Maintenance Schedule & Procedures | Teledyne M300EM guide

Manual background

Maintenance Schedule & Procedures

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

Table 12-2: M300E/EM Test Function Record

DATE RECORDED

FUNCTION

OPERATING

MODE*

STABILITY

ZERO CAL

CO MEAS

ZERO CAL

ZERO CAL

MR RATIO

SPAN CAL

PRES

SAMPLE

PHT DRIVE

SAMPLE

AFTER WARM-

UP

SLOPE

SPAN CAL

OFFSET

ZERO CAL

262

04288D DCN5752

Image 264

Teledyne M300EM operation manual Maintenance Schedule & Procedures

Contents

TELEDYNE ADVANCED POLLUTION INSTRUMENTATION 9480 CARROLL PARK DRIVE SAN DIEGO, CA USAMODEL 300E FAMILY CARBON MONOXIDE ANALYZERS Operation ManualPage SAFETY MESSAGES Safety Messages This page intentionally left blank WARRANTY WARRANTY POLICY 02024DCAUTION – Avoid Warranty Invalidation COVERAGE This page intentionally left blank 04288D DCN5752 ABOUT THIS MANUAL instrumentPart No Name/Description REVISION HISTORY 2010 JuneDocument Change Summary Revision History Revision History This page intentionally left blankviii TABLE OF CONTENTS Table of Contents PART II – OPERATING INSTRUCTIONS 6. BASIC OPERATION 7. ADVANCED FEATURES 8. REMOTE OPERATION 9. CALIBRATION PROCEDURES 10. EPA CALIBRATION PROTOCOL PART III – TECHNICAL INFORMATIONxiii 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 - GENERAL INFORMATION PartGENERAL INFORMATION Part GENERAL INFORMATIONThis page intentionally left blank 1.INTRODUCTION 1.1.M300E FAMILY OVERVIEW 1.2.ADDITIONAL DOCUMENTATION 1.2.1.USING THIS MANUAL TABLE OF CONTENTSPART I – GENERAL INFORMATION SPECIFICATIONS AND WARRANTY PART III – TECHNICAL INFORMATION APPENDICESADVANCED FEATURES OF THE M300E/EM ANALYZER MAINTENANCE SCHEDULE AND PROCEDURES 2.SPECIFICATIONS AND APPROVALS 2.1.SPECIFICATIONSTable 2-1:M 300E/300EM Basic Unit Specifications 2.2.EPA EQUIVALENCY DESIGNATION 2.4.2.SAFETY COMPLIANCE 2.3.TUV DESIGNATION2.4.CE MARK COMPLIANCE 2.4.1.EMISSIONS COMPLIANCE Specifications and Approvals This page intentionally left blank 3.GETTING STARTED 3.1.M300E/EM ANALYZER LAYOUTFigure Front Panel Layout Table 3-2:Inlet / Outlet Connector Nomenclature FigureRear Panel Layout 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 3.2.UNPACKING THE M300E/EM ANALYZER GENERAL SAFETY HAZARDpower CAUTION – Avoid Warranty Invalidation ELECTRICAL SHOCK HAZARD 3.3.1.POWER CONNECTION 3.3.ELECTRICAL CONNECTIONS3.2.1.VENTILATION CLEARANCE Do not defeat the ground wire on power plug 3.3.3.CONNECTING THE STATUS OUTPUTS 3.3.2.ANALOG OUTPUT CONNECTIONSAnalog Output Connector Figure Figure 3-8:Status Output Connector Table 3-5:Status Output SignalsSTATUS REAR PANEL 3.3.4.CONNECTING THE CONTROL INPUTS Control Input ConnectorTable 3-6:Control Input Signals Figure 3.3.5.CONNECTING THE SERIAL PORTS 3.3.6.CONNECTING TO A LAN OR THE INTERNET3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.4.PNEUMATIC CONNECTIONS 3.4.1.2.Span Gas GENERAL SAFETY HAZARD exhaust and supply gas linesglass, stainless steel or brass area or shelter surrounding the instrument 3.4.2.1.Sample Gas Source 3.4.2.2.Calibration Gas Sourcesof the analyzer 3.5.INITIAL OPERATION 3.4.2.3.Input Gas Venting3.4.2.4.Exhaust Outlet using the procedures defined in Section 3.5.1.STARTUP configuration and calibration dataSystem