Teledyne Carbon Monoxide Analyzer 300 User's Manual

INSTRUCTION MANUAL
MODEL 300
CARBON MONOXIDE ANALYZER
© Teledyne Advanced Pollution Instrumentation
(T-API)
9480 Carroll Park Drive
San Diego, CA 92121-5201
Toll Free: 800 324-5190
Telephone: 858 657-9800
Fax: 858 657-9816
Email: api-sales@teledyne.com
Website: www.teledyne-api.com
02163
Rev. G1
03/17/06
SAFETY MESSAGES
Your safety and the safety of others is very important. We have provided many
important safety messages in this manual. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each
safety message is associated with a safety alert symbol. These symbols are found in the
manual and inside the instrument. The definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the instructions for details on the
specific danger.
CAUTION: Hot Surface Warning
CAUTION: Electrical Shock Hazard
Technician Symbol: All operations marked with this symbol are to be
performed by qualified maintenance personnel only.
CAUTION
The analyzer should only be used for the purpose and in the manner
described in this manual.
If you use the analyzer in a manner other than that for which it was
intended, unpredictable behavior could ensue with possibly hazardous
consequences.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page ii
TABLE OF CONTENTS
SAFETY MESSAGES ................................................................................................... ii
TABLE OF CONTENTS............................................................................................... iii
TABLES ..........................................................................................................................v
FIGURES.........................................................................................................................v
1.0 INTRODUCTION ........................................................................................... 1
1.1 Preface ......................................................................................................................1
1.2 Warranty ...................................................................................................................2
1.3 Principle of operation................................................................................................3
1.4 Specifications............................................................................................................4
1.5 Installation and overview..........................................................................................5
1.6 Electrical and pneumatic connections.....................................................................10
1.7 Operation verification .............................................................................................18
1.8 Options....................................................................................................................20
2.0 OPERATION ............................................................................................... 23
2.1 Key features ............................................................................................................23
2.2 Front panel ..............................................................................................................25
3.0 PERFORMANCE TESTING ........................................................................ 31
3.1 Manual zero/span check..........................................................................................31
3.2 IZS zero/span check (Option) .................................................................................32
3.3 Zero/span valves (Option) ......................................................................................33
3.4 Automatic zero/span check.....................................................................................33
3.5 Summary of front panel check and calibration controls .........................................36
3.6 Remote zero/span check or adjustment (contact closure).......................................37
3.7 Remote zero/span check or adjustment (RS-232)...................................................38
3.8 Power-on hold off ...................................................................................................38
3.9 Hold off...................................................................................................................38
4.0 SETUP MODE............................................................................................. 39
4.1 Setup mode operation .............................................................................................39
4.2 Examining the carbon monoxide formula slope and offset ....................................39
4.3 Setting the time-of-day ...........................................................................................40
4.4 Setting the date........................................................................................................40
4.5 Adjusting the clock speed .......................................................................................40
4.6 Setting the CO concentration range ........................................................................41
4.7 Setting the analog output offset ..............................................................................41
4.8 Setting the RS-232 baud rate ..................................................................................42
4.9 Setting the analyzer I.D. .........................................................................................42
4.10 Disabling the calibration password.......................................................................42
4.11 Data acquisition system (DAS).............................................................................42
4.12 Software configuration .........................................................................................50
4.13 Summary of setup functions .................................................................................50
5.0 DIAGNOSTICS............................................................................................ 53
5.1 Test measurements..................................................................................................53
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page iii
5.2 Diagnostic tests .......................................................................................................53
6.0 HANDLING WARNINGS ..............................................................................59
7.0 RS-232 COMMUNICATIONS.......................................................................61
7.1 DAS reporting.........................................................................................................62
7.2 Warnings.................................................................................................................63
7.3 Status/control ..........................................................................................................64
7.4 Diagnostics..............................................................................................................65
7.5 Test measurements..................................................................................................67
7.6 Viewing and modifying variables...........................................................................68
8.0 CALIBRATION ..............................................................................................71
8.1 REQUIRED EQUIPMENT AND GAS STANDARDS ........................................71
