Teledyne T703, T703U

General Troubleshooting & Service Teledyne API T703/T703U Calibrator Operation Manual

168

Figure 8-1: Example of Signal I/O Function

07223C DCN6572

Contents

Main MODELS T703 and T703U PHOTOMETRIC O3 CALIBRATOR Page ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI) Page SAFETY MESSAGES CONSIGNES DE SCURIT WARRANTY ABOUT THIS MANUAL REVISION HISTORY Page TABLE OF CONTENTS Page Page Page Page LIST OF FIGURES LIST OF TABLES LIST OF APPENDICES Page Page 1. INTRODUCTION 1.1. T703/T703U CALIBRATOR OVERVIEW Introduction Teledyne API T703/T703U Calibrator Operation Manual 20 1.2. OPTIONS Option Option Number Description/Notes Teledyne API T703/T703U Calibrator Operation Manual Specifications and Approvals 21 2. SPECIFICATIONS AND APPROVALS 2.1. SPECIFICATIONS Table 2-1: T703/T703U System Specifications PARAMETER SPECIFICATION Table 2-2: T703/T703U Specifications for Ozone Generator 2.2. APPROVALS AND CERTIFICATIONS 2.2.1. SAFETY 2.2.2. EMC 2.2.3. OTHER TYPE CERTIFICATIONS For additional certifications, please contact Technical Support: 3. GETTING STARTED 3.1. UNPACKING AND INITIAL SETUP 3.1.1. FRONT, REAR, AND INTERNAL CALIBRATOR DESCRIPTION Page Page Teledyne API T703/T703U Calibrator Operation Manual Getting Started 27 Figure 3-4: Rear Panel Layout Table 3-2. Rear Panel Description Page Page Page Page 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 The pin assignments for the Status Outputs are: 3.2.4. CONNECTING THE CONTROL INPUTS Teledyne API T703/T703U Calibrator Operation Manual Getting Started - 35 + Figure 3-11: Digital Control Input Connectors 3.2.5. CONNECTING THE CONTROL OUTPUTS CONTROL OUTPUTS 3.2.6. COMMUNICATION CONNECTIONS 3.2.6.1. Ethernet Connection 3.2.6.2. USB Option Connection 3.2.6.3. RS-232 and RS485 Connection 3.2.6.4. Multidrop Network Connection 3.3. PNENUMATIC CONNECTIONS 3.3.1. DRY AIR IN 3.3.2. ZERO AIR IN 3.3.3. OUTPUT MANIFOLD 3.3.4. EXHAUST 3.4. INITIAL OPERATION 3.4.1. START-UP 3.4.2. WARM UP Getting Started Teledyne API T703/T703U Calibrator Operation Manual 40 3.4.3. WARNING MESSAGES Table 3-6 lists brief descriptions of the warning messages that may occur during start up. Teledyne API T703/T703U Calibrator Operation Manual Getting Started 41 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 OUTPUT FLOW RATE 3.4.7.1. Calculating Output Flow Rate ConcO LPMppb F 20 Page Page 4. OPERATING THE CALIBRATOR Operating the Calibrator Teledyne API T703/T703U Calibrator Operation Manual 48 4.1. TEST FUNCTIONS Table 4-1: Test Functions Defined TEST MEASUREMENT DESCRIPTION 4.2. OVERVIEW OF OPERATING MODES 4.3. STANDBY MODE 4.4. GENERAL INFORMATION ABOUT THE GENERATE MODE 4.4.1. GENERATE AUTO: BASIC GENERATION OF CALIBRATION GAS 4.5. AUTOMATIC CALIBRATION SEQUENCES 4.5.1. SETUP SEQ: PROGRAMMING CALIBRATION SEQUENCES Page 4.5.1.2. Naming a Sequence 4.5.1.3. Setting the Repeat Count for a Sequence 07223C DCN6572 Page To specify a starting time for the sequence, press: DAY MONTH YEAR HOUR MINUTE To set the delta timer, press: HOUR MINUTE 4.5.1.5. Setting Up Control Inputs for a Sequence Operating the Calibrator Teledyne API T703/T703U Calibrator Operation Manual 60 4.5.1.6. Setting Up Control Outputs for a Sequence They can be set to: To assign a CC OUTPUT pattern / code to a particular sequence, press. Toggle to turn the CC output ON/OFF 4.5.1.7. Setting the Progress Reporting