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Teledyne MODEL T703 8.4.2. CALIBRATING THE OUTPUT GAS FLOW

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Teledyne API T703 Calibrator Operation Manual T703 Calibration and Verification

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8.4.2. CALIBRATING THE OUTPUT GAS FLOW

8.4.2.1. Output Gas Flow Set Up

The procedure described in this section requires an independent, calibrated flow meter/monitor and the following

set up:

PHOTOMETER

PRESSURE SENSOR

O3GEN / PHOTOMETER

PRESSURE / FLOW SENSOR PCA

O3GAS INPUT

PRESSURE SENSOR

O3FLOW

SENSOR

O3Generator Assembly

GENERATOR

REF/MEAS

Valve

On Back Panel

Chassis

GAS OUTPUT MANIFOLD

PHOTOMETER

OUTLET

TO ANALYZER

VENT

TO ANALYZER

DRY AIR

ZERO AIR

PHOTOMETER

INLET

EXHAUST

PHOTOMETER

ZERO OUT

PHOTOMETER

ZERO IN

PHOTOMETER BENCH

OFF

INTERNAL

VENT

Flow Control

(5.0 lpm)

Pressure

Regulator

CHARCOAL

SCRUBBER

Filter

PUMP

Flow Control

(1.0 LPM)

FLOW

METER

CAP

CAP CAP

Flow Control

(100 cm3/min)

Flow Control

(800 cm3/min)

