Teledyne t320, t320u

Troubleshooting and Service Teledyne API – Model T300/T300M CO Analyzer

256

Figure 12-1: Viewing and Clearing Warning Messages

06864B DCN6314

Contents

Main Operation Manual Model T300/T300M Carbon Monoxide Analyzer Models T320 and T320U Analyzers Page ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI) Page IMPORTANT SAFETY INFORMATION CAUTION - General Safety Hazard CONSIGNES DE SCURIT MISE EN GARDE WARRANTY ATTENTION AVOID WARRANTY INVALIDATION Page ABOUT THIS MANUAL Page REVISION HISTORY This section provides information regarding changes to this manual. Page TABLE OF CONTENTS Page Page Page Page Page LIST OF APPENDICES LIST OF FIGURES Page LIST OF TABLES Page Page Page Page 1. INTRODUCTION, FEATURES AND OPTIONS 1.1. T300 FAMILY OVERVIEW 1.2. FEATURES 1.3. T300/T300M DOCUMENTATION 1.4. OPTIONS CAUTION - GENERAL SAFETY HAZARD Introduction, Features and Options Teledyne API Model T300/T300M CO Analyzer 28 Option Option Number Description/Notes Reference Page Page 31 2. SPECIFICATIONS AND APPROVALS 2.1. SPECIFICATIONS Table 2-1: T300/T300M Basic Unit Specifications Parameter Specification Specifications and Approvals Teledyne API Model T300/T300M CO Analyzer 32 Parameter Specification Table 2-2: O2 Sensor Option Specifications Parameter Description 2.2. EPA EQUIVALENCY DESIGNATION 2.3. APPROVALS AND CERTIFICATIONS 2.3.1. SAFETY 2.3.2. EMC 2.3.3. OTHER TYPE CERTIFICATIONS 3. GETTING STARTED 3.1. UNPACKING THE T300/T300M ANALYZER 3.1.1. VENTILATION CLEARANCE 3.2. INSTRUMENT LAYOUT 3.2.1. FRONT PANEL Page Teledyne API Model T300/T300M CO Analyzer Getting Started 39 Table 3-2: Display Screen and Touch Control Description Field Description/Function Page Page Page Page Page Page 3.3. CONNECTIONS AND SETUP 3.3.1. ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD CAUTION GENERAL SAFETY HAZARD Page CAUTION AVOID INVALIDATING WARRANTY Page Page Teledyne API Model T300/T300M CO Analyzer Getting Started 51 Table 3-6: Status Output Signals Getting Started Teledyne API Model T300/T300M CO Analyzer - + Figure 3-12: Control Input Connector Table 3-7: Control Input Signals Page Page Page Page Page Page Page Note 3.3.2. PNEUMATIC CONNECTIONS ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY IMPORTANT Leak Check 3.3.2.1. PNEUMATIC CONNECTIONS FOR BASIC CONFIGURATION Page Page Page Page Page Page Page 3.3.2.8. PNEUMATIC LAYOUT FOR ZERO SCRUBBER/PRESSURIZED SPAN OPTION Page Page Page Page 3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL CALIBRATION 3.4.1. STARTUP 3.4.2. WARNING MESSAGES Teledyne API Model T300/T300M CO Analyzer Getting Started 77 Table 3-13 lists brief descriptions of the warning messages that may occur during start up. Table 3-13: Possible Warning Messages at Start-Up Getting Started Teledyne API Model T300/T300M CO Analyzer 78 Table 3-14: Possible Startup Warning Messages T300 Analyzers