Mode for the Sequences REM ELAP Table 4-5: Sequence Progress Reporting Mode MODE DESCRIPTION 4.5.2. ADDING SEQUENCE STEPS To insert an instruction step into a sequence, navigate to the INSERT STEP submenu by pressing: 4.5.2.1. The GENERATE Step 4.5.2.2. The STANDBY Step 4.5.2.3. The DURATION Step 4.5.2.4. The EXECSEQ Step 4.5.2.5. The CC OUTPUT Step Toggle to turn the CC input ON/ OFF Page 4.5.3. DELETING A SEQUENCE To delete a sequence from the calibrators memory, press: 4.6. SETUP CFG 4.7. SETUP CLK 4.7.1. SETTING THE INTERNAL CLOCKS TIME AND DAY EXIT returns to SETUP X.X display HOUR MINUTE DAY MONTH YEAR Page 4.8. SETUP PASS EXAMPLE: This password enables the SETUP mode Press buttons to set number 4.9. SETUP DIAG TEST CHAN OUTPUT: USING THE TEST CHANNEL ANALOG OUTPUT + 4.9.1. CONFIGURING THE TEST CHANNEL ANALOG OUTPUT 4.9.1.1. The Analog I/O Configuration Submenu Table 4-7 lists the analog I/O functions that are available in the calibrator. To access the analog I/O configuration sub menu, press: Operating the Calibrator Teledyne API T703/T703U Calibrator Operation Manual 76 4.9.1.2. Selecting a TEST Channel Function to Output The Test Functions available to be reported are: Table 4-8: Test Channels Functions Available on the Analog Output To activate the TEST Channel and select a function press: setting accepts the new setting 4.9.1.3. TEST Channel Voltage Range Configuration To change the output range, press, Page 4.9.1.5. Adding a Recorder Offset to the TEST Channel 4.9.2. TEST CHANNEL CALIBRATION 4.9.2.1. Enabling or Disabling the TEST CHANNEL Auto-Cal Feature To enable or disable the Auto-Cal feature for the TEST CHANNEL, press. 4.9.2.2. Automatic TEST Channel Calibration To calibrate the outputs as a group with the AOUTS CALIBRATION command, press: Page 4.9.2.3. Manual Calibration of the TEST Channel Configured for Voltage Ranges For highest accuracy, the voltages of the analog outputs can be manually calibrated. To adjust the signal levels of an analog output channel manually, press: Only appear if AUTO-CAL is turned OFF 4.9.3. AIN CALIBRATION 4.10. SETUP MORE VARS: INTERNAL VARIABLES (VARS) 8 7 3 2 To access and navigate the VARS menu, use the following menu button sequence: In all cases: discards the new setting accepts the new setting 4.11. OPERATING THE CALIBRATOR AS AN O3 PHOTOMETER The T703/T703U can easily be configured to measure an external source of ozone. 1 4.11.1. SET UP FOR OPERATION AS AN O3 PHOTOMETER To convert the T703/T703U from an O3 calibrator to and O3 photometer: Page 4.12. SETUP LVL: SETTING UP AND USING LEADS (DASIBI) OPERATING LEVELS 4.12.1. GENERAL INFORMATION ABOUT LEADS LEVELS 4.12.2. DOT COMMANDS ^A.xxx!nn 4.12.3. LEVELS 4.12.4. ACTIVATING AN EXISTING LEVEL 4.12.5. PROGRAMMING NEW LEVELS To begin programming a new LEVEL find the LVL submenu by pressing: 4.12.5.1. Creating a Generate LEVEL To create a LEVEL using the AUTO generation function, press: 4.12.5.2. Editing or Deleting a LEVEL To edit or delete an existing LEVEL, press: Levels are displayed according to the following Format: Teledyne API T703/T703U Calibrator Operation Manual Operating the Calibrator 97 4.12.6. CONFIGURING LEVEL STATUS BLOCKS There are two STATUS BLOCKS associated with LEADS LEVELS. To configure the either of the STATUS BLOCKS, press: Turns the CC input ON/OFF Page 5. COMMUNICATIONS 5.1. USING THE ANALYSERS