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Teledyne M300EM operation manual Maintenance Schedule & Procedures

Models: M300E M300EM

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Maintenance Schedule & Procedures

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

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04288D DCN5752

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Teledyne M300EM operation manual Maintenance Schedule & Procedures

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 blankCAUTION – Avoid Warranty Invalidation WARRANTYWARRANTY POLICY 02024D COVERAGEThis page intentionally left blank 04288D DCN5752Part No ABOUT THIS MANUALinstrument Name/DescriptionDocument REVISION HISTORY2010 June Change SummaryRevision History This page intentionally left blank Revision Historyviii TABLE OF CONTENTS Table of ContentsPART II – OPERATING INSTRUCTIONS 6. BASIC OPERATION7. ADVANCED FEATURES 8. REMOTE OPERATION9. CALIBRATION PROCEDURES xiii 10. EPA CALIBRATION PROTOCOLPART III – TECHNICAL INFORMATION 11. THEORY OF OPERATION12. MAINTENANCE SCHEDULE & PROCEDURES 13. TROUBLESHOOTING & REPAIR14. A PRIMER ON ELECTRO-STATICDISCHARGE LIST OF APPENDICES LIST OF FIGURESTABLE OF CONTENTS LIST OF TABLES xviiiTable TABLE OF CONTENTS This page intentionally left blankPart PART – GENERAL INFORMATIONGENERAL INFORMATION GENERAL INFORMATION PartThis page intentionally left blank 1.INTRODUCTION 1.1.M300E FAMILY OVERVIEW1.2.ADDITIONAL DOCUMENTATION PART I – GENERAL INFORMATION 1.2.1.USING THIS MANUALTABLE OF CONTENTS SPECIFICATIONS AND WARRANTYADVANCED FEATURES OF THE M300E/EM ANALYZER PART III – TECHNICAL INFORMATIONAPPENDICES MAINTENANCE SCHEDULE AND PROCEDURES2.1.SPECIFICATIONS 2.SPECIFICATIONS AND APPROVALSTable 2-1:M 300E/300EM Basic Unit Specifications 2.2.EPA EQUIVALENCY DESIGNATION 2.4.CE MARK COMPLIANCE 2.4.2.SAFETY COMPLIANCE2.3.TUV DESIGNATION 2.4.1.EMISSIONS COMPLIANCESpecifications and Approvals This page intentionally left blankFigure 3.GETTING STARTED3.1.M300E/EM ANALYZER LAYOUT Front Panel LayoutRear Panel Layout Table 3-2:Inlet / Outlet Connector NomenclatureFigure SAMPLEGetting Started Figure 3-3:Internal Layout – M300EGetting Started Figure 3-5:Optical Bench Layout Figure 3-6:M300E/EM Internal Gas Flow Basic Configuration power CAUTION – Avoid Warranty Invalidation 3.2.UNPACKING THE M300E/EM ANALYZERGENERAL SAFETY HAZARD ELECTRICAL SHOCK HAZARD3.2.1.VENTILATION CLEARANCE 3.3.1.POWER CONNECTION3.3.ELECTRICAL CONNECTIONS Do not defeat the ground wire on power plugAnalog Output Connector 3.3.3.CONNECTING THE STATUS OUTPUTS3.3.2.ANALOG OUTPUT CONNECTIONS FigureSTATUS Figure 3-8:Status Output ConnectorTable 3-5:Status Output Signals REAR PANELTable 3-6:Control Input Signals 3.3.4.CONNECTING THE CONTROL INPUTSControl Input Connector Figure3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.3.5.CONNECTING THE SERIAL PORTS3.3.6.CONNECTING TO A LAN OR THE INTERNET 3.4.PNEUMATIC CONNECTIONS3.4.1.2.Span Gas glass, stainless steel or brass GENERAL SAFETY HAZARDexhaust and supply gas lines area or shelter surrounding the instrument3.4.2.2.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 SectionSystem waits 3 seconds then 3.5.1.STARTUPconfiguration and calibration data automatically begins its initialization routine3.5.2.WARM UP 3.5.3.WARNING MESSAGESTable 3-9:Possible Warning Messages at Start-Up 3.5.4.FUNCTIONAL CHECK 3.6.1.INTERFERENTS FOR CO2 MEASUREMENTS 3.6.INITIAL CALIBRATION OF THE M300E/EMinstalled SINGL is set for SNGLIf it is not, press ENTR3.6.2.2.