog Output Connector 3.3.3.CONNECTING THE STATUS OUTPUTS3.3.2.ANALOG OUTPUT CONNECTIONS Figure STATUS Figure 3-8:Status Output ConnectorTable 3-5:Status Output Signals REAR PANEL Table 3-6:Control Input Signals 3.3.4.CONNECTING THE CONTROL INPUTSControl Input Connector Figure 3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.3.5.CONNECTING THE SERIAL PORTS3.3.6.CONNECTING TO A LAN OR THE INTERNET 3.4.PNEUMATIC CONNECTIONS 3.4.1.2.Span Gas glass, stainless steel or brass GENERAL SAFETY HAZARDexhaust and supply gas lines area or shelter surrounding the instrument 3.4.2.2.Calibration Gas Sources 3.4.2.1.Sample Gas Sourceof the analyzer 3.4.2.4.Exhaust Outlet 3.5.INITIAL OPERATION3.4.2.3.Input Gas Venting using the procedures defined in Section System waits 3 seconds then 3.5.1.STARTUPconfiguration and calibration data automatically begins its initialization routine 3.5.2.WARM UP 3.5.3.WARNING MESSAGES 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 SINGL is set for SNGLIf it is not, press 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 The M300E/EM Analyzer is now ready for operation 3.6.3.O2 SENSOR CALIBRATION PROCEDURE3.6.4.CO2 SENSOR CALIBRATION PROCEDURE THANK YOU 4.FREQUENTLY ASKED QUESTIONS 4.1.FAQ’S Term 4.2.GLOSSARYDescription/Definition Term Description/Definition Term Description/Definition 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 5.6.2.ZERO/SPAN VALVE OPTION 50A 5.5.EXPENDABLES AND SPARES KITS OPTIONS 42A,5.6.CALIBRATION VALVES OPTIONS 50A, 50B, 50E, 50H 5.6.1.1.Gas Flow Rate 5.6.2.1.Internal Pneumatics OPT 50A Figure 5.6.2.4.Exhaust Outlet 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.3.Input Gas Venting SAMPLE GAS SOURCE 5.6.3.1.Internal Pneumatics OPT 50B 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50BFigure CALIBRATION GAS SOURCES SPAN GAS 5.6.3.2.Pneumatic Set Up OPT 50BSAMPLE GAS SOURCE ZERO AIR 5.6.4.1.Internal Pneumatics OPT 50H CALIBRATION GAS SOURCES SPAN GAS 5.6.4.2.Pneumatic Set Up OPT 50HSAMPLE GAS SOURCE ZERO AIR 5.6.5.1.Internal Pneumatics OPT 50E Scrubber CALIBRATION GAS SOURCES SPAN GAS 5.6.5.2.Pneumatic Set Up OPT 50ESAMPLE GAS SOURCE ZERO AIR 5.7.2.RS-232MULTIDROP OPTION 5.7.COMMUNICATION OPTIONS5.7.1.RS-232MODEM CABLE OPTION 60A Table 5-5:M300E/EM Modem Cable Options 5.7.3.ETHERNET OPTION 63A Figure 5-12:M300E/EM Ethernet Card 5.7.4.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 Sensor 5.9.2.THEORY OF OPERATION 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS5.9.CARBON DIOXIDE SENSOR OPTION 67A 5.9.2.1.NDIR measurement of CO2 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 5.10.CONCENTRATION ALARM RELAY OPTION Figure 5-19:Concentration Alarm Relay CO Alarm 1 = 20 PPM CO Alarm 2 = 100 PPM 5.11.3.SECOND LANGUAGE SWITCH 5.11.SPECIAL FEATURES5.11.2.MAINTENANCE MODE SWITCH 5.11.1.DILUTION RATIO OPTION PART – OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS This page intentionally left blank MODE 6.BASIC OPERATION6.1.OVERVIEW OF OPERATING MODES EXPLANATION analyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Table Test Functions Defined The IR source may be faulty 6.3.WARNING MESSAGESMEANING Table 6-3:List of Warning Messages 6.4.CALIBRATION MODE currently selected reporting range EXAMPLES Secondary Setup Mode Features and Functions 6.5.SETUP MODEPrimary Setup Mode Features and Functions instrument until the ENTR Key is pressed 6.5.1.SETUP  CFG: CONFIGURATION INFORMATION 6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATION Password Levels 6.5.3.SETUP  PASS: PASSWORD FEATURETable Basic Operation 04288D DCN5752 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 RANGE Table 6-7:M300E Family Physical range by ModelMODEL M300E Figure 6-4:Analog Output Connector Pin Out 