COMMUNICATION PORTS 5.1.1. RS-232 DTE AND DCE COMMUNICATION 5.1.2. SERIAL COM PORT DEFAULT SETTINGS AND CONNECTOR PIN ASSIGNMENTS Received from the factory, the calibrator is set up to emulate an RS-232 DCE device. Page Page 5.1.4. COM PORT COMMUNICATION MODES Page Page 5.1.6. MACHINE ID 5.1.7. TERMINAL OPERATING MODES 5.1.7.1. Help Commands in Terminal Mode 5.1.7.2. Command Syntax 5.1.7.3. Data Types 5.1.7.4. Status Reporting 5.1.7.5. General Message Format 5.1.7.6. COM Port Password Security Teledyne API T703/T703U Calibrator Operation Manual Communications 111 5.2. REMOTE ACCESS BY MODEM AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Page 5.3. MULTIDROP RS-232 SET UP Page Analyzer Analyzer Analyzer Last Analyzer Host RS-232 port 5.4. RS-485 CONFIGURATION OF COM2 5.5. REMOTE ACCESS VIA THE USB PORT (OPTION) Page 5.6. REMOTE ACCESS VIA THE ETHERNET 5.6.1. CONFIGURING THE ETHERNET INTERFACE USING DHCP Page Page 5.6.1.1. Manually Configuring the Network IP Addresses Communications Teledyne API T703/T703U Calibrator Operation Manual 122 STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing: From Step 1 above) Contact your IT Network Administrator 5.6.2. CHANGING THE CALIBRATORS HOSTNAME Contact your IT Network Administrator the new setting EXIT ignores the new setting 5.7. APICOM REMOTE CONTROL PROGRAM 6. CALIBRATION AND VERIFICATION 6.1. VERIFYING/CALIBRATING THE O3 PHOTOMETER 6.1.1. SETUP FOR VERIFYING AND CALIBRATING THE O3 PHOTOMETER 6.1.1.1. Calibration Manifold Exhaust/Vent Line 6.1.2. VERIFYING O3 PHOTOMETER PERFORMANCE To verify the performance of the internal photometer perform the following steps: 6.1.3. CALIBRATING THE O3 PHOTOMETER 6.1.3.1. Photometer Zero Calibration Page 6.1.4. O3 PHOTOMETER DARK CALIBRATION Yes No 6.1.5. O3 PHOTOMETER BACKPRESSURE COMPENSATION CALIBRATION 6.2. CALIBRATING THE O3 GENERATOR 6.2.1. O3 GENERATOR CALIBRATION TABLE Teledyne API T703/T703U Calibrator Operation Manual Calibration and Verification 133 6.2.2. VIEWING O3 GENERATOR CALIBRATION POINTS To view these calibration points, press: Page Page Page Teledyne API T703/T703U Calibrator Operation Manual Calibration and Verification 137 6.2.6. PERFORMING AN AUTOMATIC CALIBRATION OF THE O3 GENERATOR To run the automatic O3 generator calibration program, press: 6.3. CALIBRATING GAS PRESSURE SENSORS 6.3.1. GAS PRESSURE SENSOR CALIBRATION SET UP Page 6.3.2. CALIBRATING THE PRESSURE SENSORS 6.4. GAS FLOW CALIBRATION Page 6.4.1. CALIBRATING THE PHOTOMETERS SAMPLE GAS FLOW 6.4.2. CALIBRATING THE OUTPUT GAS FLOW 6.4.2.1. Output Gas Flow Set Up 6.4.2.2. Performing an Output Gas Flow Calibration Page Page Page 7. MAINTENANCE SCHEDULE & PROCEDURES 7.1. MAINTENANCE SCHEDULE Page ONLY CLEAN, DRY, PARTICULATE FREE Zero Air (Diluent Gas Page 7.2. PERFORMING LEAK CHECKS 7.2.1. PRESSURE LEAK CHECK Page 7.3. CLEANING OR REPLACING THE ABSORPTION TUBE 7.4. REBUILDING THE DRY AIR PUMP 7.5. PHOTOMETER UV SOURCE LAMP ADJUSTMENT 7.6. PHOTOMETER UV SOURCE LAMP REPLACEMENT Page 7.7. ADJUSTMENT OR REPLACEMENT OF OZONE GENERATOR UV LAMP Page 8. GENERAL TROUBLESHOOTING & SERVICE 8.1. GENERAL TROUBLESHOOTING 8.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES Teledyne API T703/T703U Calibrator Operation Manual General Troubleshooting & Service 163 General Troubleshooting & Service Teledyne API T703/T703U Calibrator Operation Manual WARNING FAULT CONDITION POSSIBLE CAUSES Teledyne API T703/T703U Calibrator Operation Manual General Troubleshooting & Service 165 8.