waits 3 seconds then 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.INITIAL CALIBRATION OF THE M300E/EM 3.6.1.INTERFERENTS FOR CO2 MEASUREMENTSinstalled is set for SNGL If it is not, pressSINGL ENTR 3.6.2.2.Dilution Ratio Set Up 3.6.2.3.Set CO Span Gas Concentration 3.6.2.4.Zero/Span Calibration STABIL= XXXX PPMSTABIL= XXXX PPM STABIL= XXXX PPM 3.6.3.O2 SENSOR CALIBRATION PROCEDURE 3.6.4.CO2 SENSOR CALIBRATION PROCEDUREThe M300E/EM Analyzer is now ready for operation THANK YOU 4.FREQUENTLY ASKED QUESTIONS 4.1.FAQ’S 4.2.GLOSSARY TermDescription/Definition Term Description/Definition Term Description/Definition 5.OPTIONAL HARDWARE AND SOFTWARE 5.1.EXTERNAL PUMPS OPTIONS 10A-10E,11,5.2.RACK MOUNT KITS OPT 20 TO OPT 5.3.CARRYING STRAP/HANDLE OPT 5.4.CURRENT LOOP ANALOG OUTPUTS OPTIONGENERAL SAFETY HAZARD Figure 5-2:Current Loop Option Installed on the Motherboard 5.5.EXPENDABLES AND SPARES KITS OPTIONS 42A, 5.6.CALIBRATION VALVES OPTIONS 50A, 50B, 50E, 50H5.6.2.ZERO/SPAN VALVE OPTION 50A 5.6.1.1.Gas Flow Rate 5.6.2.1.Internal Pneumatics OPT 50A Figure 5.6.2.2.Pneumatic Set Up OPT 50A 5.6.2.3.Input Gas Venting5.6.2.4.Exhaust Outlet SAMPLE GAS SOURCE 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50B 5.6.3.1.Internal Pneumatics OPT 50BFigure 5.6.3.2.Pneumatic Set Up OPT 50B SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR 5.6.4.1.Internal Pneumatics OPT 50H 5.6.4.2.Pneumatic Set Up OPT 50H SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR 5.6.5.1.Internal Pneumatics OPT 50E Scrubber 5.6.5.2.Pneumatic Set Up OPT 50E SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR 5.7.COMMUNICATION OPTIONS 5.7.1.RS-232MODEM CABLE OPTION 60A5.7.2.RS-232MULTIDROP OPTION Table 5-5:M300E/EM Modem Cable Options 5.7.3.ETHERNET OPTION 63A Figure 5-12:M300E/EM Ethernet Card 5.8.SECOND GAS SENSORS 5.7.4.ETHERNET + MULTIDROP OPT 63C5.8.1.OXYGEN SENSOR OPTION 65A 5.8.1.2.Operation within the M300E/EM Analyzer 5.8.1.3.Pneumatic Operation of the O2 Sensor 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS 5.9.CARBON DIOXIDE SENSOR OPTION 67A5.9.2.THEORY OF OPERATION 5.9.2.1.NDIR measurement of CO2 5.9.2.2.Operation within the M300E/EM Analyzer 5.9.2.3.Pneumatic Operation of the CO2 SensorFigure 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.SPECIAL FEATURES 5.11.2.MAINTENANCE MODE SWITCH5.11.3.SECOND LANGUAGE SWITCH 5.11.1.DILUTION RATIO OPTION PART – OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS This page intentionally left blank 6.BASIC OPERATION 6.1.OVERVIEW OF OPERATING MODESMODE EXPLANATION 6.2.SAMPLE MODE analyzer’s inability to calculate itFigure 6-2:Viewing M300E/EM Test Functions Table Test Functions Defined 6.3.WARNING MESSAGES MEANINGThe IR source may be faulty Table 6-3:List of Warning Messages 6.4.CALIBRATION MODE currently selected reporting range EXAMPLES 6.5.SETUP MODE Primary Setup Mode Features and FunctionsSecondary 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 6.5.3.SETUP  PASS: PASSWORD FEATURE Password LevelsTable 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 Table 6-7:M300E Family Physical range by Model MODELRANGE M300E 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATION Figure 6-4:Analog Output Connector Pin OutANALOG OUT 