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATIONANALOG OUT DUAL 6.6.3.REPORTING RANGE MODESSNGL AUTOPage concentrations The two ranges must be independently calibrated Basic Operation select the upper limit for the reporting range discards the new setting accepts the new settingToggle these keys to computing the CO concentration Pressure STP Basic Operationreporting units sufficient Using the dilution ratio option is a 4-stepprocess Basic Operation This page intentionally left blank LED STATE 7.ADVANCED FEATURES7.1.1.IDAS STATUS IDAS STATUS 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 0 CONC: ATIMER, 1, Channel No.: NAME: CONC TRIGGER EVENT: ATIMER 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.REMOTE IDAS CONFIGURATION 7.1.7.1.iDAS Configuration Using APICOM attempting any iDAS changes Table 7-4:Variable Names VARS 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSDEFAULT ALLOWED SETUP settingaccepts the new setting SETUP CONFIGURATION Table 7-5:Diagnostic Mode DIAG FunctionsSIGNAL I/O DIAG I/O 7.3.1.ACCESSING THE DIAGNOSTIC FEATURES SUB MENU 7.4.USING THE M300E/EM ANALYZER’S ANALOG OUTPUTSTable 7-6:DIAG - Analog I/O Functions OUTPUTPage RANGE SPAN Table 7-7:Analog Output Voltage Range Min/MaxRANGE NAME 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 GENERAL SAFETY HAZARD ground Advanced Features Resistor for 2-20mA % FSVoltage across Resistor for 4-20mAPage Page ZERO TEST CHANNELDESCRIPTION FULL SCALE SETUP settingnew setting SETUP 7.4.7.AIN CALIBRATION STATUS ALARMLIMIT SET POINT1 Advanced Features This page intentionally left blank 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 2048 8.1.4.COMM PORT COMMUNICATION MODES8192 1024 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 X ID COMMAND <CR> 8.1.7.2.Command Syntax8.1.7.3.Data Types Table 8-3:Teledyne API’s Serial I/O Command Types 8.1.7.4.Status Reporting X DDD:HH:MM Id MESSAGE<CRLF> LOGON 8.1.7.5.COMM Port Password Security940331 is the default password V RS-232 PASS=NNNNNN 8.2.MULTIDROP RS-232SET UP TAPI Analyzer HostCALIBRATOR Last INSTRUMENT 8.3.RS-485CONFIGURATION OF COM2 Figure 8-5:CPU RS-485Setup Female 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 Indicators See your network administrator Table 8-5:LAN/Internet Configuration PropertiesDEFAULT STATE PROPERTY Remote Operation ∙Your LAN is not running a DHCP software package PRIMARY SETUP MENU ON/OFFSETUP SETUP right FUNCTIONMoves the cursor one character to the left or Inserts a character before the cursor location ENTR 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEFUNCTION EXIT 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 Remote Operation To initialize the modem press 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 MODE DESCRIPTION 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODEMODE ID TEXT CO, 0, 310, REPORTED CO2, 0, 311, REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESGAS TYPE,RANGE,GAS ID,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 DEFAULT BIT 8.6.7.SETTING HESSEN PROTOCOL STATUS FLAGSTable 8-8:Default Hessen Status Flag Assignments STATUS FLAG NAME 8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM SECTION 9.1 – BEFORE CALIBRATION 9.CALIBRATION PROCEDURESCalibration Procedures SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS 9.1.2.1.Zero Air 9.1.BEFORE CALIBRATION9.1.2.CALIBRATION GASES troubleshooting tips 9.1.2.3.Traceability 9.1.3.DATA RECORDING DEVICES9.1.2.2.Span Gas calibration 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 9.2.3.2.Zero/Span Point Calibration Procedure Calibration Procedures 9.3.1.SETUP FOR CALIBRATION USING VALVE OPTIONS 9.3.MANUAL CALIBRATION WITH ZERO/SPAN VALVES 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 MODE NAME 