Figure 8-5: Output Flow Calibration Monitor Point

07223B DCN6378

Contents

Main MODEL T703 PHOTOMETRIC O3 CALIBRATOR Page ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI) Page SAFETY MESSAGES Page WARRANTY Page ABOUT THIS MANUAL REVISION HISTORY TABLE OF CONTENTS Page Page Page Page LIST OF FIGURES LIST OF TABLES LIST OF APPENDICES Page Page 1. INTRODUCTION 1.1. T703 CALIBRATOR OVERVIEW 1.2. USING THIS MANUAL TABLE OF CONTENTS: SECTION I GENERAL INFORMATION SECTION II OPERATING INSTRUCTIONS SECTION III TECHNICAL INFORMATION Teledyne API T703 Calibrator Operation Manual Specifications and Approvals 21 2. SPECIFICATIONS AND APPROVALS 2.1. SPECIFICATIONS Table 2-1: T703 System Specifications 2.2. CE MARK COMPLIANCE 3. GETTING STARTED 3.1. UNPACKING AND INITIAL SETUP Page 3.1.1. MODEL T703 CALIBRATOR Page Page Getting Started Teledyne API T703 Calibrator Operation Manual 28 Figure 3-4: T703 Rear Panel Layout Table 3-2. Rear Panel Description Page Getting Started Teledyne API T703 Calibrator Operation Manual 30 (1.0 to 2.0 LPM) Flow Control 3.2. ELECTRICAL CONNECTIONS 3.2.1. POWER CONNECTION WARNING CAUTION AVOID PERSONAL INJURY 3.2.2. ANALOG OUTPUT TEST CHANNEL CONNECTIONS 3.2.3. CONNECTING THE STATUS OUTPUTS 3.2.4. CONNECTING THE CONTROL INPUTS - + 3.2.5. CONNECTING THE CONTROL OUTPUTS CONTROL OUTPUTS 1 2 3 4 5 6 7 8 9 10 11 12 E 3.2.6. COMMUNICATION CONNECTIONS 3.3. PNENUMATIC CONNECTIONS CAUTION! 3.3.1. DRY AIR IN 3.3.2. ZERO AIR IN Page 3.4. INITIAL OPERATION 3.4.1. START-UP 3.4.2. WARM UP 3.4.3. WARNING MESSAGES Teledyne API T703 Calibrator Operation Manual Getting Started 41 Table 3-6: Possible Warning Messages at Start-Up MESSAGE MEANING 3.4.4. FUNCTIONAL CHECK 3.4.5. OPERATING MODES FOR THE O3 GENERATOR 3.4.5.1. CNST (CONSTANT) 3.4.5.2. REF (REFERENCE) 3.4.5.3. BNCH (BENCH) 3.4.6. SETTING THE O3 GENERATOR MODE 3.4.7. SETTING THE T703S OUTPUT FLOW RATE 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY 4.1. FAQS 4.2. GLOSSARY Frequently Asked Questions and Glossary Teledyne API T703 Calibrator Operation Manual 46 Teledyne API T703 Calibrator Operation Manual Frequently Asked Questions and Glossary 47 Frequently Asked Questions and Glossary Teledyne API T703 Calibrator Operation Manual 48 5. OPTIONAL HARDWARE AND SOFTWARE 5.1. CARRYING STRAP HANDLE (OPT 29) 5.2. COMMUNICATION OPTIONS 5.2.1. SERIAL COMMUNICATIONS CABLES (OPT 60A, 60B, 60C, AND 60D) 5.2.2. ETHERNET CONNECTION 5.3. NIST TRACEABLE, PRIMARY STANDARD CERTIFICATION Page Page 6. OPERATING THE T703 CALIBRATOR 6.1. TEST FUNCTIONS TEST MEASUREMENT DESCRIPTION 6.2. OVERVIEW OF OPERATING MODES MODE MEANING 6.3. STANDBY MODE 6.4. GENERAL INFORMATION ABOUT THE GENERATE MODE 6.4.1. GENERATE AUTO: BASIC GENERATION OF CALIBRATION GAS 6.5. AUTOMATIC CALIBRATION SEQUENCES 6.5.1. SETUP SEQ: PROGRAMMING CALIBRATION SEQUENCES ATTRIBUTE NAME DESCRIPTION INSTRUCTION NAME DESCRIPTION Page Operating the T703 Calibrator Teledyne API T703 Calibrator Operation Manual 60 6.5.1.2. Naming a Sequence Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 61 07223B DCN6378 6.5.1.3. Setting the Repeat Count for a Sequence Page Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 63 To specify a starting time for the sequence, press: HOUR MINUTE DAY MONTH YEAR Operating the T703 Calibrator Teledyne API T703 Calibrator Operation Manual 