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS General Troubleshooting & Service Teledyne API T703/T703U Calibrator Operation Manual 166 TEST FUNCTION DIAGNOSTIC RELEVANCE AND CAUSES OF FAULT CONDITIONS. 8.1.3. USING THE DIAGNOSTIC SIGNAL I/O FUNCTION Page Teledyne API T703/T703U Calibrator Operation Manual General Troubleshooting & Service 169 8.2. USING THE ANALOG OUTPUT TEST CHANNEL SCALE Table 8-3: Test Channel Outputs as Diagnostic Tools TEST CHANNEL DESCRIPTION ZERO FULL CAUSES OF EXTREMELY HIGH / LOW READINGS 8.3. USING THE INTERNAL ELECTRONIC STATUS LEDS 8.3.1. CPU STATUS INDICATOR 8.3.2. RELAY PCA STATUS LEDS 8.3.2.1. I2C Bus Watchdog Status LEDs Teledyne API T703/T703U Calibrator Operation Manual General Troubleshooting & Service 8.3.2.2. Troubleshooting with Relay Board Status LEDs 8.4. SUBSYSTEM CHECKOUT 8.4.1. VERIFY SUBSYSTEM CALIBRATION 8.4.2. AC MAIN POWER 8.4.3. DC POWER SUPPLY 8.4.4. I2C BUS 8.4.5. TOUCHSCREEN INTERFACE 8.4.6. LCD DISPLAY MODULE 8.4.7. RELAY PCA 8.4.8. PHOTOMETER O3 GENERATOR PRESSURE /FLOW SENSOR ASSEMBLY Page 8.4.9. MOTHERBOARD 8.4.9.1. A/D Functions 8.4.9.2. Test Channel / Analog Outputs Voltage 8.4.9.3. Status Outputs To test the status output electronics: PIN (LEFT TO RIGHT) STATUS 8.4.9.4. Control Inputs 8.4.9.5. Control Outputs 8.4.10. CPU 8.4.11. RS-232 COMMUNICATIONS 8.4.11.1. General RS-232 Troubleshooting 8.4.11.2. Troubleshooting Calibrator/Modem or Terminal Operation 8.4.12. TEMPERATURE PROBLEMS 8.4.12.1. Box / Chassis Temperature 8.4.12.2. Photometer Sample Chamber Temperature 8.4.12.3. UV Lamp Temperature 8.4.12.4. Ozone Generator Temperature 8.5. TROUBLESHOOTING THE O3 PHOTOMETER 8.5.1. DYNAMIC PROBLEMS WITH THE O3 PHOTOMETER 8.5.1.1. Noisy or Unstable O3 Readings at Zero 8.5.1.2. Noisy, Unstable, or Non-Linear Span O3 Readings 8.5.1.3. Slow Response to Changes in Concentration 8.5.1.4. The Analog Output Signal Level Does Not Agree With Front Panel Readings 8.5.1.5. Cannot Zero 8.5.1.6. Cannot Span 8.6. TROUBLE SHOOTING THE O3 GENERATOR WARNING Hazardous voltage present - use caution. 8.6.1. TROUBLESHOOTING THE O3 GENERATOR IN THE T703 (See Section 8.6.1 for troubleshooting the T703U O3 generator). 8.6.2. TROUBLESHOOTING THE O3 GENERATOR IN THE T703U 8.7. REPAIR PROCEDURES 8.7.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY General Troubleshooting & Service Teledyne API T703/T703U Calibrator Operation Manual 188 Figure 8-5: Critical Flow Restrictor Assembly Disassembly 8.7.2. DISK-ON-MODULE REPLACEMENT PROCEDURE 8.8. FAQS 8.9. TECHNICAL ASSISTANCE 9. PRINCIPLES OF OPERATION 9.1. PNEUMATIC OPERATION 9.1.1. GAS FLOW CONTROL 9.1.1.1. Photometer Critical Flow Orifice 9.1.2. INTERNAL GAS PRESSURE SENSORS Teledyne API T703/T703U Calibrator Operation Manual Principles of Operation 193 9.2. ELECTRONIC OPERATION 9.2.1. OVERVIEW I2C Bus Figure 9-3: Electronic Block Diagram 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 Principles of Operation Teledyne API T703/T703U Calibrator Operation Manual 196 I2C Connector 9.2.3.1. Valve Control Teledyne API T703/T703U Calibrator Operation Manual Principles of Operation 197 9.2.3.2. Heater Control The relay PCA controls the DC heaters for the O3 generator and photometer lamp housing. Figure 9-6: Heater Control Loop Block Diagram. 