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCALTable 9-2:AUTOCAL Modes ACTION ATTRIBUTE Table 9-3:AutoCal Attribute Setup ParametersTIMER ENABLED ACTION COMMENT MODE ANDVALUE ZERO-SPAN from the display SETUP X.X STARTING DATE: 04–SEP–08 for each FUNCTION 9.5.CO CALIBRATION QUALITYTable 9-5:Calibration Data Quality Evaluation MINIMUM VALUE SETUP 9.6.1.DARK CALIBRATION TESTSETUP DAS RNGE PASS CLK MORE 9.6.2.PRESSURE CALIBRATION atmospheric pressure 9.6.3.FLOW CALIBRATION 9.6.4.ELECTRICAL TEST CALIBRATION 9.7.CALIBRATION OF OPTIONAL SENSORS 9.7.1.O2 SENSOR CALIBRATION PROCEDURE9.7.1.1.O2 Calibration Setup Figure 9-7:O2 Sensor Calibration Set Up 9.7.1.2.Set O2 Span Gas Concentration Set the expected O2 span gas concentration 9.7.1.3.Activate O2 Sensor Stability Function complete 9.7.1.4.O2ZERO/SPAN CALIBRATION To perform the zero/span calibration procedure 9.7.2.2.Set CO2 Span Gas Concentration 9.7.2.CO2 SENSOR CALIBRATION PROCEDURE9.7.2.1.CO2 Calibration Setup Figure 9-8:CO2 Sensor Calibration Set Up 9.7.2.3.Activate CO2 Sensor Stability Function complete 9.7.2.4.CO2 Zero/Span Calibration Calibration Procedures Calibration Procedures This page intentionally left blank 10.EPA CALIBRATION PROTOCOL 10.1.CALIBRATION REQUIREMENTS 10.1.2.1.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 CHECKS 10.2.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 10.4.1.CALIBRATION AUDIT 10.4.AUDITING PROCEDURE10.3.1.PRECISION CALIBRATION PROCEDURES 10.4.2.DATA REDUCTION 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 Technical information This page intentionally left blank 11.2.MEASUREMENT FUNDAMENTALS 11.THEORY OF OPERATION11.1.MEASUREMENT METHOD 11.1.1.BEER’S LAW 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 11.2.1.3.Summary Interference Rejection Figure 11-6:Chopped IR Signal maintenance schedule, Table 11.3.PNEUMATIC OPERATIONGENERAL SAFETY HAZARD over ambient pressure 11.4.FLOW RATE CONTROL 11.4.1.1.Critical Flow Orifice 11.4.3.1.Sample Pressure Sensor 11.4.2.PARTICULATE FILTER11.4.3.PNEUMATIC SENSORS 11.4.3.2.Sample Flow Sensor 11.5.ELECTRONIC OPERATION 11.5.1.OVERVIEW MOTHER PC 104 BusFigure 11-9:M300E/EM Electronic Block Diagram BOARD DISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.2.IR Source 11.5.3.OPTICAL BENCH & GFC WHEEL11.5.3.1.Temperature Control 11.5.3.3.GFC Wheel Figure 11-11:Segment Sensor and M/R Sensor Output Figure 11-10:GFC Light Mask M/R SENSORSEGMENT SENSOR SCHMIDT TRIGGERS 11.5.3.4.IR Photo-Detector 11.5.4.1.Overview Figure 11.5.4.2.Signal Synchronization and DemodulationM300E/EM Sync/Demod Block Diagram Table 11-2:Sync DEMOD Sample and Hold Circuits 11.5.4.4.Photo-DetectorTemperature Control 11.5.4.5.Dark Calibration Switch11.5.4.3.Sync/Demod Status LED’s Figure 11-13:Sample & Hold Timing 11.5.5.1.Heater Control 11.5.4.6.Electric Test Switch11.5.5.RELAY BOARD 11.5.5.2.GFC Wheel Motor Control 11.5.5.5.Status LED’s RELAY PCA PNSTATUS LED’s DC VOLTAGE TEST 11.5.6.2.Sensor Inputs 11.5.6.MOTHERBOARD11.5.6.1.A to D Conversion 11.5.6.3.Thermistor Interface 11.5.6.6.External Digital I/O 11.5.6.4.Analog Outputs11.5.6.5.Internal Digital I/O BENCH TEMPERATURE SENSOR POWER UP CIRCUIT 11.5.8.POWER SUPPLY/ CIRCUIT BREAKER11.5.7.I2C DATA BUS GENERAL SAFETY HAZARD Figure 11-15:Power Distribution Block Diagram Theory of Operation Mother 11.5.9.COMMUNICATION INTERFACEFigure 11-16:Interface Block Diagram Board 11.5.10.2.Keyboard 11.5.10.FRONT PANEL INTERFACE11.5.10.1.Analyzer Status LED’s Figure 11-17:M300E/EM Front Panel Layout I2C Interface 11.5.10.3.Display11.5.10.4.Keyboard/Display Interface Electronics 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY KEYPAD DECODER KEY-DEPRESS-DETECTCIRCUIT DISPLAY DATA DECODER DISPLAY POWER WATCH DOGI2C INTERFACE CHIP DISPLAY CONTROLLER 11.5.12.