Teledyne T802 9. CALIBRATION PROCEDURES

07275A (DCN6005) 169

9. CALIBRATION PROCEDURES

This section contains a variety of information regarding the various methods for

calibrating a T802 as well as other supporting information

This section is organized as follows:

Section 9.1 – Before Calibration

This section contains general information you should know before calibrating the

analyzer.

SECTION 9.2 – Manual Calibration Checks and Calibration

This section describes the procedure for checking the calibration of the T802 and

calibrating the instrument. Also included are instructions for selecting the

reporting range to be calibrated when the T802 analyzer is set to operate in either

the DUAL or AUTO reporting range modes.

SECTION 9.3 – Assessing Calibration Quality

This section describes how to judge the effectiveness of a recently performed

calibration.

SECTION 9.4 – Calibration of the T802’s Electronic Subsystems

This section describes how to perform calibrations of the T802’s electronic

systems, including:

 adjusting the analyzers internal flow sensor

 adjusting the analyzers internal pressure sensor

SECTION 9.5 – Calibration of the Optional CO2 Sensor

This section describes how to perform calibrations of the optional CO2 Sensor.

Note Throughout this Section are various diagrams showing pneumatic

connections between the T802 and various other pieces of equipment such

as calibrators and zero air sources. These diagrams are only intended to be

schematic representations of these connections and do not reflect actual

physical locations of equipment and fitting location or orientation. Contact

your regional EPA or other appropriate governing agency for more detailed

recommendations..