6.6.3.REPORTING RANGE MODES SNGLDUAL AUTOPage concentrations The two ranges must be independently calibrated Basic Operation discards the new setting accepts the new setting Toggle these keys toselect the upper limit for the reporting range computing the CO concentration Basic Operation reporting unitsPressure STP sufficient Using the dilution ratio option is a 4-stepprocess Basic Operation This page intentionally left blank 7.ADVANCED FEATURES 7.1.1.IDAS STATUSLED STATE IDAS STATUS 7.1.2.IDAS STRUCTURE 7.1.2.1.iDAS ChannelsTable 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 7.1.5.3.Editing iDAS Parameters found in Appendix A-5Table 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 7.1.5.9.The Compact Report Feature 7.1.5.10.The Starting Date 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 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARS DEFAULTTable 7-4:Variable Names VARS ALLOWED setting accepts the new settingSETUP SETUP Table 7-5:Diagnostic Mode DIAG Functions SIGNAL I/OCONFIGURATION DIAG I/O 7.3.1.ACCESSING THE DIAGNOSTIC FEATURES 7.4.USING THE M300E/EM ANALYZER’S ANALOG OUTPUTS Table 7-6:DIAG - Analog I/O FunctionsSUB MENU OUTPUTPage Table 7-7:Analog Output Voltage Range Min/Max RANGE NAMERANGE SPAN MINIMUM OUTPUT 04288D DCN5752 7.4.3.CALIBRATION OF THE ANALOG OUTPUTS See Section Manual calibration should be used for any analog output set for a 0.1V output range or in cases where Page The menu for manually adjusting the analog output signal level will only appear if the AUTO-CALfeature Advanced Features GENERAL SAFETY HAZARD ground Advanced Features % FS Voltage acrossResistor for 2-20mA Resistor for 4-20mAPage Page TEST CHANNEL DESCRIPTIONZERO FULL SCALE setting new settingSETUP SETUP 7.4.7.AIN CALIBRATION ALARM STATUSLIMIT SET POINT1 Advanced Features This page intentionally left blank 8.1.2.COMM PORT DEFAULT SETTINGS 8.REMOTE OPERATION8.1.1.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 8.1.4.COMM PORT COMMUNICATION MODES 81922048 1024 Remote Operation 8.1.5.COMM PORT TESTING 8.1.6.MACHINE ID 8.1.7.1.Help Commands in Terminal Mode 8.1.7.TERMINAL OPERATING MODESTable 8-2:Terminal Mode Software Commands 8.1.7.2.Command Syntax 8.1.7.3.Data TypesX ID COMMAND <CR> Table 8-3:Teledyne API’s Serial I/O Command Types 8.1.7.4.Status Reporting X DDD:HH:MM Id MESSAGE<CRLF> 8.1.7.5.COMM Port Password Security 940331 is the default passwordLOGON V RS-232 PASS=NNNNNN 8.2.MULTIDROP RS-232SET UP Host CALIBRATORTAPI Analyzer Last INSTRUMENT 8.3.RS-485CONFIGURATION OF COM2 Figure 8-5:CPU RS-485Setup The DCE/DTE switch has no effect on COM2 Female DB-9COM2RX/TX RX/TX+ 8.4.REMOTE ACCESS VIA THE ETHERNET Table 8-4:Ethernet Status Indicators Table 8-5:LAN/Internet Configuration Properties DEFAULT STATESee your network administrator PROPERTY Remote Operation ∙Your LAN is not running a DHCP software package ON/OFF SETUPPRIMARY SETUP MENU SETUP FUNCTION Moves the cursor one character to the left orright Inserts a character before the cursor location 8.4.4.CHANGING THE ANALYZER’S HOSTNAME FUNCTIONENTR EXIT 8.5.MODBUS SETUP Minimum RequirementsActions 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 8.6.2.HESSEN COMM PORT CONFIGURATION 8.6.1.GENERAL OVERVIEW OF HESSEN PROTOCOLProtocol