with Options Message Meaning 3.4.3. FUNCTIONAL CHECKS 3.4.4. INITIAL CALIBRATION Page Page Page Page Page Page Page Page Page 4. OVERVIEW OF OPERATING MODES 4.1. SAMPLE MODE 4.1.1. TEST FUNCTIONS IMPORTANT IMPACT ON READING OR DATA Overview of Operating Modes Teledyne API Model T300/T300M CO Analyzer 92 Table 4-2: Test Functions Defined Teledyne API Model T300/T300M CO Analyzer Overview of Operating Modes 93 4.1.2. WARNING MESSAGES Table 4-3: List of Warning Messages 4.2. CALIBRATION MODE 4.3. SETUP MODE 4.3.1. PASSWORD SECURITY Overview of Operating Modes Teledyne API Model T300/T300M CO Analyzer 96 4.3.4. SECONDARY SETUP MENU (SETUP>MORE) Table 4-5: Secondary Setup Mode (SETUP>MORE) Features and Functions 5. SETUP MENU 5.1. SETUP CFG: CONFIGURATION INFORMATION To access the configuration table, press: Page Page 5.4.2. PHYSICAL RANGE VS ANALOG OUTPUT REPORTING RANGES 5.4.3. REPORTING RANGE MODES: SINGLE, DUAL, AUTO RANGES Page Page Page Page Page Page 5.4.4. RANGE UNITS 5.4.5. DILUTION RATIO (OPTION) 5.5. SETUP PASS: PASSWORD PROTECTION Page 5.6. SETUP CLK: SETTING THE INTERNAL TIME-OF-DAY CLOCK AND ADJUSTING SPEED Page 5.7. SETUP COMM: COMMUNICATIONS PORTS 5.7.1. ID (MACHINE IDENTIFICATION) 5.7.2. INET (ETHERNET) 5.7.3. COM1 AND COM2 (MODE, BAUD RATE AND TEST PORT) Setup Menu Teledyne API Model T300/T300M CO Analyzer 5.8. SETUP VARS: VARIABLES SETUP AND DEFINITION 4 3 2 1 To access and navigate the VARS menu, use the following button sequence. In all cases: EXIT discards the new setting. ENTR accepts the new setting. 5.9. SETUP DIAG: DIAGNOSTICS FUNCTIONS Page 5.9.1. SIGNAL I/O 5.9.2. ANALOG OUTPUT 5.9.3. ANALOG I/O CONFIGURATION The T300/T300M Analyzer comes equipped with four analog outputs. Table 5-5 lists the analog I/O functions that are available in the T300/T300M Analyzer. Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page To access and adjust settings for the external Analog Inputs option channels press: 5.9.4. ELECTRICAL TEST 5.9.5. DARK CALIBRATION 5.9.6. PRESSURE CALIBRATION 5.9.7. FLOW CALIBRATION 5.9.8. TEST CHAN OUTPUT * To activate the TEST Channel and select the CO MEASURE function, press: setting. ENTR accepts the new setting. 5.10. SETUP MORE ALRM (OPTION): USING THE GAS CONCENTRATION ALARMS 5.10.1. SETTING THE T300 CONCENTRATION ALARM LIMITS To enable either of the CO concentration alarms and set the limit points, press: EXIT discards the new setting ENTR accepts the new setting Page 6. COMMUNICATIONS SETUP AND OPERATION 6.1. DATA TERMINAL/COMMUNICATION EQUIPMENT (DTE DCE) 6.2. COM MUNICATI ON MODES , BAUD RATE AND PORT TESTING 6.2.1. COMMUNICATION MODES Teledyne API Model T300/T300M CO Analyzer Communications Setup and Operation 145 Figure 6-1: COM1[2] Communication Modes Setup Page 6.2.3. COM PORT TESTING 6.3. RS-232 6.4. RS-485 (OPTION) 6.5. ETHERNET 6.5.1. CONFIGURING ETHERNET COMMUNICATION MANUALLY (STATIC IP ADDRESS) To configure Ethernet communication manually: Communications Setup and Operation Teledyne API Model T300/T300M CO Analyzer 150 Internet Configuration Button Functions Figure 6-4: COMM LAN / Internet Manual Configuration Page Communications Setup and Operation Teledyne API Model T300/T300M CO Analyzer 152 6.5.3. CHANGING THE ANALYZERS HOSTNAME 6.6. USB PORT (OPTION) FOR REMOTE ACCESS for multidrop communication. Teledyne API Model T300/T300M CO Analyzer Communications Setup and Operation 155 6.7. COMMUNICATIONS PROTOCOLS 6.7.1. MODBUS www.modbustools.com) MODBUS Setup: Example Read/Write Definition window: 6.7.2. HESSEN Page Page Page Page Page 6.7.3. HESSEN PROTOCOL GAS LIST ENTRIES [GAS TYPE],[RANGE],[GAS ID],[REPORTED] CO, 0, 310, REPORTED CO2, 0, 311, REPORTED O2, 0, 312, REPORTED CO, 2, 310, REPORTED Page Page Teledyne API Model T300/T300M CO Analyzer Communications Setup and Operation 165 OPERATIONAL FLAGS1 SPARE/UNUSED BITS UNASSIGNED FLAGS (0000) Page 7. DATA ACQUISITION SYSTEM (DAS) AND APICOM 7.1. DAS STRUCTURE 7.1.1. DAS DATA CHANNELS 7.1.2. DEFAULT DAS CHANNELS Page Teledyne API Model T300/T300M CO Analyzer Data Acquisition System (DAS) and APICOM 171 Triggering Events and Data Parameters/Functions for these default channels are: Parameters: 1 Parameters: 2 List of ParametersList of Channels Figure 7-1: Default DAS Channel Setup 7.1.3. VIEWING DAS CHANNELS AND INDIVIDUAL RECORDS PREV <PRM PRM> PV10 NEXT NX10 Button 7.1.4. EDITING DAS CHANNELS Page 7.1.5. EDITING DAS TRIGGERING EVENTS 7.1.6. EDITING DAS PARAMETERS Page 7.1.7. SAMPLE PERIOD AND REPORT PERIOD Page Page 7.1.8. NUMBER OF RECORDS Page 7.1.9. RS-232 REPORT FUNCTION 7.1.10. DISABLING/ENABLING DATA CHANNELS 7.1.11. HOLDOFF FEATURE 7.2. REMOTE DAS CONFIGURATION 7.2.1. DAS CONFIGURATION VIA APICOM Page 7.2.2. DAS CONFIGURATION USING TERMINAL EMULATION PROGRAMS 8. REMOTE OPERATION 8.1. COMPUTER MODE 8.1.1. REMOTE CONTROL VIA APICOM 8.2. INTERACTIVE MODE 8.2.1. REMOTE CONTROL VIA A TERMINAL EMULATION PROGRAM Page 8.3. REMOTE ACCESS BY MODEM Page Page 8.4. PASSWORD SECURITY FOR SERIAL REMOTE COMMUNICATIONS Page 9. CALIBRATION PROCEDURES 9.1. CALIBRATION PREPARATIONS 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES Page 9.1.2. DATA RECORDING DEVICES 9.2. MANUAL CALIBRATION 9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION STEP ONE: Connect the Sources of Zero Air and Span Gas as shown below. Page 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION Page Page 9.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES 9.3.1. SETUP FOR CALIBRATION USING VALVE OPTIONS Page Page Page 9.3.3. MANUAL CALIBRATION USING VALVE OPTIONS Page Page 9.