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 PPMThe M300E/EM Analyzer is now ready for operation 3.6.3.O2 SENSOR CALIBRATION PROCEDURE3.6.4.CO2 SENSOR CALIBRATION PROCEDURE THANK YOU4.FREQUENTLY ASKED QUESTIONS 4.1.FAQ’STerm 4.2.GLOSSARYDescription/Definition Term Description/DefinitionTerm Description/Definition5.1.EXTERNAL PUMPS OPTIONS 10A-10E,11, 5.OPTIONAL HARDWARE AND SOFTWARE5.2.RACK MOUNT KITS OPT 20 TO OPT 5.4.CURRENT LOOP ANALOG OUTPUTS OPTION 5.3.CARRYING STRAP/HANDLE OPTGENERAL SAFETY HAZARD Figure 5-2:Current Loop Option Installed on the Motherboard 5.6.2.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 Rate5.6.2.1.Internal Pneumatics OPT 50A Figure5.6.2.4.Exhaust Outlet 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.3.Input Gas Venting SAMPLE GAS SOURCE5.6.3.1.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 AIR5.6.4.1.Internal Pneumatics OPT 50H CALIBRATION GAS SOURCES SPAN GAS 5.6.4.2.Pneumatic Set Up OPT 50HSAMPLE GAS SOURCE ZERO AIR5.6.5.1.Internal Pneumatics OPT 50E ScrubberCALIBRATION GAS SOURCES SPAN GAS 5.6.5.2.Pneumatic Set Up OPT 50ESAMPLE GAS SOURCE ZERO AIR5.7.2.RS-232MULTIDROP OPTION 5.7.COMMUNICATION OPTIONS5.7.1.RS-232MODEM CABLE OPTION 60A Table 5-5:M300E/EM Modem Cable Options5.7.3.ETHERNET OPTION 63A Figure 5-12:M300E/EM Ethernet Card5.7.4.ETHERNET + MULTIDROP OPT 63C 5.8.SECOND GAS SENSORS5.8.1.OXYGEN SENSOR OPTION 65A 5.8.1.2.Operation within the M300E/EM Analyzer 5.8.1.3.Pneumatic Operation of the O2 Sensor5.9.2.THEORY OF OPERATION 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS5.9.CARBON DIOXIDE SENSOR OPTION 67A 5.9.2.1.NDIR measurement of CO25.9.2.3.Pneumatic Operation of the CO2 Sensor 5.9.2.2.Operation within the M300E/EM AnalyzerFigure 5-16:CO2 sensor Theory of Operation 5.9.2.4.Electronic Operation of the CO2 Sensor 5.10.CONCENTRATION ALARM RELAY OPTION Figure 5-19:Concentration Alarm RelayCO Alarm 1 = 20 PPM CO Alarm 2 = 100 PPM 5.11.3.SECOND LANGUAGE SWITCH 5.11.SPECIAL FEATURES5.11.2.MAINTENANCE MODE SWITCH 5.11.1.DILUTION RATIO OPTIONPART – OPERATING INSTRUCTIONS OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS This page intentionally left blankMODE 6.BASIC OPERATION6.1.OVERVIEW OF OPERATING MODES EXPLANATIONanalyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Table Test Functions DefinedThe IR source may be faulty 6.3.WARNING MESSAGESMEANING Table 6-3:List of Warning Messages6.4.CALIBRATION MODE currently selected reporting range EXAMPLESSecondary Setup Mode Features and Functions 6.5.SETUP MODEPrimary Setup Mode Features and Functions instrument until the ENTR Key is pressed6.5.1.SETUP  CFG: CONFIGURATION INFORMATION 6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATIONPassword Levels 6.5.3.SETUP  PASS: PASSWORD FEATURETable Basic Operation 04288D DCN5752the required number code 6.5.4.1.Setting the internal Clock’s Time and Day 6.5.4.2.Adjusting the Internal Clock’s Speed RANGE Table 6-7:M300E Family Physical range by ModelMODEL M300EFigure 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 calibratedBasic Operation select the upper limit for the reporting range discards the new setting accepts the new settingToggle these keys to computing the CO concentrationPressure STP Basic Operationreporting units sufficientUsing the dilution ratio option is a 