9.2.3.3. Relay PCA Status LEDs and Watch Dog Circuitry Figure 9-7: Status LED Locations Relay PCA 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/T703U Calibrator Operation Manual Principles of Operation RELAY PCA 201 Figure 9-8: Power Distribution Block diagram 9.2.6. AC POWER CONFIGURATION 9.2.6.1. AC Configuration Internal Pump (JP7) AC power configuration for the internal dry air pump is set using Jumper set 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 Page 9.5.2. GENERATOR PNEUMATIC OPERATION 9.5.3. O3 GENERATOR ELECTRONIC OPERATION Principles of Operation Teledyne API T703/T703U Calibrator Operation Manual Lamp Heater O3Generator O3Generator 208 9.5.3.1. O3 Generator Temperature Control 9.6. PHOTOMETER OPERATION II 9.6.1. MEASUREMENT METHOD 9.6.1.1. Calculating O3 Concentration T P Page Page 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 Motherboard 9.6.4.1. O3 Photometer Temperature Control 9.6.4.2. Pneumatic Sensors for the O3 Photometer 10. A PRIMER ON ELECTRO-STATIC DISCHARGE 10.1. HOW STATIC CHARGES ARE CREATED 10.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE 10.3. COMMON MYTHS ABOUT ESD DAMAGE 10.4. BASIC PRINCIPLES OF STATIC CONTROL 10.4.1. GENERAL RULES Page 10.4.2. BASIC ANTI-ESD PROCEDURES FOR INSTRUMENT REPAIR AND MAINTENANCE 10.4.2.1. Working at the Instrument Rack 10.4.2.2. Working at an Anti-ESD Work Bench. 10.4.2.3. Transferring Components from Rack to Bench and Back 10.4.2.4. Opening Shipments from Teledyne API Always unpack shipments from Teledyne API as follows: 10.4.2.5. Packing Components for Return to Teledyne API WARNING Teledyne API T703/T703U Calibrator Operation Manual A Primer on Electro-Static Discharge 227 GLOSSARY Note: Some terms in this glossary may not occur elsewhere in this manual. A Primer on lectro-Static Discharge Teledyne API T703/T703U Calibrator Operation Manual 228 Teledyne API T703/T703U Calibrator Operation Manual A Primer on Electro-Static Discharge 229 Page APPENDIX A Software Documentation Page A-3 APPENDIX A-1: Software Menu Trees 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 APPENDIX A-2: Serial I/O Setup Variables Table A-1: Setup Variables O3_PHOTO_BENCH_ONLY A-12 A-13 A-14 A-15 A-16 00000000 A-17 A-18 A-19 Table A-3: Test Functions Page A-21 Description A-22 MODELS T703, T703U, 703E I/O Signal List for Latest Revision Signal Name Bit or Channel Number Description Page A-24 APPENDIX A-5: Terminal Command Designators Table A-5: Terminal Command Designators Table A-6: Terminal Key Assignments A-25 MODBUS Register Address (dec., 0-based) MODBUS Discrete Input Registers (single-bit; read-only) Page APPENDIX B - Spare Parts Page Page T703 Spare Parts List Page T703U Spare Parts List Appendix C Warranty/Repair Questionnaire T703, T703U, 703E PARAMETER VALUE Appendix C Warranty/Repair Questionnaire T703, T703U, 703E 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 B S4 CON4 C3 1.0 PCA, UV DETECTOR PREAMP 04420 B 1 13-Aug-2004 A + PHOTO_OUT NOTE: THIS SCHEMATIC APPLIES TO THE FOLLOWING PCA'S: CHANGE NOTES D-10 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 &21752/,13876 D-21 D-22 D-23 Page TPS65150PWP D-25 To old TScreen To new TScreen D-26 TOUCH SCREEN INTERFACE CIRCUITRY ( TBD) Option D-27 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 C26 1uF C25 C22 Auxiliary I/O Board (ADC) C13 C14 C12 C11 0.01uF