network 8.6.3.ACTIVATING HESSEN PROTOCOL 8.6.4.SELECTING A HESSEN PROTOCOL TYPE 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODE MODE IDMODE DESCRIPTION TEXT 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIES GAS TYPE,RANGE,GAS ID,REPORTEDCO, 0, 310, REPORTED CO2, 0, 311, REPORTED O2, 0, 312, REPORTED 8.6.6.2.Editing or Adding HESSEN Gas List Entries 8.6.6.3.Deleting HESSEN Gas List Entries 8.6.7.SETTING HESSEN PROTOCOL STATUS FLAGS Table 8-8:Default Hessen Status Flag AssignmentsDEFAULT BIT STATUS FLAG NAME 8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM 9.CALIBRATION PROCEDURES Calibration ProceduresSECTION 9.1 – BEFORE CALIBRATION SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS 9.1.BEFORE CALIBRATION 9.1.2.CALIBRATION GASES9.1.2.1.Zero Air troubleshooting tips 9.1.3.DATA RECORDING DEVICES 9.1.2.2.Span Gas9.1.2.3.Traceability calibration and alters the instrument’s Calibration Calibration Procedures 9.2.2.PERFORMING A BASIC MANUAL CALIBRATION CHECK See Section 12 for troubleshooting tipsallowed for a reliable calibration 9.2.3.PERFORMING A BASIC MANUAL CALIBRATION the SPAN gasthe 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 9.3.3.MANUAL CALIBRATION USING VALVE OPTIONS the SPAN gasthe bottle 9.3.3.2.Zero/Span Point Calibration Procedure 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCAL Table 9-2:AUTOCAL ModesMODE NAME ACTION Table 9-3:AutoCal Attribute Setup Parameters TIMER ENABLEDATTRIBUTE ACTION MODE AND VALUECOMMENT ZERO-SPAN from the display SETUP X.X STARTING DATE: 04–SEP–08 for each 9.5.CO CALIBRATION QUALITY Table 9-5:Calibration Data Quality EvaluationFUNCTION MINIMUM VALUE 9.6.1.DARK CALIBRATION TEST SETUPSETUP DAS RNGE PASS CLK MORE 9.6.2.PRESSURE CALIBRATION atmospheric pressure 9.6.3.FLOW CALIBRATION 9.6.4.ELECTRICAL TEST CALIBRATION 9.7.1.O2 SENSOR CALIBRATION PROCEDURE 9.7.1.1.O2 Calibration Setup9.7.CALIBRATION OF OPTIONAL SENSORS 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.CO2 SENSOR CALIBRATION PROCEDURE 9.7.2.1.CO2 Calibration Setup9.7.2.2.Set CO2 Span Gas Concentration 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 & 10.2.1.ZERO/SPAN CHECK PROCEDURES 10.3.PRECISIONS CALIBRATION10.2.2.PRECISION CHECK 10.4.AUDITING PROCEDURE 10.3.1.PRECISION CALIBRATION PROCEDURES10.4.1.CALIBRATION AUDIT 10.4.2.DATA REDUCTION AUDIT 10.5.DYNAMIC MULTIPOINT CALIBRATION PROCEDURE 10.4.3.SYSTEM AUDIT/VALIDATION10.5.1.LINEARITY TEST ∙Leaks ∙Correct flow 10.6.REFERENCES PART – TECHNICAL INFORMATION PARTTECHNICAL INFORMATION Technical information This page intentionally left blank 11.THEORY OF OPERATION 11.1.MEASUREMENT METHOD11.2.MEASUREMENT FUNDAMENTALS 11.1.1.BEER’S LAW 11.2.1.GAS FILTER CORRELATION Figure 11-1:Measurement FundamentalsFigure 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 11.3.PNEUMATIC OPERATION GENERAL SAFETY HAZARDmaintenance schedule, Table over ambient pressure 11.4.FLOW RATE CONTROL 11.4.1.1.Critical Flow Orifice 11.4.2.PARTICULATE FILTER 11.4.3.PNEUMATIC SENSORS11.4.3.1.Sample Pressure Sensor 11.4.3.2.Sample Flow Sensor 11.5.ELECTRONIC OPERATION 11.5.1.OVERVIEW PC 104 Bus Figure 11-9:M300E/EM Electronic Block DiagramMOTHER BOARD 11.5.2.CENTRAL PROCESSING UNIT CPU DISK-ON-MODULEDOMFLASH CHIP 11.5.3.OPTICAL