07275B DCN6418

Contents

Main MODEL T802 PARAMAGNETIC OXYGEN ANALYZER Page ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI) Page SAFETY MESSAGES CONSIGNES DE SCURIT WARRANTY Page ABOUT THIS MANUAL ORGANIZATION CONVENTIONS USED ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY IMPORTANT IMPACT ON READINGS OR DATA REVISION HISTORY TABLE OF CONTENTS Page Page LIST OF FIGURES LIST OF TABLES LIST OF APPENDICES Page Page 1. INTRODUCTION, FEATURES AND OPTIONS 1.1. T802 OVERVIEW 1.2. FEATURES 1.3. OPTIONS Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Introduction, Features and Options Option Option Number Description/Notes Reference CAUTION - GENERAL SAFETY HAZARD Introduction, Features and Options Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 20 Option Option Number Description/Notes Reference 2. SPECIFICATIONS, APPROVALS & COMPLIANCE 2.1. SPECIFICATIONS Table 2-1: T802 Specifications 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 THE T802 ANALYZER Page 3.1.1. VENTILATION CLEARANCE 3.2. INSTRUMENT LAYOUT 3.2.1. FRONT PANEL Page Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Table 3-2. Display Screen and Touch Control Description Field Description/Function Page Page Page Page 3.3. CONNECTIONS AND SETUP 3.3.1. ELECTRICAL CONNECTIONS WARNING - ELECTRICAL SHOCK HAZARD CAUTION GENERAL SAFETY HAZARD Page Page C ONVERTING C URRENT L OOP ANALOG OUTPUTS TO S VOLTAGE OUTPUTS Page + - ALARM 1 RELAY ALARM 2 RELAY & ALARM 3 RELAY ALARM 4 RELAY ETHERNET CONNECTION RS-232 CONNECTION Page RS-232 MULTIDROP OPTION CONNECTION Page Page Note RS-485 CONNECTION 3.3.2. PNEUMATIC CONNECTIONS CAUTION GENERAL SAFETY HAZARD ZERO GAS CAUTION GENERAL SAFETY HAZARD Page CAUTION Page Page IMPORTANT Leak Check: 3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL CALIBRATION 3.4.1. STARTUP Page 3.4.2. FUNCTIONAL CHECKS 3.4.3. INITIAL CALIBRATION Page Page 3.4.3.2. DILUTION RATIO (OPTION) SET UP Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 3.4.3.3. SET O2 SPAN GAS CONCENTRATION Page SECTION II OPERATING INSTRUCTIONS Page 4. BASIC OPERATION 4.1. OVERVIEW OF OPERATING MODES Basic Operation Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 64 Figure 4-1: Front Panel Touchscreen and Display MODE EXPLANATION [type:] 4.2. SAMPLE MODE Basic Operation Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 66 Table 4-2: Test Functions Defined % 4.3. CALIBRATION MODE 4.4. SETUP MODE 4.4.1. PRIMARY SETUP MENU Basic Operation Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 68 4.4.2. SECONDARY SETUP MENU (SETUP>MORE) Table 6-5: Secondary Setup Mode Features and Functions 5. SETUP MENU 5.1. SETUP CFG: CONFIGURATION INFORMATION 5.2. SETUP ACAL: [NOT USED] 5.3. SETUP DAS: INTERNAL DATA ACQUISITION SYSTEM 5.4. SETUP RNGE: ANALOG OUTPUT REPORTING RANGE CONFIGURATION 5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING RANGES 5.4.2. ANALOG OUTPUT RANGES FOR O2 CONCENTRATION 5.4.3. REPORTING RANGE MODES Page Page To set the upper range limit for each independent reporting range, press: Page 5.4.4. SETUP RNGE DIL: USING THE OPTIONAL DILUTION RATIO FEATURE 5.5. SETUP PASS: PASSWORD FEATURE Page Page 5.6. SETUP CLK: SETTING THE T802 ANALYZERS INTERNAL CLOCK 5.6.1. SETTING THE INTERNAL CLOCKS TIME AND DAY 5.6.2. ADJUSTING THE INTERNAL CLOCKS SPEED 5.7. SETUP MORE COMM: COMMUNICATION PORTS 5.7.1. ID (MACHINE IDENTIFICATION) 5.7.2. INET (ETHERNET) 5.7.3. COM1[COM2] (MODE, BAUDE RATE AND TEST PORT) 5.8. SETUP MORE VARS: INTERNAL VARIABLES (VARS) Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 0 86 Table 5-2: Variable Names (VARS) NO. VARIABLE DESCRIPTION ALLOWED SETTINGS 8 7 To access and navigate the VARS menu, use the following key sequence. In all cases: EXIT discards the new setting ENTR accepts the new setting 5.9. SETUP MORE DIAG: DIAGNOSTICS FUNCTIONS To access the DIAG functions press the following menu sequence: 5.9.1. SIGNAL I/O 5.9.2. ANALOG OUTPUT The T802 analyzer comes equipped with four analog outputs. 5.9.3. ANALOG I/O CONFIGURATION The following lists the analog I/O functions that are available in the T802 analyzer. Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual To access the ANALOG I/O CONFIGURATION sub menu, press: (The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory). Page Page Page Page Page Page Page CAUTION - GENERAL SAFETY HAZARD Page Page Page 5.9.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT 5.9.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4 setting ENTR accepts the new setting 5.9.7. AIN CALIBRATION Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 108 5.9.8. ANALOG INPUTS (XIN1XIN8) OPTION CONFIGURATION To configure the analyzers optional analog inputs, define for each channel: To adjust settings for the Analog Inputs option parameters press: 5.10. SETUP MORE ALRM: USING THE GAS CONCENTRATION ALARMS (OPTION 61) Page Page Page 6. COMMUNICATIONS SETUP AND OPERATION 6.1. DATA TERMINAL/COMMUNICATION EQUIPMENT (DTE DCE) 6.2. COMMUNICATION MODES, BAUD RATE AND PORT TESTING 6.2.1. COM PORT COMMUNICATION MODES Page Page 6.2.3. COM PORT TESTING 6.3. REMOTE ACCESS VIA THE ETHERNET 6.3.1. CONFIGURING THE ETHERNET INTERFACE USING DHCP Page Page 6.3.2. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES (Continued from preceding illustration) Contact your IT Networ k Ad mini str ator To change this name (particularly if you have more than one T802 analyzer on your network), press: 6.4. USB PORT FOR REMOTE ACCESS except for multidrop communication. Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 126 6.5. COMMUNICATIONS PROTOCOLS This section presents MODBUS and HESSEN information. 6.5.1. MODBUS SETUP www.modbustools.com) Actions Page 6.5.2. HESSEN Page Page Page [GAS TYPE],[RANGE],[GAS ID],[REPORTED] O2, 0, 110, REPORTED Page Page Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual SPARE/UNUSED BITS OPERATIONAL FLAGS1 UNITS OF MEASURE FLAGS UNASSIGNED FLAGS (0000) To assign or reset the status flag bit assignments, press: Page 7. DATA ACQUISITION SYSTEM (DAS) & APICOM 7.1. DAS STRUCTURE 7.1.1. DAS CHANNELS 7.1.2. DEFAULT DAS CHANNELS Page Page 143 7.1.3. SETUP DAS VIEW: VIEWING DAS CHANNELS AND INDIVIDUAL RECORDS DAS data and settings can be viewed on the front panel through the following keystroke sequence. PREV <PRM PRM> PV10 NEXT NX10 7.1.4. SETUP DAS EDIT: ACCESSING THE DAS EDIT MODE Page Page Page Page Page Page Page Page Page Page Page Page 7.2. REMOTE DAS CONFIGURATION 7.2.1. DAS CONFIGURATION VIA APICOM IMPORTANT IMPACT ON READINGS OR DATA Avoid losing data and saved configurations: 7.2.2. DAS CONFIGURATION VIA 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 Page 8.3. REMOTE ACCESS BY MODEM Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Remote Operation 07275A (DCN6005) 165 To initialize the modem press: 8.4. COM PORT PASSWORD SECURITY Page Page 9. CALIBRATION PROCEDURES 9.1. BEFORE CALIBRATION 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES 9.1.2. CALIBRATION GASES Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Calibration Procedures 07275A (DCN6005) 171 9.1.3. DATA RECORDING DEVICES 9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION 9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION 9.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION Page 9.3. ASSESSING CALIBRATION QUALITY 9.4. CALIBRATION OF THE T802S ELECTRONIC SUBSYSTEMS 9.4.1. PRESSURE CALIBRATION Page 9.4.2. FLOW CALIBRATION 9.5. CALIBRATION OF THE OPTIONAL CO2 SENSOR 9.5.1. CO2 CALIBRATION SETUP 9.5.2. SET CO2 SPAN GAS CONCENTRATION 9.5.3. ACTIVATE CO2 SENSOR STABILITY FUNCTION To change the stability test function from O2 concentration to the CO2 sensor output, press: Press 3 times to return to menu 9.5.4. CO2 ZERO/SPAN CALIBRATION: To perform the zero/span calibration procedure: Page Page Page 10. MAINTENANCE SCHEDULE & PROCEDURES 10.1. MAINTENANCE SCHEDULE HAZARD STRONG OXIDIZER CAUTION GENERAL SAFETY HAZARD CAUTION QUALIFIED PERSONNEL Page DATE PERFORMED ITEM ACTION FREQ CAL CHECK REQD. MANUAL Page 10.2. PREDICTIVE DIAGNOSTICS 10.3. MAINTENANCE PROCEDURES 10.3.1. REPLACING THE SAMPLE PARTICULATE FILTER 10.3.2. REBUILDING THE SAMPLE PUMP 10.3.3. PERFORMING LEAK CHECKS 10.3.4. PERFORMING A SAMPLE FLOW CHECK 10.3.5. CLEANING THE OPTICAL BENCH 10.3.6. CLEANING EXTERIOR SURFACES OF THE T802 Page 11. TROUBLESHOOTING AND SERVICE HAZARD QUALIFIED PERSONNEL ONLY CAUTION RISK OF ELECTRICAL SHOCK 11.1. GENERAL TROUBLESHOOTING 11.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES The analyzer will also alert the user via the Serial I/O COM port(s). Troubleshooting and Service Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual 198 To view or clear the various warning messages press: Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Troubleshooting and Service 199 11.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS The following table contains some of the more common causes for these values to be out of range. 11.1.3. DIAG SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O FUNCTION Page 11.2. USING THE INTERNAL ELECTRONIC STATUS LEDS 11.2.1. CPU STATUS INDICATOR 11.2.2. RELAY PCA STATUS INDICATORS Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Troubleshooting and Service 203 11.3. GAS FLOW PROBLEMS 11.3.1. T802 INTERNAL GAS FLOW DIAGRAMS 11.3.2. TYPICAL SAMPLE GAS FLOW PROBLEMS Page 11.4. CALIBRATION PROBLEMS 11.4.1. MISCALIBRATED 11.4.2. NON-REPEATABLE ZERO AND SPAN 11.4.3. INABILITY TO SPAN NO SPAN BUTTON 11.4.4. INABILITY TO ZERO NO ZERO BUTTON 11.5. OTHER PERFORMANCE PROBLEMS 11.5.1. TEMPERATURE PROBLEMS 11.6. SUBSYSTEM CHECKOUT 11.6.1. AC MAINS CONFIGURATION 11.6.2. DC POWER SUPPLY 11.6.3. I2C BUS 11.6.4. TOUCHSCREEN INTERFACE 11.6.5. LCD DISPLAY MODULE 11.6.6. RELAY BOARD 11.6.7. SENSOR ASSEMBLY 11.6.8. PRESSURE/FLOW SENSOR ASSEMBLY 11.6.9. MOTHERBOARD 11.6.10. CPU 11.6.11. RS-232 COMMUNICATIONS 11.6.12. OPTIONAL CO2 SENSOR 11.7. REPAIR PROCEDURES 11.7.