4-stepprocess Basic Operation This page intentionally left blankLED STATE 7.ADVANCED FEATURES7.1.1.IDAS STATUS IDAS STATUS7.1.2.1.iDAS Channels 7.1.2.IDAS STRUCTURETable 7-2:iDAS Data Channel Properties 7.1.3.DEFAULT IDAS CHANNELS Figure 7-1:Default iDAS Channel Setup Continue pressing to view remaining iDAS channels 0 CONC: ATIMER, 1, Channel No.: NAME: CONC TRIGGER EVENT: ATIMER7.1.5.1.Editing iDAS Data Channel Names 7.1.5.2.Editing iDAS Triggering Events found in Appendix A-5 7.1.5.3.Editing iDAS ParametersTable 7-3:iDAS Data Parameter Functions When the STORE NUM SAMPLES feature is turned on, the instrument will store how many 7.1.5.4.Editing Sample Period and Report Period In AVG, SDEV, MIN or MAX sample modes see Section 7.1.5.3, the settings for the Sample Period and the Report Period determine the number of data points used each time the parameter is calculated, stored and reported to the COMM ports 7.1.5.6.Editing the Number of Records 7.1.5.7.RS-232Report Function 7.1.5.8.Enabling/Disabling the HOLDOFF Feature 7.1.5.10.The Starting Date Feature 7.1.5.9.The Compact Report Feature7.1.6.DISABLING/ENABLING DATA CHANNELS 7.1.7.REMOTE IDAS CONFIGURATION 7.1.7.1.iDAS Configuration Using APICOMattempting any iDAS changes Table 7-4:Variable Names VARS 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSDEFAULT ALLOWEDSETUP settingaccepts the new setting SETUPCONFIGURATION Table 7-5:Diagnostic Mode DIAG FunctionsSIGNAL I/O DIAG I/O7.3.1.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 OUTPUT04288D DCN5752 7.4.3.CALIBRATION OF THE ANALOG OUTPUTS See Section Manual calibration should be used for any analog output set for a 0.1V output range or in cases where Page The menu for manually adjusting the analog output signal level will only appear if the AUTO-CALfeature Advanced Features GENERAL SAFETY HAZARD groundAdvanced Features Resistor for 2-20mA % FSVoltage across Resistor for 4-20mAPage Page ZERO TEST CHANNELDESCRIPTION FULL SCALESETUP settingnew setting SETUP7.4.7.AIN CALIBRATION STATUS ALARMLIMIT SET POINT1 Advanced Features This page intentionally left blank8.REMOTE OPERATION 8.1.2.COMM PORT DEFAULT SETTINGS8.1.1.RS-232DTE AND DCE COMMUNICATION Figure 8-1:Default Pin Assignments for Back Panel COMM Port connectors RS-232DCE & DTE 8.1.3.COMM PORT BAUD RATE 2048 8.1.4.COMM PORT COMMUNICATION MODES8192 1024Remote Operation 8.1.5.COMM PORT TESTING 8.1.6.MACHINE ID 8.1.7.TERMINAL OPERATING MODES 8.1.7.1.Help Commands in Terminal ModeTable 8-2:Terminal Mode Software Commands 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 Types8.1.7.4.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=NNNNNN8.2.MULTIDROP RS-232SET UP TAPI Analyzer HostCALIBRATOR Last INSTRUMENT8.3.RS-485CONFIGURATION OF COM2 Figure 8-5:CPU RS-485SetupFemale DB-9COM2 The DCE/DTE switch has no effect on COM2RX/TX RX/TX+ 8.4.REMOTE ACCESS VIA THE ETHERNET Table 8-4:Ethernet Status IndicatorsSee your network administrator Table 8-5:LAN/Internet Configuration PropertiesDEFAULT STATE PROPERTYRemote Operation ∙Your LAN is not running a DHCP software package PRIMARY SETUP MENU ON/OFFSETUP SETUPright FUNCTIONMoves the cursor one character to the left or Inserts a character before the cursor locationENTR 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEFUNCTION EXITMinimum Requirements 8.5.MODBUS SETUPActions 8.5.1.REMOTE ACCESS BY MODEM AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Remote Operation To initialize the modem press8.6.1.GENERAL OVERVIEW OF HESSEN PROTOCOL 8.6.2.HESSEN COMM PORT CONFIGURATIONProtocol network 8.6.3.ACTIVATING HESSEN PROTOCOL 8.6.4.SELECTING A HESSEN PROTOCOL TYPE MODE DESCRIPTION 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODEMODE ID TEXTCO, 0, 310, REPORTED CO2, 0, 311, REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESGAS TYPE,RANGE,GAS ID,REPORTED O2, 0, 312, REPORTED8.6.6.2.