BENCH & GFC WHEEL 11.5.3.1.Temperature Control11.5.3.2.IR Source 11.5.3.3.GFC Wheel Figure 11-10:GFC Light Mask M/R SENSOR SEGMENT SENSORFigure 11-11:Segment Sensor and M/R Sensor Output SCHMIDT TRIGGERS 11.5.3.4.IR Photo-Detector 11.5.4.1.Overview 11.5.4.2.Signal Synchronization and Demodulation M300E/EM Sync/Demod Block DiagramFigure Table 11-2:Sync DEMOD Sample and Hold Circuits 11.5.4.5.Dark Calibration Switch 11.5.4.3.Sync/Demod Status LED’s11.5.4.4.Photo-DetectorTemperature Control Figure 11-13:Sample & Hold Timing 11.5.4.6.Electric Test Switch 11.5.5.RELAY BOARD11.5.5.1.Heater Control 11.5.5.2.GFC Wheel Motor Control RELAY PCA PN STATUS LED’s11.5.5.5.Status LED’s DC VOLTAGE TEST 11.5.6.MOTHERBOARD 11.5.6.1.A to D Conversion11.5.6.2.Sensor Inputs 11.5.6.3.Thermistor Interface 11.5.6.4.Analog Outputs 11.5.6.5.Internal Digital I/O11.5.6.6.External Digital I/O BENCH TEMPERATURE SENSOR 11.5.8.POWER SUPPLY/ CIRCUIT BREAKER 11.5.7.I2C DATA BUSPOWER UP CIRCUIT GENERAL SAFETY HAZARD Figure 11-15:Power Distribution Block Diagram Theory of Operation 11.5.9.COMMUNICATION INTERFACE Figure 11-16:Interface Block DiagramMother Board 11.5.10.FRONT PANEL INTERFACE 11.5.10.1.Analyzer Status LED’s11.5.10.2.Keyboard Figure 11-17:M300E/EM Front Panel Layout 11.5.10.3.Display 11.5.10.4.Keyboard/Display Interface ElectronicsI2C Interface 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY KEYPAD DECODER KEY-DEPRESS-DETECTCIRCUIT DISPLAY POWER WATCH DOG I2C INTERFACE CHIPDISPLAY DATA DECODER DISPLAY CONTROLLER 11.5.11.SOFTWARE OPERATION 11.5.12.ADAPTIVE FILTERFigure 11-19:Basic Software Operation 11.5.13.CALIBRATION - SLOPE AND OFFSET 11.5.14.MEASUREMENT ALGORITHM11.5.15.TEMPERATURE AND PRESSURE COMPENSATION 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDAS Theory of Operation This page intentionally left blank 12.MAINTENANCE SCHEDULE & PROCEDURES 12.1.MAINTENANCE SCHEDULEGENERAL SAFETY HAZARD QUALIFIED PERSONNEL Maintenance Schedule & Procedures ITEM ACTIONFREQ CAL CHECK MANUAL REQ’D Maintenance Schedule & Procedures 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONS Table 12-3:Predictive uses for Test FunctionsFUNCTION CONDITION 12.3.MAINTENANCE PROCEDURES 12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER12.3.2.REBUILDING THE SAMPLE PUMP Figure 12-1:Sample Particulate Filter Assembly 12.3.3.PERFORMING LEAK CHECKS 12.3.3.1.Vacuum Leak Check and Pump Check12.3.3.2.Pressure Leak Check GENERAL SAFETY HAZARD 12.3.5.CLEANING THE OPTICAL BENCH 12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM12.3.4.PERFORMING A SAMPLE FLOW CHECK GENERAL SAFETY HAZARD 13.TROUBLESHOOTING & REPAIR 13.1.GENERAL TROUBLESHOOTINGGENERAL SAFETY HAZARD QUALIFIED PERSONNEL 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGES CLR SETUPSAMPLE BENCH TEMP WARNING Table 13-1 Warning Messages - Indicated Failures 13.1.2.FAULT DIAGNOSIS WITH TEST FUNCTIONS INDICATED FAILURES PRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMPBOX TEMP Table 13-2:Test Functions - Indicated Failures INDICATED FAILURES PHT DRIVE SLOPE OFFSET Figure 13-2:Example of Signal I/O Function 13.1.4.1.CPU Status Indicator 13.1.4.INTERNAL ELECTRONIC STATUS LED’SMotherboard P/N CPU Status LED Figure 13-3:CPU Status Indicator JP4 Connector