8.2 MULTI-POINT CALIBRATION...........................................................................73
8.3 ZERO/SPAN CHECKING .....................................................................................76
9.0 ADJUSTMENTS...........................................................................................77
9.1 Power supply board adjustment..............................................................................77
9.2 A/D - D/A Calibration procedure ...........................................................................79
9.3 Dark current signal adjust procedure ......................................................................79
9.4 Output voltage range changes.................................................................................80
9.5 Flow readout adjustment.........................................................................................81
9.6 DC power supply ....................................................................................................81
9.7 CPU.........................................................................................................................81
10.0 TROUBLESHOOTING ...............................................................................83
10.1 Overview...............................................................................................................83
10.2 Troubleshooting fundamental analyzer operation ................................................84
10.3 Troubleshooting using warning messages ............................................................85
10.4 Troubleshooting using test function values ..........................................................87
10.5 Troubleshooting dynamic problems .....................................................................88
10.6 Troubleshooting individual sub-assemblies and components ..............................90
10.7 Warranty/repair questionnaire ..............................................................................99
11.0 ROUTINE MAINTENANCE ......................................................................101
11.1 Model 300 maintenance schedule.......................................................................101
11.2 Replacement of sample filter ..............................................................................101
11.3 Leak checking .....................................................................................................102
11.4 Changing the prom..............................................................................................103
12.0 SPARE PARTS LISTS .............................................................................105
12.1 SPARE PARTS FOR CE MARK UNITS..........................................................105
12.2 SPARE PARTS FOR NON-CE MARK UNITS................................................107
APPENDIX A - LIST OF AVAILABLE MODEL 300 OPTIONS............................109
APPENDIX B: TIPS ON CONNECTING THE TELEDYNE API ANALYZER
RS-232 INTERFACE ..................................................................................................111
APPENDIX C - ELECTRICAL SCHEMATIC INDEX.............................................115
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page iv
TABLES
TABLE 1.1 STATUS OUTPUTS...................................................................................11
TABLE 1.1 FINAL TEST AND CALIBRATION VALUES.........................................19
TABLE 2.1 PASSWORD LEVELS ................................................................................24
TABLE 2.2 SYSTEM MODES.......................................................................................26
TABLE 2.3 TEST MEASUREMENTS ..........................................................................26
TABLE 2.4 WARNING MESSAGES ............................................................................27
TABLE 2.5 STATUS LEDS............................................................................................29
TABLE 3.1 CALIBRATION CONTROLS ....................................................................36
TABLE 4.1 SETUP FUNCTIONS ..................................................................................51
TABLE 5.1 DIAGNOSTIC TESTS ................................................................................54
TABLE 5.2 I/O SIGNALS ................................................................................................57
TABLE 7.1 RS-232 MESSAGE TYPES.........................................................................61
TABLE 7.2 WARNING MESSAGE CLEAR COMMANDS ........................................64
TABLE 7.3 STATUS REPORTS ....................................................................................64
TABLE 7.4 CONTROL COMMANDS ..........................................................................65
TABLE 7.5 DIAGNOSTIC COMMANDS.....................................................................66
TABLE 7.6 DIAGNOSTIC REPORTS...........................................................................66
TABLE 7.7 TEST MEASUREMENT REQUEST COMMANDS .................................67
TABLE 7.9 RS-232 VARIABLE NAMES .....................................................................69
TABLE 9.1 V/F BOARD SWITCH SETTINGS ............................................................80
TABLE 10.1 WARNING MESSAGES ..........................................................................86
TABLE 10.2 TEST FUNCTION VALUES ....................................................................88
TABLE 10.3 V/F BOARD JUMPERS - FACTORY SETTINGS ..................................94
TABLE 10.4 V/F BOARD JUMPERS - RANGES FOR ANALOG OUTPUT .............95
TABLE 11.1 MAINTENANCE SCHEDULE ...............................................................101
FIGURES
FIGURE 1.1
FIGURE 1.2
FIGURE 1.3
FIGURE 1.4
FIGURE 1.5
FIGURE 1.6
FIGURE 2.1
FIGURE 2.2
FIGURE 8.1
FIGURE 8.2
FIGURE 9.1
FIGURE 9.2
CARBON MONOXIDE ANALYZER ........................................................8
REAR PANEL ELECTRICAL CONNECTIONS.......................................9
FLOW DIAGRAM.....................................................................................14
REAR PANEL PHEUMATIC CONNECTIONS ......................................15
REAR PANEL............................................................................................16
MODEL 300 ASSEMBLY LAYOUT .......................................................17
MODEL 300 FRONT PANEL...................................................................25
ILLUSTRATION OF NORMAL DISPLAY.............................................28
GAS GENERATION SYSTEM.................................................................72
INLET VENTING RECOMMENDATIONS ............................................72
M300 ELECTRICAL BLOCK DIAGRAM ..............................................78
FLOW AND PRESSURE READOUT ADJUSTMENT ...........................81
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page v
FIGURE 10.1 OPTO PICKUP WAVEFORM ..................................................................97
FIGURE 10.2 DETECTOR WAVEFORM......................................................................97
FIGURE B.1 RS-232 PIN ASSIGNMENTS.................................................................111
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page vi
1.0 INTRODUCTION
1.1 Preface
Teledyne API is pleased that you have purchased the Model 300. We at Teledyne API
will be pleased to provide you with any support required so that you may utilize our
equipment to the fullest extent.