64 To set the delta timer, press: HOUR MINUTE 6.5.1.5. Setting Up Control Inputs for a Sequence 6.5.1.6. Setting Up Control Outputs for a Sequence Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 67 6.5.1.7. Setting the Progress Reporting Mode for the Sequences REM ELAP MODE DESCRIPTION STEP 6.5.2. ADDING SEQUENCE STEPS To insert an instruction step into a sequence, navigate to the INSERT STEP submenu by pressing: Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 69 6.5.2.1. The GENERATE Step 6.5.2.2. The STANDBY Step 6.5.2.3. The DURATION Step 6.5.2.4. The EXECSEQ Step 6.5.2.5. The CC OUTPUT Step Page 6.5.3. DELETING A SEQUENCE 6.6. SETUP CFG Operating the T703 Calibrator Teledyne API T703 Calibrator Operation Manual 76 6.7. SETUP CLK 6.7.1. SETTING THE INTERNAL CLOCKS TIME AND DAY EXIT returns to SETUP X.X display HOUR MINUTE DAY MONTH YEAR Page 6.8. SETUP PASS EXAMPLE: This password enables the SETUP mode Press buttons to set number 6.9. SETUP DIAG TEST CHAN OUTPUT: USING THE TEST CHANNEL ANALOG OUTPUT + 6.9.1. CONFIGURING THE TEST CHANNEL ANALOG OUTPUT 6.9.1.1. The Analog I/O Configuration Submenu Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 81 To access the analog I/O configuration sub menu, press: Operating the T703 Calibrator Teledyne API T703 Calibrator Operation Manual 6.9.1.2. Selecting a TEST Channel Function to Output Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 83 To activate the TEST Channel and select a function press: setting accepts the new setting 6.9.1.3. TEST Channel Voltage Range Configuration Page Page 6.9.2. TEST CHANNEL CALIBRATION 6.9.2.1. Enabling or Disabling the TEST CHANNEL Auto-Cal Feature 6.9.2.2. Automatic TEST Channel Calibration Page Page 6.9.2.3. Manual Calibration of the TEST Channel Configured for Voltage Ranges Operating the T703 Calibrator Teledyne API T703 Calibrator Operation Manual 92 To adjust the signal levels of an analog output channel manually, press: Only appear if AUTO-CAL is turned OFF Page 6.10. SETUP MORE VARS: INTERNAL VARIABLES (VARS) 0 7 3 2 Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 95 To access and navigate the VARS menu, use the following key sequence: In all cases: discards the new setting accepts the new setting 6.11. OPERATING THE T703 CALIBRATOR AS AN O3 PHOTOMETER 6.11.1. SET UP FOR OPERATING THE T703 AS AN O3 PHOTOMETER Minimum input gas flow for Photometer is 800 cc3/min Page 6.12. SETUP LVL: SETTING UP AND USING LEADS (DASIBI) OPERATING LEVELS 6.12.1. GENERAL INFORMATION ABOUT LEADS LEVELS 6.12.2. DOT COMMANDS ^A.xxx!nn 6.12.3. LEVELS 6.12.4. ACTIVATING AN EXISTING LEVEL 6.12.5. PROGRAMMING NEW LEVELS Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 101 6.12.5.1. Creating a Generate LEVEL To create a LEVEL using the T703s AUTO generation function, press: 6.12.5.2. Editing or Deleting a LEVEL Teledyne API T703 Calibrator Operation Manual Operating the T703 Calibrator 103 6.12.6. CONFIGURING LEVEL STATUS BLOCKS Turns the CC input ON/OFF 7. OPERATING THE T703 OVER THE SERIAL I/O PORTS 7.1. USING THE ANALYSERS COMMUNICATION PORTS 7.1.1. RS-232 DTE AND DCE COMMUNICATION 7.1.2. SERIAL COM PORT DEFAULT SETTINGS AND CONNECTOR PIN ASSIGNMENTS Page Page Operating The T703 over the Serial I/O Ports Teledyne API T703 Calibrator Operation Manual 108 7.1.4. COM PORT COMMUNICATION MODES