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 IDAS Theory of Operation This page intentionally left blank GENERAL SAFETY HAZARD 12.MAINTENANCE SCHEDULE & PROCEDURES12.1.MAINTENANCE SCHEDULE QUALIFIED PERSONNEL Maintenance Schedule & Procedures FREQ ITEMACTION CAL CHECK MANUAL REQ’D Maintenance Schedule & Procedures FUNCTION 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSTable 12-3:Predictive uses for Test Functions CONDITION 12.3.2.REBUILDING THE SAMPLE PUMP 12.3.MAINTENANCE PROCEDURES12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER Figure 12-1:Sample Particulate Filter Assembly 12.3.3.2.Pressure Leak Check 12.3.3.PERFORMING LEAK CHECKS12.3.3.1.Vacuum Leak Check and Pump Check GENERAL SAFETY HAZARD 12.3.4.PERFORMING A SAMPLE FLOW CHECK 12.3.5.CLEANING THE OPTICAL BENCH12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM GENERAL SAFETY HAZARD GENERAL SAFETY HAZARD 13.TROUBLESHOOTING & REPAIR13.1.GENERAL TROUBLESHOOTING QUALIFIED PERSONNEL SAMPLE 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESCLR SETUP BENCH TEMP WARNING Table 13-1 Warning Messages - Indicated Failures 13.1.2.FAULT DIAGNOSIS WITH TEST FUNCTIONS BOX TEMP INDICATED FAILURESPRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMP Table 13-2:Test Functions - Indicated Failures INDICATED FAILURES PHT DRIVE SLOPE OFFSET Figure 13-2:Example of Signal I/O Function Motherboard P/N 13.1.4.1.CPU Status Indicator13.1.4.INTERNAL ELECTRONIC STATUS LED’S CPU Status LED Figure 13-3:CPU Status Indicator D1 – M/R Sensor Status JP4 Connector to Opto-Pickup13.1.4.2.Sync Demodulator Status LED’s Board DC VOLTAGE TEST RELAY PCA PNSTATUS LED’s POINTS Table Relay Board Status LED Failure Indications 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 13.2.2.2.Low Flow 13.2.2.TYPICAL SAMPLE GAS FLOW PROBLEMS13.2.2.1.Flow is Zero 13.2.2.3.High Flow 13.2.2.4.Displayed Flow = “Warnings” 13.3.CALIBRATION PROBLEMS13.3.1.MISCALIBRATED 13.2.2.6.Sample Pump 13.3.3.INABILITY TO SPAN – NO SPAN KEY 13.3.2.NON-REPEATABLEZERO AND SPAN13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.4.1.1.Box or Sample Temperature 13.4.OTHER PERFORMANCE PROBLEMS13.4.1.TEMPERATURE PROBLEMS 13.4.1.2.Bench Temperature ELECTRICAL SHOCK HAZARD 13.4.1.3.GFC Wheel Temperature13.4.1.4.IR Photo-DetectorTEC Temperature Hazardous Voltages are present during this test 13.4.2.EXCESSIVE NOISE 13.5.SUBSYSTEM CHECKOUT 13.5.1.AC MAINS CONFIGURATION13.5.2.DC POWER SUPPLY DC Power Test Point and Wiring Color Codes DC Power Supply Acceptable Levels 13.5.3.I2C BUS13.5.4.KEYBOARD/DISPLAY INTERFACE Table FUNCTION 13.5.5.RELAY BOARDTable 13-8:Relay Board Control Devices CONTROL 13.5.6.1.Sync/Demodulator Assembly 13.5.6.SENSOR ASSEMBLY13.5.6.2.Electrical Test 13.5.6.5.IR Source 13.5.6.3.Opto Pickup Assembly13.5.6.4.GFC Wheel Drive Table 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 13.5.7.4.Status Outputs Table 13-12:Status Outputs Check 13.5.9.RS-232COMMUNICATIONS 13.5.9.1.General RS-232Troubleshooting13.5.8.CPU 13.5.7.5.Control Inputs – Remote Zero, Span 13.5.10.THE OPTIONAL CO2 SENSOR 13.6.REPAIR PROCEDURES 13.6.1.REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 13.6.2.REMOVING/REPLACING THE GFC WHEEL Figure 13-15:Opening the GFC Wheel Housing 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 Teledyne API, Customer Service 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURE13.7.TECHNICAL ASSISTANCE 9480 Carroll Park Drive 14.1.HOW STATIC CHARGES ARE CREATED 14.A PRIMER ON ELECTRO-STATICDISCHARGEFigure 14-1:Triboelectric Charging 14.2.HOW ELECTRO-STATICCHARGES CAUSE DAMAGE 14.4.1.GENERAL RULES 14.3.COMMON MYTHS ABOUT ESD DAMAGE14.4.BASIC PRINCIPLES OF STATIC CONTROL 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 14.4.2.1.Working at the Instrument Rack 14.4.2.2.Working at an Anti-ESDWork Bench 4.