The Teledyne API Model 300 keyboard/operator interface makes the Teledyne API a
very user-friendly system. We hope you will not experience any problems with the
Model 300 but if you do, the built-in tests and diagnostics should allow you to quickly
and easily find the problem. In addition, our customer service department is always
available to answer your questions.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 1
1.2 Warranty
WARRANTY POLICY
Prior to shipment, Teledyne API equipment is thoroughly inspected and tested. Should
equipment failure occur, Teledyne API assures its customers that prompt service and
support is available.
COVERAGE
After the warranty period and throughout the equipment lifetime, Teledyne API stands
ready to provide on-site or in-plant service at reasonable rates similar to those of other
manufacturers in the industry. All maintenance and the first level of field troubleshooting
is to be performed by the customer.
NON-TELEDYNE API MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by Teledyne API is warranted and will be
repaired to the extent and according to the current terms and conditions of the respective
equipment manufacturer’s warranty.
GENERAL
Teledyne API warrants each Product manufactured by Teledyne API to be free from
defects in material and workmanship under normal use and service for a period of one
year from the date of delivery.
If a Product fails to perform to its specifications, Teledyne API shall correct such defect
by, in Teledyne API's discretion, repairing or replacing such defective Product or
refunding the purchase price of such Product.
The warranties set forth in this section shall be of no force or effect with respect to any
Product: (i) that has been altered or subjected to misuse, negligence or accident, or (ii)
that has been used in any manner other than in accordance with the instruction provided
by Teledyne API or (iii) not properly maintained.
THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES
THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER
WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED.
THE
REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR
BREACH OF ANY WARRANTY CONTAINED HEREIN. TELEDYNE API SHALL
NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API’s
PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR
OTHERWISE.
TERMS AND CONDITIONS
All units or components returned to Teledyne API should be properly packed for
handling and returned freight prepaid to the nearest designated Service Center. After the
repair, the equipment will be returned, freight prepaid.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 2
1.3 Principle of operation
The detection and measurement of carbon monoxide in the Model 300 is based on the
absorption of Infra Red (IR) radiation by CO molecules at wave lengths near 4.7 microns.
In practice, the Model 300 uses a high energy heated element to generate broad-band IR
light. This light is passed through a rotating Gas Filter Wheel which causes the beam to
alternately pass through a gas cell filled with Nitrogen, (the Measure Cell) and a cell
filled with CO/Nitrogen Mixture (the Reference Cell). This alternation occurs at a rate of
30 cycles/second and causes the beam to be modulated into Reference and Measure
pulses. During a Reference pulse, the CO in the gas filter wheel effectively strips the
beam of all IR energy at wave lengths where CO can absorb. This results in a beam
which is unaffected by any CO in the Sample Cell. During the Measure pulse, the
Nitrogen in the filter wheel does not effect the beam which can subsequently be
alternated by any CO in the sample cell. The Gas Filter wheel also incorporates an
optical chopping mark which superimposes a 360 Cycles/Second Light/Dark modulation
on the IR Beam. This high frequency modulation is included to maximize detector
signal-to-noise performance.
After the gas filter wheel the IR beam enters the multi-pass sample cell. This sample cell
uses folding optics to generate a 16 meter absorption path length in order to achieve
maximum sensitivity.