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL) Page Page Teledyne API Model T300/T300M CO Analyzer Calibration Procedures 215 9.4.1. SETUP ACAL: PROGRAMMING AND AUTO CAL SEQUENCE Calibration Procedures Teledyne API Model T300/T300M CO Analyzer 216 Teledyne API Model T300/T300M CO Analyzer Calibration Procedures 217 9.5. CO CALIBRATION QUALITY 9.6. CALIBRATION OF THE T300/T300MS ELECTRONIC SUBSYSTEMS 9.6.1. DARK CALIBRATION TEST 9.6.2. PRESSURE CALIBRATION Page 9.6.3. FLOW CALIBRATION 9.7. CALIBRATION OF OPTIONAL SENSORS 9.7.1. O2 SENSOR CALIBRATION Page Page Page 9.7.2. CO2 SENSOR CALIBRATION PROCEDURE Page Page Page 10. EPA CALIBRATION PROTOCOL 10.1. CALIBRATION REQUIREMENTS 10.1.1. CALIBRATION OF EQUIPMENT - GENERAL GUIDELINES 10.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES Teledyne API Model T300/T300M CO Analyzer EPA Calibration Protocol 233 Table 10-1: Matrix for Calibration Equipment & Supplies 10.1.3. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY To assure data of desired quality, two considerations are essential: EPA Calibration Protocol Teledyne API Model T300/T300M CO Analyzer 234 10.1.4. CALIBRATION FREQUENCY Table 10-2: Activity Matrix for Quality Assurance Checks . 10.1.5. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS Teledyne API Model T300/T300M CO Analyzer EPA Calibration Protocol 10.2. ZERO AND SPAN CHECKS 10.2.1. ZERO/SPAN CHECK PROCEDURES 10.2.2. PRECISION CHECK 10.3. PRECISIONS CALIBRATION 10.3.1. PRECISION CALIBRATION PROCEDURES 10.4. AUDITING PROCEDURE 10.4.1. CALIBRATION AUDIT 10.4.2. DATA REDUCTION AUDIT 10.5. DYNAMIC MULTIPOINT CALIBRATION PROCEDURE 10.5.1. LINEARITY TEST For each mid point: 10.6. REFERENCES Page Page Page Page 11. MAINTENANCE SCHEDULE & PROCEDURES 11.1. MAINTENANCE SCHEDULE CAUTION GENERAL SAFETY HAZARD CAUTION QUALIFIED PERSONNEL Page DATE PERFORMED ITEM ACTION FREQ CAL CHECK REQD MANUAL Page 249 11.2. PREDICTING FAILURES USING THE TEST FUNCTIONS Table 11-3: Predictive uses for Test Functions FUNCTION CONDITION BEHAVIOR INTERPRETATION 11.3. MAINTENANCE PROCEDURES 11.3.1. REPLACING THE SAMPLE PARTICULATE FILTER 11.3.2. REBUILDING THE SAMPLE PUMP 11.3.3. PERFORMING LEAK CHECKS 11.3.4. PERFORMING A SAMPLE FLOW CHECK 11.3.5. CLEANING THE OPTICAL BENCH 11.3.6. CLEANING EXTERIOR SURFACES OF THE T300/T300M 12. TROUBLESHOOTING AND SERVICE NOTE QUALIFIED PERSONNEL CAUTION GENERAL SAFETY HAZARD 12.1. GENERAL TROUBLESHOOTING 12.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES Page Page Teledyne API Model T300/T300M CO Analyzer Troubleshooting and Service 257 Table 12-1: Warning Messages - Indicated Failures Troubleshooting and Service Teledyne API Model T300/T300M CO Analyzer 258 12.