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 NAME8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM SECTION 9.1 – BEFORE CALIBRATION 9.CALIBRATION PROCEDURESCalibration Procedures SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS9.1.2.1.Zero Air 9.1.BEFORE CALIBRATION9.1.2.CALIBRATION GASES troubleshooting tips9.1.2.3.Traceability 9.1.3.DATA RECORDING DEVICES9.1.2.2.Span Gas calibrationand alters the instrument’s Calibration Calibration Procedures See Section 12 for troubleshooting tips 9.2.2.PERFORMING A BASIC MANUAL CALIBRATION CHECKallowed for a reliable calibration the SPAN gas 9.2.3.PERFORMING A BASIC MANUAL CALIBRATIONthe bottle 9.2.3.2.Zero/Span Point Calibration Procedure Calibration Procedures9.3.1.SETUP FOR CALIBRATION USING VALVE OPTIONS 9.3.MANUAL CALIBRATION WITH ZERO/SPAN VALVESFigure 9-5:Pneumatic Connections – Option 51B: Zero/Span Calibration Valves Calibration Procedures the SPAN gas 9.3.3.MANUAL CALIBRATION USING VALVE OPTIONSthe bottle 9.3.3.2.Zero/Span Point Calibration Procedure MODE NAME 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCALTable 9-2:AUTOCAL Modes ACTIONATTRIBUTE Table 9-3:AutoCal Attribute Setup ParametersTIMER ENABLED ACTIONCOMMENT MODE ANDVALUE ZERO-SPANfrom 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 VALUESETUP 9.6.1.DARK CALIBRATION TESTSETUP DAS RNGE PASS CLK MORE9.6.2.PRESSURE CALIBRATION atmospheric pressure9.6.3.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 Up9.7.1.2.Set O2 Span Gas Concentration Set the expected O2 span gas concentration9.7.1.3.Activate O2 Sensor Stability Function complete9.7.1.4.O2ZERO/SPAN CALIBRATION To perform the zero/span calibration procedure9.7.2.2.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 Up9.7.2.3.Activate CO2 Sensor Stability Function complete9.7.2.4.CO2 Zero/Span Calibration Calibration ProceduresCalibration Procedures This page intentionally left blank10.EPA CALIBRATION PROTOCOL 10.1.CALIBRATION REQUIREMENTS10.1.2.1.Data Recording Device 10.1.2.2.Spare Parts and Expendable SuppliesPage 10.1.4.CALIBRATION FREQUENCY 10.1.5.LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS10.2.ZERO AND SPAN CHECKS Q.A. Handbook1 Vol II, Part1, Section 12.3 &10.3.PRECISIONS CALIBRATION 10.2.1.ZERO/SPAN CHECK PROCEDURES10.2.2.PRECISION CHECK 10.4.1.CALIBRATION AUDIT 10.4.AUDITING PROCEDURE10.3.1.PRECISION CALIBRATION PROCEDURES 10.4.2.DATA REDUCTION AUDIT10.4.3.SYSTEM AUDIT/VALIDATION 10.5.DYNAMIC MULTIPOINT CALIBRATION PROCEDURE10.5.1.LINEARITY TEST ∙Leaks ∙Correct flow 10.6.REFERENCES PART PART – TECHNICAL INFORMATIONTECHNICAL INFORMATION Technical information This page intentionally left blank11.2.MEASUREMENT FUNDAMENTALS 11.THEORY OF OPERATION11.1.MEASUREMENT METHOD 11.1.1.BEER’S LAWFigure 11-1:Measurement Fundamentals 11.2.1.GAS FILTER CORRELATIONFigure 11-2:GFC Wheel 11.2.1.1.The GFC Wheel 11.2.1.2.The Measure Reference Ratio 11.2.1.3.Summary Interference Rejection Figure 11-6:Chopped IR Signalmaintenance schedule, Table 