Teledyne T803 11. TROUBLESHOOTING AND SERVICE

181

11. TROUBLESHOOTING AND SERVICE

This section describes a variety of methods for identifying the source of

performance problems with the analyzer. Also included here are procedures that

are used to repair the instrument.

HAZARD

STRONG OXIDIZER

OXYGEN IS A STRONG OXIDIZER.

Before working with the casing open, be sure to turn off power supply, and perform

air or N2 gas purging of not only the analyzer inside, but also the sample gas line.

In addition, carefully prevent oil and grease from adhering to any piping. Otherwise,

poisoning, fire or explosion may be caused due to gas leakage, etc.

NOTE

QUALIFIED PERSONNEL

The operations outlined in this Section must be performed by qualified maintenance

personnel only.

CAUTION

RISK OF ELECTRICAL SHOCK

Some operations need to be carried out with the instrument open and running.

Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to

the analyzer.

Do not drop tools into the analyzer or leave them after your procedures.

Do not shorten or touch electric connections with metallic tools while operating

inside the analyzer.

Use common sense when operating inside a running analyzer.

11.1. GENERAL TROUBLESHOOTING

The T803 CO2/O2 analyzer has been designed so that problems can be rapidly

detected, evaluated and repaired. During operation, it continuously performs

diagnostic tests and provides the ability to evaluate its key operating parameters

without disturbing monitoring operations.

A systematic approach to troubleshooting will generally consist of the following

five steps:

07276B DCN6418

Contents

Main Page A BOUT T ELEDYNE ADVANCED P OLLUTION I Page SAFETY MESSAGES CONSIGNES DE SCURIT WARRANTY Page ABOUT THIS MANUAL ORGANIZATION REVISION HISTORY TABLE OF CONTENTS Page Page LIST OF FIGURES LIST OF TABLES LIST OF APPENDICES Page Page 1. INTRODUCTION, FEATUERES, AND OPTIONS 1.1. T803 OVERVIEW 1.2. FEATURES 1.3. OPTIONS Teledyne API T803 CO2/O2 Analyzer Operation Manual Introduction, Featueres, and Options Option Option Number Description/Notes Reference CAUTION - GENERAL SAFETY HAZARD Introduction, Featueres, and Options Teledyne API T803 CO2/O2 Analyzer Operation Manual 20 Option Option Number Description/Notes Reference 2. SPECIFICATIONS, APPROVALS & COMPLIANCE 2.1. SPECIFICATIONS Table 2-1: T803 Specifications Parameter Description CO2 O2 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 T803 ANALYZER Page 3.1.1. VENTILATION CLEARANCE 3.2. INSTRUMENT LAYOUT 3.2.1. FRONT PANEL Page Teledyne API T803 CO2/O2 Analyzer Operation Manual Getting Started 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 Pin assignments for the Analog In connector are presented in Table 3-4. Page Page Page STATUS + Getting Started Teledyne API T803 CO2/O2 Analyzer Operation Manual 38 + - Figure 3-10: Control Input Connector Table 3-7: Control Input Signals A Page Page Page Page Page Note RS-485 CONNECTION 3.3.2. PNEUMATIC CONNECTIONS CAUTION GENERAL SAFETY HAZARD: CO2 CAUTION GENERAL SAFETY HAZARD: O2 CAUTION Page IMPORTANT Leak Check: 3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL CALIBRATION 3.4.1. STARTUP 3.4.2. WARM UP 3.5. WARNING MESSAGES Teledyne API T803 CO2/O2 Analyzer Operation Manual Getting Started Table 3-9: Warning Messages 3.5.1. FUNCTIONAL CHECK 3.5.2. INITIAL CALIBRATION Page Page Page 4. BASIC OPERATION 4.1. OVERVIEW OF OPERATING MODES 4.2. SAMPLE MODE Page Basic Operation Teledyne API T803 CO2/O2 Analyzer Operation Manual 60 Table 4-2: Test Functions Defined % 4.3. CALIBRATION MODE 4.4. SETUP MODE Basic Operation Teledyne API T803 CO2/O2 Analyzer Operation Manual 62 Table 6-5: Secondary Setup Mode Features and Functions 5. SETUP MENU 5.1. SETUP CFG: CONFIGURATION INFORMATION 5.2. S ETUP 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 CO2 AND O2 CONCENTRATION 5.4.3. REPORTING RANGE MODES Page Page Page 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 T803 ANALYZERS INTERNAL CLOCK 5.6.1. SETTING THE INTERNAL CLOCKS TIME AND DAY 5.6.2. ADJUSTING THE INTERNAL CLOCKS SPEED Page Page 0 1 8 7 6 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 MORE DIAG: USING THE DIAGNOSTICS FUNCTIONS 5.9.1. ACCESSING THE DIAGNOSTIC FEATURES To access the DIAG functions press the following buttons: returns to the Activates the selected submenu 5.10. USING THE T803 ANALYZERS ANALOG OUTPUTS The T803 analyzer comes equipped with four analog outputs. 5.10.1. ACCESSING THE ANALOG OUTPUT SIGNAL CONFIGURATION SUBMENU The following lists the analog I/O functions that are available in the T803 analyzer. To access the ANALOG I/O CONFIGURAT ION sub menu, press: 5.10.2. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION 5.10.3. CALIBRATION OF THE ANALOG OUTPUTS Page Page Page Page Page CAUTION - GENERAL SAFETY HAZARD Page Page Page 5.10.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT 5.10.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4 The test functions available to be reported are: To activate the TEST Channel and select a function (in this example SAMPLE PRESSURE), press: setting ENTR accepts the new setting 5.10.7. AIN CALIBRATION Teledyne API T803 CO2/O2 Analyzer Operation Manual Setup Menu 5.10.8. 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: 5.11. SETUP MORE ALRM: USING THE GAS CONCENTRATION ALARMS (OPTION 61) 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 Page 6.2.3. COM PORT TESTING 6.2.4. MACHINE ID 6.3. REMOTE ACCESS VIA THE ETHERNET 6.3.1. CONFIGURING THE ETHERNET USING DHCP Page Page 6.3.2. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES (Continued from preceding illustration) Contact your IT Network Administrator Communications Setup and Operation Teledyne API T803 CO2/O2 Analyzer Operation Manual 114 6.3.3. CHANGING THE ANALYZERS HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network. The default name for all Teledyne API T803 analyzers is T803. To change this name (particularly if you have more than one T803 analyzer on your network), press: 6.4. USB PORT FOR REMOTE ACCESS except for multidrop communication. Teledyne API T803 CO2/O2 Analyzer Operation Manual Communications Setup and Operation 6.5. COMMUNICATIONS PROTOCOLS This section presents MODBUS and HESSEN informtion. 6.5.1. MODBUS SETUP www.modbustools.com) Actions 6.5.2. HESSEN Page Page Page Page [GAS TYPE],[RANGE],[GAS ID],[REPORTED] The T803 analyzer measures CO2 and O2. The default gas list entries are: O2, 0, 110, REPORTED CO2, 0, 111, REPORTED CO2, 2, 111, REPORTED Page Page Communications Setup and Operation Teledyne API T803 CO2/O2 Analyzer Operation Manual 126 6.5.3. SETTING HESSEN PROTOCOL STATUS FLAGS 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. SETUP DAS: USING THE DATA ACQUISITION SYSTEM (DAS) 7.1.1. DAS STATUS 7.1.2. DAS STRUCTURE 7.1.3. DEFAULT DAS CHANNELS Page Page Data Acquisition System (DAS & APICOM Teledyne API T803 CO2/O2 Analyzer Operation Manual 134 7.1.4. SETUP DAS VIEW: VIEWING DAS CHANNELS AND INDIVIDUAL RECORDS PREV <PRM PRM> PV10 NEXT NX10 Button 7.1.5. SETUP DAS EDIT: ACCESSING THE DAS EDIT MODE Button FUNCTION DAS EDIT Touchscreen Button Functions Page Page Page