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS Teledyne API Model T300/T300M CO Analyzer Troubleshooting and Service 259 The following table contains some of the more common causes for these values to be out of range. PHT DRIVE Table 12-2: Test Functions - Indicated Failures PRES SAMPLE FL SAMP TEMP BENCH TEMP Page 12.1.3. THE DIAGNOSTIC SIGNAL I/O FUNCTION Page 12.1.4. STATUS LEDS Motherboard Troubleshooting and Service Teledyne API Model T300/T300M CO Analyzer 264 Table 12-3: Sync/Demod Board Status Failure Indications D2 Segment Sensor Status JP4 Connector to Opto-Pickup Board Figure 12-4: Sync/Demod Board Status LED Locations STATUS LEDs DC VOLTAGE TEST POINTS RELAY PCA PN 04135 Troubleshooting and Service Teledyne API Model T300/T300M CO Analyzer 266 Table 12-5: Relay Board Status LED Failure Indications 12.2. GAS FLOW PROBLEMS Page Page Page 12.2.2. TYPICAL SAMPLE GAS FLOW PROBLEMS Page 12.3. CALIBRATION PROBLEMS 12.3.1. MISCALIBRATED 12.3.2. NON-REPEATABLE ZERO AND SPAN 12.3.3. INABILITY TO SPAN NO SPAN BUTTON (CALS) 12.3.4. INABILITY TO ZERO NO ZERO BUTTON (CALZ) 12.4. OTHER PERFORMANCE PROBLEMS 12.4.1. TEMPERATURE PROBLEMS Page 12.4.2. EXCESSIVE NOISE 12.5. SUBSYSTEM CHECKOUT 12.5.1. AC MAINS CONFIGURATION 12.5.2. DC POWER SUPPLY 12.5.3. I2C BUS 12.5.4. TOUCHSCREEN INTERFACE 12.5.5. LCD DISPLAY MODULE 12.5.6. RELAY BOARD 12.5.7. SENSOR ASSEMBLY Page Page 12.5.8. MOTHERBOARD Page Page 12.5.9. CPU 12.5.10. RS-232 COMMUNICATIONS 12.5.11. THE OPTIONAL CO2 SENSOR 12.6. REPAIR PROCEDURES 12.6.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 12.6.2. REMOVING/REPLACING THE GFC WHEEL Page 12.6.3. CHECKING AND ADJUSTING THE SYNC/DEMODULATOR, CIRCUIT GAIN (CO MEAS) V R1 Adjustment Mad e Here 12.6.4. DISK-ON-MODULE REPLACEMENT 12.7. FREQUENTLY ASKED QUESTIONS 12.8. TECHNICAL ASSISTANCE 13. THEORY OF OPERATION 13.1. MEASUREMENT METHOD 13.1.1. BEERS LAW I = Io e-Lc I I L C 13.2. MEASUREMENT FUNDAMENTALS 13.2.1. GAS FILTER CORRELATION Page Teledyne API Model T300/T300M CO Analyzer Theory of Operation 301 M/R is reduced Figure 13-4: Affect of CO in the Sample on CO MEAS & CO REF Page CAUTION GENERAL SAFETY HAZARD 13.3. FLOW RATE CONTROL Page 13.3.2. PARTICULATE FILTER 13.3.3. PNEUMATIC SENSORS 13.4. ELECTRONIC OPERATION Page Theory of Operation Teledyne API Model T300/T300M CO Analyzer PC 104 Bus (optional) PUMP Sensor Inputs 308 13.4.1. CPU 13.4.2. OPTICAL BENCH & GFC WHEEL Page 13.4.3. SYNCHRONOUS DEMODULATOR (SYNC/DEMOD) ASSEMBLY Teledyne API Model T300/T300M CO Analyzer Theory of Operation 313 Sample & Hold Circuits (x4) CO Reference Phase Lock Loop Page 13.4.4. RELAY BOARD Page STATUS LEDs DC VOLTAGE TEST POINTS RELAY PCA PN 04135 13.4.5. MOTHERBOARD Page 13.4.6. I2C DATA BUS 13.4.7. POWER SUPPLY/ CIRCUIT BREAKER Page 13.4.8. FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE 13.5. SOFTWARE OPERATION 13.5.1. ADAPTIVE FILTER 13.5.2. CALIBRATION - SLOPE AND OFFSET 13.5.3. MEASUREMENT ALGORITHM 13.5.4. TEMPERATURE AND PRESSURE COMPENSATION 13.5.5. INTERNAL DATA ACQUISITION SYSTEM (DAS) 14. A PRIMER ON ELECTRO-STATIC DISCHARGE 14.1. HOW STATIC CHARGES ARE CREATED 14.