Note Communication Modes for each COM port must be configured independently. Page Page 7.1.6. MACHINE ID 7.1.7. TERMINAL OPERATING MODES 7.1.7.1. Help Commands in Terminal Mode 7.1.7.2. Command Syntax 7.1.7.3. Data Types 7.1.7.4. Status Reporting 7.1.7.5. COM Port Password Security 7.2. REMOTE ACCESS BY MODEM Page 7.3. MULTIDROP RS-232 SET UP Analyzer Analyzer Analyzer Last Analyzer Host RS-232 port 7.4. RS-485 CONFIGURATION OF COM2 7.5. REMOTE ACCESS VIA THE ETHERNET 7.5.1. CONFIGURING THE ETHERNET INTERFACE USING DHCP Page 7.5.1.1. Manually Configuring the Network IP Addresses Operating The T703 over the Serial I/O Ports Teledyne API T703 Calibrator Operation Manual 124 STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing: From Step 1 above) Contact your IT Network Administrator 7.5.2. CHANGING THE CALIBRATORS HOSTNAME Contact your IT Network Administrator the new setting EXIT ignores the new setting 7.6. APICOM REMOTE CONTROL PROGRAM Page Page 8. T703 CALIBRATION AND VERIFICATION 8.1. VERIFYING AND CALIBRATING THE T703S O3 PHOTOMETER 8.1.1. SETUP FOR VERIFYING AND CALIBRATING THE O3 PHOTOMETER 8.1.1.1. Calibration Manifold Exhaust/Vent Line 8.1.2. VERIFYING O3 PHOTOMETER PERFORMANCE Page Page 8.1.4. O3 PHOTOMETER DARK CALIBRATION Yes No 8.1.5. O3 PHOTOMETER BACKPRESSURE CALIBRATION 8.2. CALIBRATING THE O3 GENERATOR 8.2.1. O3 GENERATOR CALIBRATION TABLE Teledyne API T703 Calibrator Operation Manual T703 Calibration and Verification 137 8.2.2. VIEWING O3 GENERATOR CALIBRATION POINTS To view these calibration points, press: Page Page Page Teledyne API T703 Calibrator Operation Manual T703 Calibration and Verification 141 8.2.6. PERFORMING AN AUTOMATIC CALIBRATION OF THE O3 GENERATOR To run the automatic O3 generator calibration program, press: T703 Calibration and Verification Teledyne API T703 Calibrator Operation Manual 142 8.3. T703 GAS PRESSURE SENSOR CALIBRATION SENSOR ASSOCIATED TEST FUNCTION UNITS PRESSURE MONITOR Use monitor to measure ambient atmospheric pressure at the calibrators location. 8.3.1.1. Gas Pressure Sensor Calibration Set Up Page Page 8.4. T703 GAS FLOW CALIBRATION 8.4.1. CALIBRATING THE PHOTOMETERS SAMPLE GAS FLOW Teledyne API T703 Calibrator Operation Manual T703 Calibration and Verification 147 8.4.2. CALIBRATING THE OUTPUT GAS FLOW (100 cm3/min) Flow Control CAP CAP PUMP Page Page Page Teledyne API T703 Calibrator Operation Manual Theory of Operation 151 9. THEORY OF OPERATION yel grn orn orn orn blu 9.1.2. INTERNAL GAS PRESSURE SENSORS Teledyne API T703 Calibrator Operation Manual Theory of Operation 153 9.2. ELECTRONIC OPERATION 9.2.1. OVERVIEW I2C Bus 9.2.2. CENTRAL PROCESSING UNIT (CPU) 9.2.2.1. Disk On Module (DOM) 9.2.2.2. Flash Chip 9.2.3. RELAY PCA 9.2.3.1. Valve Control 9.2.3.2. Heater Control 9.2.3.3. Relay PCA Status LEDs and Watch Dog Circuitry 9.2.3.4. Relay PCA Watchdog Indicator (D1) 9.2.4. MOTHERBOARD 9.2.4.1. A to D Conversion 9.2.4.2. Sensor Inputs 9.2.4.3. Thermistor Interface 9.2.4.4. Analog Outputs 9.2.5. POWER SUPPLY AND CIRCUIT BREAKER Teledyne API T703 Calibrator Operation Manual Theory of Operation RELAY PCA 161 Figure 9-7: T703 Power Distribution Block diagram 9.2.6. AC POWER CONFIGURATION 9.2.6.1. AC configuration Internal Pump (JP7) 9.3. FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE 9.3.1.1. Front Panel