to Opto-Pickup 13.1.4.2.Sync Demodulator Status LED’sD1 – M/R Sensor Status Board RELAY PCA PN STATUS LED’sDC VOLTAGE TEST POINTS Table Relay Board Status LED Failure Indications 13.2.GAS FLOW PROBLEMS 13.2.1.M300E/EM INTERNAL GAS FLOW DIAGRAMSFigure 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.TYPICAL SAMPLE GAS FLOW PROBLEMS 13.2.2.1.Flow is Zero13.2.2.2.Low Flow 13.2.2.3.High Flow 13.3.CALIBRATION PROBLEMS 13.3.1.MISCALIBRATED13.2.2.4.Displayed Flow = “Warnings” 13.2.2.6.Sample Pump 13.3.2.NON-REPEATABLEZERO AND SPAN 13.3.3.INABILITY TO SPAN – NO SPAN KEY13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.4.OTHER PERFORMANCE PROBLEMS 13.4.1.TEMPERATURE PROBLEMS13.4.1.1.Box or Sample Temperature 13.4.1.2.Bench Temperature 13.4.1.3.GFC Wheel Temperature 13.4.1.4.IR Photo-DetectorTEC TemperatureELECTRICAL SHOCK HAZARD Hazardous Voltages are present during this test 13.4.2.EXCESSIVE NOISE 13.5.1.AC MAINS CONFIGURATION 13.5.2.DC POWER SUPPLY13.5.SUBSYSTEM CHECKOUT DC Power Test Point and Wiring Color Codes 13.5.3.I2C BUS 13.5.4.KEYBOARD/DISPLAY INTERFACEDC Power Supply Acceptable Levels Table 13.5.5.RELAY BOARD Table 13-8:Relay Board Control DevicesFUNCTION CONTROL 13.5.6.SENSOR ASSEMBLY 13.5.6.1.Sync/Demodulator Assembly13.5.6.2.Electrical Test 13.5.6.3.Opto Pickup Assembly 13.5.6.4.GFC Wheel Drive13.5.6.5.IR Source Table 13.5.6.6.Pressure/Flow Sensor Assembly 13.5.7.MOTHERBOARD 13.5.7.1.A/D Functions13.5.7.2.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 13.5.9.1.General RS-232Troubleshooting 13.5.8.CPU13.5.9.RS-232COMMUNICATIONS 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 13-16:Removing the Opto-PickupAssembly Figure 13-17:Removing the GFC Wheel HousingOpto-Pickup Figure 13-18:Removing the GFC Wheel VR1 Adjustment Made Here Housing Mounting Screws Sync/Demod PCA HousingOptical Bench 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURE 13.7.TECHNICAL ASSISTANCETeledyne API, Customer Service 9480 Carroll Park Drive 14.A PRIMER ON ELECTRO-STATICDISCHARGE 14.1.HOW STATIC CHARGES ARE CREATEDFigure 14-1:Triboelectric Charging 14.2.HOW ELECTRO-STATICCHARGES CAUSE DAMAGE 14.3.COMMON MYTHS ABOUT ESD DAMAGE 14.4.BASIC PRINCIPLES OF STATIC CONTROL14.4.1.GENERAL RULES Figure 14-2:Basic anti-ESDWorkbench Always wear an Anti-ESDwrist strap when working on the electronic assemblies of your analyzer. An anti-ESDwrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels. Anti-ESDwrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug 14.4.2.1.Working at the Instrument Rack 14.4.2.2.Working at an Anti-ESDWork Bench 4.Place the item in the container ESD Hazard CAUTION – Avoid Warranty Invalidation∙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 SAMPLE TEST1MSG1 SAMPLE SETUP RNGE PASSCLK MORE <TST TST> Figure A-3:Primary Setup Menu  DAS Submenu APPENDIX A-1:Software Menu Trees, Revision L.8ACAL1 APPENDIX A-1:Software Menu Trees, Revision L.8 SAMPLESETUP CO, 310, REPORTED CO2, 311, REPORTEDO2, 312 REPORTED Figure A-6:DIAG Menu A-7 APPENDIX A-1:Software Menu Trees, Revision L.8 Setup Variable Default ValueNumeric Units Value Range Default NumericValue Units Setup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O Numeric Setup Variable DefaultNumeric Value