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE Potentially damaging electro-static discharges can occur: 14.3. COMMON MYTHS ABOUT ESD DAMAGE 14.4. BASIC PRINCIPLES OF STATIC CONTROL 14.4.1. GENERAL RULES 14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE Page CAUTION Page GLOSSARY Page Page Page INDEX 6 A B C D E F G H I L M N O R S INDEX Teledyne API Model T300/T300M CO Analyzer 342 Status Outputs, 99, 242 T Teledyne Contact Information Terminal Mode, 153 Test Channel, 123, 125, 140 Test Function Z Page APPENDIX A - Version Specific Software Documentation Page Page A-4 Figure A-3: Primary Setup Menu Page Page A-7 Figure A-6: DIAG Menu A-8 Setup Variable Numeric Units Default Value Value Range Description Medium Access Level Setup Variables (929 password) A-9 A-10 A-11 A-12 CO2_TARG_MID1_CONC CO2_TARG_MID2_CONC CO2_TARG_SPAN_CON C 10 A-13 A-14 Page A-16 14002200 15002500 A-17 A-18 00000000 A-19 A-20 A-21 Name 1 Message Text Description A-22 Name 1 Message Text Description A-23 Table A-3: T300/T300M and M300E/EM Test Functions, Revision L.8 A-24 A-25 A-26 A-27 A-28 A-29 A-30 A-31 Name Description A-32 Table A-6: T300/T300M and M300E/EM DAS Parameters, Revision L.8 Name Description Units A-33 Name Description Units A-34 APPENDIX A-6: Terminal Command Designators Table A-7: Terminal Command Designators A-35 Table A-8: Terminal Key Assignments APPENDIX A-7: MODBUS Register Map Table A-9: MODBUS Register Map MODBUS Register Address (dec., 0-based) A-36 MODBUS Register Address (dec., 0-based) Description Units A-37 MODBUS Register Address (dec., 0-based) Description Units MODBUS Discrete Input Registers (single-bit; read-only) Page APPENDIX B - Spare Parts Page Page T300 Spare Parts List T300 Recommended Spare Parts Stocking Levels * Page T300M Spare Parts List T300M Recommended Spare Parts Stocking Levels * APPENDIX C Warranty/Repair Questionnaire T300/T300M and M300E/EM Please complete the following table: APPENDIX C Warranty/Repair Questionnaire T300/T300M and M300E/EM Page Page D-3 D-4 D-5 Page Page PREAMP D-8 TEC CONTROL Printed documents are Uncontrolled. 2. Use PCB 03295. Note: 1. This schematics is for PCA 03296. D-9 BIAS SUPPLY D-10 PCA 03631, Isolated 0-20ma, E Series 03632 A 1119-Jul-2002 D-11 B +VS1 SCH, PCA 04003, PRESS/FLOW, 'E' SERIES 04354D 113-Dec-2007 B S4 CON4 C3 1.0 Schematics for PWB 05031 A 1 1 8-Jun-2004 D-13 B and PCA 05032 OPTO-INTERRUPTER Schematic, PCA 04135 Revision A, M300E Relay PCA 04136 B WHEEL BENCH SPARE OTE: 1. Use PWB 04134 N WATCHDOG TIMER SCH, E-Series Analog Output Isolator, PCA 04467 04468 B D-15 D-16 D-17 D-18 D-19 D-20 D-21 &21752/,13876 D-22 D-23 D-24 Page TPS65150PWP D-26 To old TScreen To new TScreen D-27 TOUCH SCREEN INTERFACE CIRCUITRY ( TBD) Option D-28 LVDS, Transmitter Board From ICOP CPU To LCD Display Auxiliary I/O Board (PWR-ETHERNET) C18 100uF C28 .01/2KV Auxiliary I/O Board (USB) C24 PRINTED DOCUMENTS ARE UNCONTROLLED 4.7uF C26 1uF Auxiliary I/O Board (ADC) C13 C14 C12 C11 0.01uF