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 blank APPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 TEST1 SAMPLEMSG1 CLK MORE SAMPLE SETUPRNGE PASS <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.8 Numeric Units Setup VariableDefault Value Value Range Value DefaultNumeric Units APPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault Numeric Numeric Setup VariableDefault Value APPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault Numeric Numeric Setup VariableDefault Value Same settings as Setup VariableDefault Numeric Numeric Setup VariableDefault Value APPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault Numeric Numeric Setup VariableDefault Value APPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault Numeric Numeric Setup VariableDefault Value APPENDIX A-2 Setup Variables For Serial I/O Setup VariableDefault Numeric Description NameMessage Text APPENDIX A-3:Warnings and Test Functions Description NameMessage Text A-22 MESSAGE TEXT A-23TEST FUNCTION NAME DESCRIPTION APPENDIX A-3 Warnings and Test Functions A-24STABIL_SAMPLES MESSAGE TEXT A-25TEST FUNCTION NAME DESCRIPTION APPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number APPENDIX A-4:Signal I/O Definitions Description Signal NameBit or Channel Number A-27 Signal Name Bit or ChannelNumber Description Description Signal NameBit or Channel Number A-29 Bit or Channel Number Signal NameAPPENDIX A-4:Signal I/O Definitions Description APPENDIX A-5:DAS Triggers and Parameters NameDescription A-31 Units NameDescription A-32 Units NameDescription A-33 APPENDIX A-6:Terminal Command Designators APPENDIX A-6:Terminal Command DesignatorsTable A-7:Terminal Command Designators COMMAND dec., 0-based MODBUSRegister Address MODBUS Floating Point Input Registers Description MODBUS Floating Point Holding RegistersMODBUS Units MODBUS MODBUS Discrete Input Registerssingle-bit; read-only Description MODBUS MODBUS Coil Registerssingle-bit;read/write Description APPENDIX B - Spare Parts 04288D DCN5752 This page intentionally left blank Part Number M300E Spare Parts ListDescription Part Number M300E Spare Parts ListReference: 05362J DCN5494 Description Part Number M300EM Spare Parts ListDescription Part Number M300EM Spare Parts ListReference: 05424H DCN5494 Description 11-20 M300EM Recommended Spare Parts Stocking Levels6-10 21-30 M300E/EX Expendables Kit Reference: 0096004C 009550500 000941000ORIFICE, 13 MIL SAMPLE FLOW ASSY, SOURCE 009560301 Email: api-customerservice@teledyne.com APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM Please complete the following table T300/T300M and M300E/EM APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com 2v/DIV APPENDIX D – Wire List and Electronic Schematics 04288D DCN5752 This page intentionally left blank 04288D DCN5752 Interconnect List, M300E/EU, SNs 100 and greater FROM FROM This page intentionally left blank Page Sync Demod Page 2 03297k_2.sch D C B ASync Demod Page 1 03297k_1.sch Sync Demod Page 3 03297k_3.sch Signal 1. This schematics is for PCASchematics for PCA 03296, Sync Demod proper authorization TV_ENAB Schematics for PCA 03296, Sync DemodPREAMP_ENAB SYNC_10 BIAS SUPPLY Schematics for PCA 03296, Sync Demodproper authorization 17-Sep-2008 19-Jul-2002 PCA 03631, Isolated 0-20ma,E Series03632 1 of PWB PN, 03974 and applies to 1. This schematic is based on theNOTES PCA PN, +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 SPARE Schematic, PCA 04135 Revision A, M300E Relay PCABENCH NOTE: 1. Use PWB applies to PCA PN, 1. This schematic is based onNOTES the PWB PN, 03974 and 1 A B C D 1 SCH, E-SeriesAnalog Output Isolator, PCA04468 Not Used