Interface PCA 9.4. SOFTWARE OPERATION 9.5. O3 GENERATOR OPERATION 9.5.1. PRINCIPLE OF PHOTOLYTIC O3 GENERATION 9.5.2. GENERATOR PNEUMATIC OPERATION 9.5.3. O3 GENERATOR ELECTRONIC OPERATION Teledyne API T703 Calibrator Operation Manual Theory of Operation Lamp Heater O3Generator O3Generator 167 9.5.3.1. O3 Generator Temperature Control II e at STP T P Teledyne API T703 Calibrator Operation Manual Theory of Operation 171 (100 cm3/min) Flow Control PUMP 9.6.1.3. The Absorption Path 9.6.1.4. Interferent Rejection 9.6.2. PHOTOMETER LAYOUT 9.6.3. PHOTOMETER PNEUMATIC OPERATION 9.6.4. PHOTOMETER ELECTRONIC OPERATION Photometer Motherboard I2C Bus PC 104 CPU Card 9.6.4.1. O3 Photometer Temperature Control 9.6.4.2. Pneumatic Sensors for the O3 Photometer 10. MAINTENANCE SCHEDULE & PROCEDURES 10.1. MAINTENANCE SCHEDULE Page ONLY CLEAN, DRY, PARTICULATE FREE Zero Air (Diluent Gas Page 10.2. PERFORMING LEAK CHECKS 10.2.1. PRESSURE LEAK CHECK Page Page 10.3. CLEANING OR REPLACING THE ABSORPTION TUBE 10.4. REBUILDING THE DRY AIR PUMP 10.5. PHOTOMETER UV SOURCE LAMP ADJUSTMENT 10.6. PHOTOMETER UV SOURCE LAMP REPLACEMENT 10.7. ADJUSTMENT OR REPLACEMENT OF OZONE GENERATOR UV LAMP Page 11. GENERAL TROUBLESHOOTING & REPAIR 11.1. GENERAL TROUBLESHOOTING 11.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES Teledyne API T703 Calibrator Operation Manual General Troubleshooting & Repair 191 To view or clear the various warning messages press: General Troubleshooting & Repair Teledyne API T703 Calibrator Operation Manual WARNING FAULT CONDITION POSSIBLE CAUSES 11.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS General Troubleshooting & Repair Teledyne API T703 Calibrator Operation Manual 194 11.1.3. USING THE DIAGNOSTIC SIGNAL I/O FUNCTION General Troubleshooting & Repair Teledyne API T703 Calibrator Operation Manual 196 11.2. USING THE ANALOG OUTPUT TEST CHANNEL SCALE TEST CHANNEL DESCRIPTION ZERO FULL CAUSES OF EXTREMELY HIGH / LOW READINGS 11.3. USING THE INTERNAL ELECTRONIC STATUS LEDS 11.3.1. CPU STATUS INDICATOR Motherboard 11.3.2. RELAY PCA STATUS LEDS 11.3.2.1. I2C Bus Watchdog Status LEDs 11.3.2.2. O3 Status LEDs D2 (Yellow) Dry (zero) Air Pump Status D15 (Green) - Photometer Lamp Heater D16 (Yellow) O3 Generator Lamp Heater D9 (Green) External Zero Air Valve Status D1 (RED) Watchdog Indicator 11.4. SUBSYSTEM CHECKOUT 11.4.1. VERIFY SUBSYSTEM CALIBRATION 11.4.2. AC MAIN POWER 11.4.3. DC POWER SUPPLY 11.4.4. I2C BUS 11.4.5. TOUCHSCREEN INTERFACE 11.4.6. LCD DISPLAY MODULE 11.4.7. RELAY PCA 11.4.8. PHOTOMETER O3 GENERATOR PRESSURE /FLOW SENSOR ASSEMBLY Page 11.4.9. MOTHERBOARD 11.4.9.1. A/D Functions 11.4.9.2. Test Channel / Analog Outputs Voltage 11.4.9.3. Status Outputs PIN (LEFT TO RIGHT) STATUS 11.4.9.4. Control Inputs 11.4.9.5. Control Outputs 11.4.10. CPU 11.4.11. RS-232 COMMUNICATIONS 11.4.11.1. General RS-232 Troubleshooting 11.4.11.2. Troubleshooting Calibrator/Modem or Terminal Operation 11.4.12. TEMPERATURE PROBLEMS 11.4.12.1. Box / Chassis Temperature 11.4.12.2. Photometer Sample Chamber Temperature 11.4.12.3. UV Lamp Temperature 11.4.12.4. Ozone Generator Temperature 11.5. TROUBLESHOOTING THE O3 PHOTOMETER 11.5.1. DYNAMIC PROBLEMS WITH THE O3 PHOTOMETER 11.5.1.1. Noisy or Unstable O3 Readings at Zero 11.5.1.2. Noisy, Unstable, or Non-Linear Span O3 Readings 11.5.1.3. Slow Response to Changes in Concentration 11.5.1.4. The Analog Output Signal Level Does Not Agree With Front Panel Readings 11.5.1.5. Cannot Zero 11.5.1.6. Cannot Span 11.5.2. CHECKING MEASURE / REFERENCE VALVE 11.6. TROUBLESHOOTING THE O3 GENERATOR 11.6.1. CHECKING THE UV LAMP POWER SUPPLY WARNING Hazardous voltage present - use caution. 