Setup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O Numeric Setup Variable DefaultNumeric Value Setup Variable DefaultSame settings as Numeric Setup Variable DefaultNumeric Value Setup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O Numeric Setup Variable DefaultNumeric Value Setup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O Numeric Setup Variable DefaultNumeric Value Setup Variable DefaultAPPENDIX A-2 Setup Variables For Serial I/O Numeric Name Message TextDescription APPENDIX A-3:Warnings and Test Functions Name Message TextDescription A-22 A-23 TEST FUNCTION NAMEMESSAGE TEXT DESCRIPTION A-24 APPENDIX A-3 Warnings and Test FunctionsSTABIL_SAMPLES A-25 TEST FUNCTION NAMEMESSAGE TEXT DESCRIPTION Signal Name Bit or Channel NumberAPPENDIX A-4:Signal I/O Definitions APPENDIX A-4:Signal I/O Definitions Signal Name Bit or Channel NumberDescription A-27 Bit or Channel NumberSignal Name Description Signal Name Bit or Channel NumberDescription A-29 Signal Name APPENDIX A-4:Signal I/O DefinitionsBit or Channel Number Description Name DescriptionAPPENDIX A-5:DAS Triggers and Parameters A-31 Name DescriptionUnits A-32 Name DescriptionUnits A-33 APPENDIX A-6:Terminal Command Designators Table A-7:Terminal Command DesignatorsAPPENDIX A-6:Terminal Command Designators COMMAND MODBUS Register Addressdec., 0-based MODBUS Floating Point Input Registers MODBUS Floating Point Holding Registers MODBUSDescription Units MODBUS Discrete Input Registers single-bit; read-onlyMODBUS Description MODBUS Coil Registers single-bit;read/writeMODBUS Description APPENDIX B - Spare Parts 04288D DCN5752 This page intentionally left blank M300E Spare Parts List Part NumberDescription M300E Spare Parts List Reference: 05362J DCN5494Part Number Description M300EM Spare Parts List Part NumberDescription M300EM Spare Parts List Reference: 05424H DCN5494Part Number Description M300EM Recommended Spare Parts Stocking Levels 6-1011-20 21-30 M300E/EX Expendables Kit Reference: 0096004C 000941000 ORIFICE, 13 MIL SAMPLE FLOW009550500 ASSY, SOURCE 009560301 APPENDIX C Warranty/Repair Questionnaire T300/T300M and M300E/EMEmail: api-customerservice@teledyne.com Please complete the following table APPENDIX C Warranty/Repair Questionnaire Email: api-customerservice@teledyne.comT300/T300M and M300E/EM 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 D C B A Sync Demod Page 1 03297k_1.schSync Demod Page 2 03297k_2.sch Sync Demod Page 3 03297k_3.sch 1. This schematics is for PCA Schematics for PCA 03296, Sync DemodSignal proper authorization Schematics for PCA 03296, Sync Demod PREAMP_ENABTV_ENAB SYNC_10 Schematics for PCA 03296, Sync Demod proper authorizationBIAS SUPPLY 17-Sep-2008 PCA 03631, Isolated 0-20ma,E Series 0363219-Jul-2002 1 of 1. This schematic is based on the NOTESPWB PN, 03974 and applies to PCA PN, +15V +15V+15V +15V ADDR=0x360 DEFAULT Schematic for E Series Motherboard PCA05703 TX for Com1 RX for Com205703 +15V J109 +15V CONTROL INPUTS D2 D3 D4 D5 D6 D7 SHDN Schematics for PWB and PCAOPTO-INTERRUPTER Schematic, PCA 04135 Revision A, M300E Relay PCA BENCHSPARE NOTE: 1. Use PWB 1. This schematic is based on NOTESapplies to PCA PN, the PWB PN, 03974 and SCH, E-SeriesAnalog Output Isolator, PCA 044681 A B C D 1 Not Used