11.3.PNEUMATIC OPERATIONGENERAL SAFETY HAZARD over ambient pressure11.4.FLOW RATE CONTROL 11.4.1.1.Critical Flow Orifice11.4.3.1.Sample Pressure Sensor 11.4.2.PARTICULATE FILTER11.4.3.PNEUMATIC SENSORS 11.4.3.2.Sample Flow Sensor11.5.ELECTRONIC OPERATION 11.5.1.OVERVIEWMOTHER PC 104 BusFigure 11-9:M300E/EM Electronic Block Diagram BOARDDISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.2.IR Source 11.5.3.1.Temperature Control11.5.3.OPTICAL BENCH & GFC WHEEL 11.5.3.3.GFC WheelFigure 11-11:Segment Sensor and M/R Sensor Output Figure 11-10:GFC Light Mask M/R SENSORSEGMENT SENSOR SCHMIDT TRIGGERS11.5.3.4.IR Photo-Detector 11.5.4.1.OverviewFigure 11.5.4.2.Signal Synchronization and DemodulationM300E/EM Sync/Demod Block Diagram Table 11-2:Sync DEMOD Sample and Hold Circuits11.5.4.3.Sync/Demod Status LED’s 11.5.4.4.Photo-DetectorTemperature Control11.5.4.5.Dark Calibration Switch Figure 11-13:Sample & Hold Timing11.5.5.1.Heater Control 11.5.4.6.Electric Test Switch11.5.5.RELAY BOARD 11.5.5.2.GFC Wheel Motor Control11.5.5.5.Status LED’s RELAY PCA PNSTATUS LED’s DC VOLTAGE TEST11.5.6.2.Sensor Inputs 11.5.6.MOTHERBOARD11.5.6.1.A to D Conversion 11.5.6.3.Thermistor Interface11.5.6.6.External Digital I/O 11.5.6.4.Analog Outputs11.5.6.5.Internal Digital I/O BENCH TEMPERATURE SENSORPOWER UP CIRCUIT 11.5.8.POWER SUPPLY/ CIRCUIT BREAKER11.5.7.I2C DATA BUS GENERAL SAFETY HAZARDFigure 11-15:Power Distribution Block Diagram Theory of OperationMother 11.5.9.COMMUNICATION INTERFACEFigure 11-16:Interface Block Diagram Board11.5.10.2.Keyboard 11.5.10.FRONT PANEL INTERFACE11.5.10.1.Analyzer Status LED’s Figure 11-17:M300E/EM Front Panel LayoutI2C Interface 11.5.10.3.Display11.5.10.4.Keyboard/Display Interface Electronics 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAYKEYPAD DECODER KEY-DEPRESS-DETECTCIRCUITDISPLAY DATA DECODER DISPLAY POWER WATCH DOGI2C INTERFACE CHIP DISPLAY CONTROLLER11.5.12.ADAPTIVE FILTER 11.5.11.SOFTWARE OPERATIONFigure 11-19:Basic Software Operation 11.5.14.MEASUREMENT ALGORITHM 11.5.15.TEMPERATURE AND PRESSURE COMPENSATION11.5.13.CALIBRATION - SLOPE AND OFFSET 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDASTheory of Operation This page intentionally left blankGENERAL SAFETY HAZARD 12.MAINTENANCE SCHEDULE & PROCEDURES12.1.MAINTENANCE SCHEDULE QUALIFIED PERSONNELMaintenance Schedule & Procedures FREQ ITEMACTION CAL CHECK MANUAL REQ’DMaintenance Schedule & Procedures FUNCTION 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSTable 12-3:Predictive uses for Test Functions CONDITION12.3.2.REBUILDING THE SAMPLE PUMP 12.3.MAINTENANCE PROCEDURES12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER Figure 12-1:Sample Particulate Filter Assembly12.3.3.2.Pressure Leak Check 12.3.3.PERFORMING LEAK CHECKS12.3.3.1.Vacuum Leak Check and Pump Check GENERAL SAFETY HAZARD12.3.4.PERFORMING A SAMPLE FLOW CHECK 12.3.5.CLEANING THE OPTICAL BENCH12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM GENERAL SAFETY HAZARDGENERAL SAFETY HAZARD 13.TROUBLESHOOTING & REPAIR13.1.GENERAL TROUBLESHOOTING QUALIFIED PERSONNELSAMPLE 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESCLR SETUP BENCH TEMP WARNINGTable 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 FailuresINDICATED FAILURES PHT DRIVE SLOPE OFFSETFigure 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 IndicatorD1 – M/R Sensor Status JP4 Connector to Opto-Pickup13.1.4.2.Sync Demodulator Status