11.7. TROUBLE SHOOTING THE OPTIONAL O3 GENERATOR 11.7.1. CHECKING THE UV SOURCE LAMP POWER SUPPLY WARNING Hazardous voltage present - use caution. 11.8. REPAIR PROCEDURES 11.8.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 11.8.2. DISK-ON-MODULE REPLACEMENT PROCEDURE 11.9. TECHNICAL ASSISTANCE TELEDYNE-API, CUSTOMER SERVICE, 12. A PRIMER ON ELECTRO-STATIC DISCHARGE 12.1. HOW STATIC CHARGES ARE CREATED 12.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE 12.3. COMMON MYTHS ABOUT ESD DAMAGE 12.4. BASIC PRINCIPLES OF STATIC CONTROL 12.4.1. GENERAL RULES Page 12.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 12.4.2.1. Working at the Instrument Rack 12.4.2.2. Working at an Anti-ESD Work Bench. 12.4.2.3. Transferring Components from Rack to Bench and Back 12.4.2.4. Opening Shipments from Teledyne API Customer Service. 12.4.2.5. Packing Components for Return to Teledyne API Customer Service. WARNING Page APPENDIX A Version Specific Software Documentation Page A-3 APPENDIX A-1: Software Menu Trees, Software Version C.0 Figure A-1: Main Menu A-4 MAIN MENU SETUP O3 PASSCFG CLK MORE ON OFF TIME DATE PHOTMODE ADJ CNST REF BNCH Page A-6 INET <SET ID EDITSET><SET COM1 COM2 BAUD RATE A-7 Figure A-5: SECONDARY SETUP Menu; DIAG Submenu Basics Page Page Page A-11 A-12 MODELS T703, 703E SETUP VARIABLES FOR LATEST REVISION A-13 MODELS T703, 703E SETUP VARIABLES FOR LATEST REVISION MODEM_INIT2 BA UD_RA TE 2 RS232_MODE2 A-14 MODELS T703, 703E SETUP VARIABLES FOR LATEST REVISION A-15 MODELS T703, 703E SETUP VARIABLES FOR LATEST REVISION A-16 A-17 Table A-3: MODELS T703, 703E Test Functions Page A-19 Description A-20 MODELS T703, 703E I/O Signal List for Latest Revision Signal Name Bit or Channel Number Description Page A-22 Table A-6: Terminal Key Assignments APPENDIX B - Spare Parts Page Page T703 Spare Parts List 1 2-5 6-10 11-20 21-30 Units Part Number Description Page Appendix C Warranty/Repair Questionnaire T703, M703E PARAMETER RECORDED VALUE ACCEPTABLE VALUE Appendix C Warranty/Repair Questionnaire T703, M703E Page Page T703 Interconnect List D-3 T703 Interconnect List D-4 T703 Interconnect List D-5 Page Page SCH, PCA 04003, PRESS/FLOW, 'E' SERIES 04354D 113-Dec-2007 D-8 B S4 CON4 PCA, UV DETECTOR PREAMP 04420 B 1 13-Aug-2004 A + PHOTO_OUT NOTE: THIS SCHEMATIC APPLIES TO THE FOLLOWING PCA'S: CHANGE NOTES SCH, DC HEATER/THERMISTOR 04422 A 111-Aug-2002 D-11 B DCN:6161 D-12 Teledyne API Printed documents are uncontrolled D-13 DCN:6161 Teledyne API D-14 D-15 D-16 D-17 D-18 D-19 D-20 CONTROL INPUTS D-21 D-22 D-23 Make Model JP2 JP3 PIC102 POAR7 POAR6 POADATA ENABLE POAB6 D-24 POAB5 POAB4 PITP501 COR9 PIU308 PIU2024 PIU2014 PIA101PIA102PIA103PIA104PIA105 COR37 COJ6 PIC6001 PIU801 PIU802 PIU803 PIU804 PIU805 PIU806 PIU807 PIU808 PIU809 PIFB1501 COFB14 PIC4602 COC58 PIC5801 From ICOP CPU To LCD Display Auxiliary I/O Board (PWR-ETHERNET) C18 100uF C28 .01/2KV Auxiliary I/O Board (USB) C24 C26 1uF C25 C22 Auxiliary I/O Board (ADC) C13 C14 C12 C11 0.01uF