Upon exiting the sample cell, the beam passes through a band-pass interference filter to
limit the light to wave length of interest.
Finally, the beam strikes the detector which is a thermoelectricly cooled solid-state
photo-conductor.
This detector, along with its pre-amplifier and bias voltage supply convert the light signal
into a modulated voltage signal.
The detector output is electronically demodulated to generate two DC voltages, CO
MEAS and CO REF. These voltages are proportional to the light intensity striking the
detector during the Measure Pulse and Reference Pulse, respectively.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 3
1.4 Specifications
Ranges
Zero Noise
Span Noise
Lower Detectable Limit
Zero Drift (24 hours)
Zero Drift (7 days)
Span Drift (7 days)
Linearity
Precision
Lag Time
Rise/Fall Time (95%)
Sample Flow Rate
Temperature Range
Humidity Range
Temp Coefficient
Voltage Coefficient
Dimensions HxWxD
Weight
Power
Power, CE
Environmental Conditions
Recorder Outputs
Status
User selectable to any full-scale range from 1 ppm
to 1,000 ppm
< 0.025 ppm (rms)
< 0.5% of reading (rms)
< 0.050 ppm
* <0.1 ppm
* <0.2 ppm
* 1% of reading
1% FS
0.5% of reading
10 sec
<60 sec
800cc/min. ± 10%
5-40°C
0-95% RH, non-condensing
< 0.05 % per °C
< 0.05 % per V
7"x 17"x 25"
(178mm x 432mm x 660mm)
50 lbs (22.7 kg)
110V~/60Hz, 220V~/50Hz., 240V~/50Hz. 250 Watts
230V~/50Hz, 2.5 A
Installation Category (Overvoltage Category) II
Pollution Degree 2
± 100 mV, ± 1 V, ± 5 V, ±10 V (Bi-Polar)
12 status outputs from opto-isolators
* at constant temperature and voltage
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 4
1.5 Installation and overview
The Model 300 is shipped with the following standard equipment:
1.
Power cord.
2. Instruction manual.
CAUTION
To avoid personal injury, always use two persons to lift and
carry the Model 300.
Upon receiving the Model 300 please do the following:
1.
Verify no apparent shipping damage. (If damage has occurred please
advise shipper first, then Teledyne API.)
2.
When installing the Model 300, allow a minimum of 4 inches (100mm) of
clearance at the back of the instrument and 1 inch (25mm) of clearance on
each side for proper ventilation. Also, be sure that the clearance below the
chassis is unobstructed by at least the height of the instrument feet.
3.
Connect sample inlet line to the sample port on rear panel.
NOTE
SEE FIGURE 1.4 FOR REAR PANEL PNEUMATIC
CONNECTIONS. SAMPLE GAS SHOULD ONLY COME
INTO CONTACT WITH PTFE, GLASS OR STAINLESS
STEEL. LEAK CHECK ALL FITTINGS WITH SOAP
SOLUTION.
MAXIMUM PRESSURE FOR LEAK CHECK IS 5 PSI.
CAUTION
Connect the exhaust fitting on the rear panel (See Fig. 1.4) to a
suitable vent outside the analyzer area.
4.
5.
6.
Connect IZS inlet input (if installed) to a clean, dry air supply.
Connect a recording device to the terminal strip connections on the rear
panel (See Figure 1.2).
Connect the power cord to an appropriate power outlet (see the serial
number tag for correct voltage and frequency).
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 5
CAUTION
CHECK THAT ANALYZER IS SET UP FOR PROPER
VOLTAGE AND FREQUENCY.
CAUTION
POWER PLUG MUST HAVE GROUND LUG.
7.
8.
9.
10.
Turn on the M300 by switching the switch on the lower right corner of the
front panel (See Figure 2.1). The front panel display should light with a
sequence of messages, -API - M300 - software version number, then a
normal display as shown in Figure 2.2.
Allow about 60 minutes for the temperatures to come up to their
respective setpoints then press the left most button on the front keyboard
to scroll through the TEST values. Compare these values to those noted
during the final factory checkout listed in Table 1.1. The values observed
should closely match the Table 1.1 values.
Select the range on which the analyzer will be calibrated.
a. From the SAMPLE menu press SETUP to enter the SETUP menu.