Page Page Page Page Page Page Page Page 7.1.6. DISABLING/ENABLING DATA CHANNELS 7.2. REMOTE DAS CONFIGURATION 7.2.1. DAS CONFIGURATION VIA APICOM Page Page 8. REMOTE OPERATION 8.1. COMPUTER MODE 8.1.1. REMOTE CONTROL VIA APICOM 8.2. INTERACTIVE MODE Page Page 8.3. REMOTE ACCESS BY MODEM Page Teledyne API T803 CO2/O2 Analyzer Operation Manual Remote Operation 157 To initialize the modem press: Page 9. CALIBRATION PROCEDURES 9.1. BEFORE CALIBRATION 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES 9.1.2. CALIBRATION GASES 9.1.3. DATA RECORDING DEVICES 9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE T803 ANALYZER 9.2.1. SETUP FOR CALIBRATION CHECKS AND CALIBRATION 9.2.2. PERFORMING A MANUAL CALIBRATION CHECK 9.2.3. PERFORMING A MANUAL CALIBRATION Page Page 9.3. ASSESSING CALIBRATION QUALITY 9.4. CALIBRATION OF THE T803S ELECTRONIC SUBSYSTEMS 9.4.1. PRESSURE CALIBRATION Page 9.4.2. FLOW CALIBRATION Page Page Page 10. MAINTENANCE SCHEDULE & PROCEDURES 10.1. MAINTENANCE SCHEDULE HAZARD 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 EXTERIOR SURFACES OF THE T803 11. TROUBLESHOOTING AND SERVICE HAZARD NOTE QUALIFIED PERSONNEL CAUTION RISK OF ELECTRICAL SHOCK 11.1. GENERAL TROUBLESHOOTING 11.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES Page Troubleshooting and Service Teledyne API T803 CO2/O2 Analyzer Operation Manual 184 To view or clear the various warning messages press: Teledyne API T803 CO2/O2 Analyzer Operation Manual Troubleshooting and Service 185 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 11.2.2.2. RELAY PCA STATUS LED S 11.3. GAS FLOW PROBLEMS 11.3.1. T803 INTERNAL GAS FLOW DIAGRAMS 11.3.2. TYPICAL SAMPLE GAS FLOW PROBLEMS 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 Page 11.6.9. MOTHERBOARD 11.6.10. CPU 11.6.11. RS-232 COMMUNICATIONS 11.6.12. CO2 SENSOR STATUS LEDS 11.7. REPAIR PROCEDURES 11.7.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 11.7.2. DISK-ON-MODULE REPLACEMENT PROCEDURE 11.8. FREQUENTLY ASKED QUESTIONS (FAQS) 11.9. TECHNICAL ASSISTANCE 12. PRINCIPLES OF OPERATION 12.1. O2 SENSOR 12.1.1. MAGNETIC PROPERTIES OF O2 GAS 12.1.2. PARAMAGNETIC MEASUREMENT OF O2 Page 12.2. CO2 SENSOR 12.2.1. NDIR MEASUREMENT OF CO2 12.3. OPERATION WITHIN THE T803 ANALYZER 12.4. PNEUMATIC OPERATION CAUTION GENERAL SAFETY HAZARD I T IS IMPORTANT THAT THE SAMPLE AIRFLOW SYSTEM IS BOTH LEAK - 12.5. FLOW RATE CONTROL 12.5.1. CRITICAL FLOW ORIFICE 12.5.2. PARTICULATE FILTER 12.5.3. PNEUMATIC SENSORS 12.6. ELECTRONIC OPERATION 12.6.1. OVERVIEW Teledyne API T803 CO2/O2 Analyzer Operation Manual Principles of Operation 213 CO2Sensor Heater 12.6.2. CENTRAL PROCESSING UNIT (CPU) Page Teledyne API T803 CO2/O2 Analyzer Operation Manual Principles of Operation 215 12.6.3. RELAY BOARD C I Figure 12-9: Relay PCA Layout (PN 04135) AC Relay Retainer Plate Retainer Mounting Screws 12.6.4. HEATER CONTROL 12.6.5. MOTHERBOARD 12.6.6. I2C DATA BUS 12.6.7. POWER SUPPLY / CIRCUIT BREAKER 12.6.8. FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE 12.6.9. SOFTWARE OPERATION 12.6.10. ADAPTIVE FILTER 12.6.11. CALIBRATION - SLOPE AND OFFSET 12.6.12. TEMPERATURE AND PRESSURE COMPENSATION 12.6.13. INTERNAL DATA ACQUISITION SYSTEM (DAS) Page 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 13.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE Page Page CAUTION ESD Hazard Never carry the component or assembly without placing it in an anti-ESD bag or bin. GLOSSARY Page Page Page INDEX A B C Index Teledyne API T803 CO2/O2 Analyzer Operation Manual D E F G H I K P R S T V W Z APPENDIX A Version Specific Software Documentation Page Appendix A Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) A-3 APPENDIX A-1: Menu Trees, Soft ware Versions 1.0.3 (T-Series)/A.3 (E-Series) SAMPLE MSG1CLR1SETUP <TST TST> CALTEST1 CO2 DIAGCOMM VARS ALAR2 CONCZERO SPAN DASCFG ACAL CLKRNGE PASS MORE Page Appendix A Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) A-5 Figure A-4: Primary Setup Menu (iDAS) Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418) Appendix A Go to Menu Tree A-6 Go to COMM / Hessen Menu Tree Figure A-5: Secondary Setup Menu (COMM & VARS ) Page Page Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Setup Variable Numeric Units Default Value Value Range Description 00000000 Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Setup Variable Numeric Units Default Value Value Range Description Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-17 Appendix A Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Table A-3: Test Measurements Name 1 Message Text Description Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-19 Name 1 Message Text Description Appendix A Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Signal Name Bit or Channel Number Description Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Name Description Units Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-27 COMMAND ADDITIONAL COMMAND SYNTAX DESCRIPTION Page Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) Appendix A Error! Unknown document property name.Error! Unknown document property name. A-29 Appendix A Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C DCN6418) MODBUS Register Address (dec., 0-based) Description Units Models T803, 803E Appendix A Menu Trees (Referen ce: 06763C 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 Appendix C Warranty/Repair Questionnaire T80X, M80XE Page Page T80X Interconnect List D-3 07276B DCN6418 T80X Interconnect List 07276B 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