LED’s BoardDC VOLTAGE TEST RELAY PCA PNSTATUS LED’s POINTSTable Relay Board Status LED Failure Indications13.2.1.M300E/EM INTERNAL GAS FLOW DIAGRAMS 13.2.GAS FLOW PROBLEMSFigure 13-6:M300E/EM – Basic Internal Gas Flow Figure 13-7:Internal Pneumatic Flow OPT 50A – Zero/Span Valves OPT 50A & 50B Figure 13-9:Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber Figure 13-11:M300E/EM – Internal Pneumatics with O2 Sensor Option 13.2.2.2.Low Flow 13.2.2.TYPICAL SAMPLE GAS FLOW PROBLEMS13.2.2.1.Flow is Zero 13.2.2.3.High Flow13.2.2.4.Displayed Flow = “Warnings” 13.3.CALIBRATION PROBLEMS13.3.1.MISCALIBRATED 13.2.2.6.Sample Pump13.3.3.INABILITY TO SPAN – NO SPAN KEY 13.3.2.NON-REPEATABLEZERO AND SPAN13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.4.1.1.Box or Sample Temperature 13.4.OTHER PERFORMANCE PROBLEMS13.4.1.TEMPERATURE PROBLEMS 13.4.1.2.Bench TemperatureELECTRICAL SHOCK HAZARD 13.4.1.3.GFC Wheel Temperature13.4.1.4.IR Photo-DetectorTEC Temperature Hazardous Voltages are present during this test13.4.2.EXCESSIVE NOISE 13.5.SUBSYSTEM CHECKOUT 13.5.1.AC MAINS CONFIGURATION13.5.2.DC POWER SUPPLY DC Power Test Point and Wiring Color CodesDC Power Supply Acceptable Levels 13.5.3.I2C BUS13.5.4.KEYBOARD/DISPLAY INTERFACE TableFUNCTION 13.5.5.RELAY BOARDTable 13-8:Relay Board Control Devices CONTROL13.5.6.1.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 Table13.5.6.6.Pressure/Flow Sensor Assembly 13.5.7.1.A/D Functions 13.5.7.MOTHERBOARD13.5.7.2.Test Channel / Analog Outputs Voltage 13.5.7.3.Analog Outputs: Current Loop 13.5.7.4.Status Outputs Table 13-12:Status Outputs Check13.5.9.RS-232COMMUNICATIONS 13.5.9.1.General RS-232Troubleshooting13.5.8.CPU 13.5.7.5.Control Inputs – Remote Zero, Span13.5.10.THE OPTIONAL CO2 SENSOR 13.6.REPAIR PROCEDURES 13.6.1.REPAIRING SAMPLE FLOW CONTROL ASSEMBLY13.6.2.REMOVING/REPLACING THE GFC WHEEL Figure 13-15:Opening the GFC Wheel HousingFigure 13-17:Removing the GFC Wheel Housing Figure 13-16:Removing the Opto-PickupAssemblyOpto-Pickup Figure 13-18:Removing the GFC Wheel Housing Mounting Screws Sync/Demod PCA Housing VR1 Adjustment Made HereOptical Bench Teledyne API, Customer Service 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURE13.7.TECHNICAL ASSISTANCE 9480 Carroll Park Drive14.1.HOW STATIC CHARGES ARE CREATED 14.A PRIMER ON ELECTRO-STATICDISCHARGEFigure 14-1:Triboelectric Charging 14.2.HOW ELECTRO-STATICCHARGES CAUSE DAMAGE 14.4.1.GENERAL RULES 14.3.COMMON MYTHS ABOUT ESD DAMAGE14.4.BASIC PRINCIPLES OF STATIC CONTROL Figure 14-2:Basic anti-ESDWorkbenchAlways wear an Anti-ESDwrist strap when working on the electronic assemblies of your analyzer. An anti-ESDwrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels. Anti-ESDwrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug 14.4.2.1.Working at the Instrument Rack 14.4.2.2.Working at an Anti-ESDWork Bench4.Place the item in the container CAUTION – Avoid Warranty Invalidation ESD Hazard∙DO NOT use pink-polybags A Primer on Electro-StaticDischarge This page intentionally left blankPage Page Page Page Page Page Warnings, Technical Manual - Model 300E Family CO Analyzers This page intentionally left blankAPPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 TEST1 SAMPLEMSG1 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.8Numeric Units Setup VariableDefault Value Value RangeValue DefaultNumeric UnitsAPPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault NumericNumeric Setup VariableDefault ValueAPPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault NumericNumeric Setup VariableDefault ValueSame settings as Setup VariableDefault NumericNumeric Setup VariableDefault ValueAPPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault NumericNumeric Setup VariableDefault ValueAPPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault NumericNumeric Setup VariableDefault ValueAPPENDIX A-2:Setup Variables For Serial I/O Setup VariableDefault NumericDescription NameMessage Text APPENDIX A-3:Warnings and Test FunctionsDescription NameMessage Text A-22MESSAGE TEXT A-23TEST FUNCTION NAME DESCRIPTIONAPPENDIX A-3:Warnings and Test Functions A-24STABIL_SAMPLES MESSAGE TEXT A-25TEST FUNCTION NAME DESCRIPTIONAPPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number APPENDIX A-4:Signal I/O DefinitionsDescription Signal NameBit or Channel Number A-27Signal Name Bit or ChannelNumber DescriptionBit or Channel Number Signal NameRear board temperature MUX analog inputs DescriptionBit or Channel Number Signal NameAPPENDIX A-4:Signal I/O Definitions DescriptionAPPENDIX A-5:DAS Triggers and Parameters NameDescription A-31Units NameDescription A-32Units NameDescription A-33APPENDIX A-6:Terminal Command Designators APPENDIX A-6:Terminal Command DesignatorsTable A-7:Terminal Command Designators COMMANDdec., 0-based MODBUSRegister Address MODBUS Floating Point Input RegistersDescription MODBUS Floating Point Holding RegistersMODBUS UnitsMODBUS MODBUS Discrete Input Registerssingle-bit; read-only DescriptionMODBUS MODBUS Coil Registerssingle-bit;read/write DescriptionAPPENDIX B - Spare Parts 04288D DCN5752This page intentionally left blank Part Number M300E Spare Parts ListDescription Part Number M300E Spare Parts ListReference: 05362J DCN5494 DescriptionPart Number M300EM Spare Parts ListDescription Part Number M300EM Spare Parts ListReference: 05424H DCN5494 Description11-20 M300EM Recommended Spare Parts Stocking Levels6-10 21-30M300E/EX Expendables Kit Reference: 0096004C009550500 000941000ORIFICE, 13 MIL SAMPLE FLOW ASSY, SOURCE009560301 Email: api-customerservice@teledyne.com APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM Please complete the following tableT300/T300M and M300E/EM APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com 2v/DIVAPPENDIX D – Wire List and Electronic Schematics 04288D DCN5752This page intentionally left blank 04288D DCN5752Interconnect List, M300E/EU, SNs 100 and greater FROM FROM This page intentionally left blank Page Sync Demod Page 2 03297k_2.sch D C B ASync Demod Page 1 03297k_1.sch Sync Demod Page 3 03297k_3.schSignal 1. This schematics is for PCASchematics for PCA 03296, Sync Demod proper authorizationTV_ENAB Schematics for PCA 03296, Sync DemodPREAMP_ENAB SYNC_10BIAS SUPPLY Schematics for PCA 03296, Sync Demodproper authorization 17-Sep-200819-Jul-2002 PCA 03631, Isolated 0-20ma,E Series03632 1 ofPWB PN, 03974 and applies to 1. This schematic is based on theNOTES PCA PN,+15V +15V+15V +15VSchematic for E Series Motherboard PCA ADDR=0x360 DEFAULT05703 RX for Com2 TX for Com105703 +15V J109 +15V CONTROL INPUTS D2 D3 D4 D5 D6 D7 SHDN and PCA Schematics for PWBOPTO-INTERRUPTER SPARE Schematic, PCA 04135 Revision A, M300E Relay PCABENCH NOTE: 1. Use PWBapplies to PCA PN, 1. This schematic is based onNOTES the PWB PN, 03974 and1 A B C D 1 SCH, E-SeriesAnalog Output Isolator, PCA04468 Not Used