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 11.7.2. DISK-ON-MODULE REPLACEMENT PROCEDURE 11.8. FAQS 11.9. TECHNICAL ASSISTANCE 12. PRINCIPLES OF OPERATION 12.1. PARAMAGNETIC OXYGEN MEASUREMENT 12.1.1. MAGNETIC PROPERTIES OF O2 GAS 12.1.2. PRINCIPLE OF MEASUREMENT Page 12.2. NDIR MEASUREMENT OF CO2 12.2.1. OPERATION WITHIN THE T802 ANALYZER 12.3. PNEUMATIC OPERATION CAUTION GENERAL SAFETY HAZARD I T IS IMPORTANT THAT THE SAMPLE AIRFLOW SYSTEM IS BOTH LEAK - 12.3.1. PNEUMATIC OPERATION OF THE CO2 SENSOR 12.4. FLOW RATE CONTROL 12.4.1. CRITICAL FLOW ORIFICE 12.4.2. PARTICULATE FILTER 12.4.3. PNEUMATIC SENSORS 12.5. ELECTRONIC OPERATION 12.5.1. OVERVIEW Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Principles of Operation 227 MOTHERBOARD 12.5.2. ELECTRONIC OPERATION OF THE CO2 SENSOR 12.5.3. CENTRAL PROCESSING UNIT (CPU) 12.5.4. RELAY BOARD CAUTION ELECTRICAL SHOCK HAZARD AC Relay Retainer Plate Retainer Mounting Screws 12.5.5. HEATER CONTROL 12.5.6. MOTHERBOARD Page Page Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Principles of Operation RELAY PCA 235 Figure 12-13: Power Distribution Block Diagram 12.5.7. FRONT PANEL TOUCH SCREEN/DISPLAY INTERFACE Page 12.5.8. SOFTWARE OPERATION 12.5.9. ADAPTIVE FILTER 12.5.10. CALIBRATION - SLOPE AND OFFSET 12.5.11. TEMPERATURE AND PRESSURE COMPENSATION 12.5.12. INTERNAL DATA ACQUISITION SYSTEM (DAS) 13. A PRIMER ON ELECTRO-STATIC DISCHARGE 13.1. HOW STATIC CHARGES ARE CREATED 13.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE 13.3. COMMON MYTHS ABOUT ESD DAMAGE 13.4. BASIC PRINCIPLES OF STATIC CONTROL 13.4.1. GENERAL RULES Page 13.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE Page CAUTION ESD HAZARD GLOSSARY Note: Some terms in this glossary may not occur elsewhere in this manual. Page Page Page APPENDIX A Version Specific Software Documentation Page Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-3 APPENDIX A-1: Software Menu Trees, Software Versions 1.0.3 (T-Series)/A.3 (E-Series) SAMPLE MSG1CLR1SETUP <TST TST> CALTEST1 O2 DIAGCOMM VARS ALAR3 CONCZERO SPAN DASCFG ACAL CLKRNGE PASS MORE Page Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-5 Figure A-4: Primary Setup Menu Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Go to Menu Tree A-6 Error! Unknown document property name.Error! Unknown document property name. Go to COMM / Hessen Menu Tree Figure A-5: Secondary Setup Menu (COMM & VARS) Page Page Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-9 Value Value Range Description Medium Access Level Setup Variables (929 password) Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-11 Setup Variable Numeric Units Default Value Value Range Description Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-13 NONE, SAMPLE PRESSURE , SAMPLE FLOW, O2 CELL TEMP 3, CO2 CELL TEMP 1, CHASSIS TEMP Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Setup Variable Numeric Units Default Value Value Range Description 00000000 Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-15 Setup Variable Numeric Units Default Value Value Range Description Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-17 Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Table A-3: Test Measurements Name 1 Message Text Description Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-19 Name 1 Message Text Description Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-21 Signal Name Bit or Channel Number Description Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Signal Name Bit or Channel Number Description Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-23 Signal Name Bit or Channel Number Description Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-25 Table A-6: DAS Parameters Name Description Units Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Name Description Units Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-27 COMMAND ADDITIONAL COMMAND SYNTAX DESCRIPTION Page Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-29 Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) MODBUS Register Address (dec., 0-based) Description Units Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-31 MODBUS Register Address (dec., 0-based) Description Units MODBUS Discrete Input Registers (single-bit; read-only) Page APPENDIX B - Spare Parts Page Page T80XSparePartsList Page Page Page Appendix C Warranty/Repair Questionnaire T80X, M80XE Page Page T80X Interconnect List D-3 07275B DCN6418 T80X Interconnect List 07275B DCN6418 D-4 ' TELEDYNE % ' & % OP30 D-6 D-7 D-8 D-9 D-10 D-11 &21752/,13876 D-12 D-13 D-14 Page TPS65150PWP D-16 To old TScreen To new TScreen D-17 TOUCH SCREEN INTERFACE CIRCUITRY ( TBD) Option D-18 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