(See Figure 2.2 for appearance of front panel.)
b. Enter the PASSWORD (818).
c. Press RNGE (RANGE).
d. Press SET.
e. Enter the derived full scale range for analog outputs and press ENTR.
f. Press EXIT 2 times to return to the SAMPLE menu.
Adjust the analyzer zero point.
a.
Input zero air into the sample port.
b.
Press CAL from the SAMPLE menu and enter the password (818).
c.
Press ZERO.
d.
It usually takes about 5 to 10 minutes for the reading to stabilize
near zero. After a stable reading has been obtained press ENTR.
The display should now read 0.0 ppm carbon monoxide.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 6
NOTE
REPEATEDLY PRESSING ENTR TO GET THE
INSTRUMENT TO DISPLAY THE CORRECT SPAN/ZERO
VALVE DOES NOT IMPROVE THE ACCURACY OF THE
CALIBRATION, NOR DOES IT SPEED UP
STABILIZATION. THE REASON FOR WAITING 5-10
MIN. IS THAT IT TAKES THE INSTRUMENT A PERIOD
OF TIME TO ESTABLISH AN ACCURATE AVERAGE
FOR THE SPAN/ZERO READING.
11.
Adjust the Analyzer span point.
a.
Input span gas of approximately 80% of the related full scale range
concentration from a known source through the sample port of the
Analyzer.
b. Go to manual calibration by pressing the CAL button while in the
sample mode.
c. Enter the operator password (512).
d. The menu should now show SPAN, CONC, and EXIT. Enter the
concentration of the CO calibration gas by pressing CONC and
entering the value from the keyboard.
e. Wait 10 minutes for a stable reading to be attained and then press
SPAN, followed by ENTR. If the SPAN button is not displayed, this
means that the Analyzer is too far out of adjustment to do a reliable
calibration and thus it is not permitted (see Section 3.1 for information
on the calibration limits). The operator can exit the manual calibration
procedure only by pressing the EXIT button.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 7
CARBON MONOXIDE ANALYZER
FIGURE 1.1
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 8
REAR PANEL ELECTRICAL CONNECTIONS
FIGURE 1.2
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 9
1.6 Electrical and pneumatic connections
1.6.1 Electrical connections
Output #1 Carbon Monoxide concentration - Chart Recorder (REC)
Output #2 Carbon Monoxide concentration - Data Acquisition System (DAS)
Output #3 Test function analog output
Input #4 Zero valve request
Input #5 Span valve request
Input #6 Not Used
There are 2 six-pin connector strips on the rear panel shown in Figure 1.2. The pins
are divided into 3-plus/minus pairs and have the functions shown above.
Outputs 1 and 2 have identical signals and electrical characteristics. Output 3 is the same
as 1 and 2 electrically, but has analog TEST function signals routed to it. See
Diagnostics in Section 5 for details.
1.6.2 Remote contact closures zero/span inputs and status
outputs
Remote contact closures can be used to remotely energize the zero/span valves to do a
zero or span check. The external contact closure should be capable of switching 12 VDC
at 50 ma.
Refer to Figure 1.2 for connection location. See Sections 1.8.6 and 3.6 for further details.
NOTE
ZERO OR SPAN CHECKS CAN BE PERFORMED IN ANY
ORDER.
1.6.3 Status Outputs
Status outputs report analyzer conditions via contact closures located on the DB-50
connector on the rear panel. The contacts are NPN transistors which can pass 50 mA of
DC current. The pin assignments are listed in Table 1.1 below:
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 10
OUTPUT #
STATUS
CONDITION
1
PIN PAIR
(LOW, HIGH)
1,2
ZERO CAL
2
3,4
SPAN CAL
3
5,6
FLOW ALARM
4
7,8
TEMP ALARM
5
9, 10
DIAG MODE
6
11,12
POWER ON
7
13,14
PRESS ALARM
8
15,16
HIGH RANGE
SELECTED
9
17,18
SYSTEM OK
TRUE DURING ZERO
CALIBRATION
TRUE DURING SPAN
CALIBRATION
TRUE IF A FLOW
WARNING EXISTS
TRUE IF ANY TEMP
WARNING EXISTS
TRUE IF IN
DIAGNOSTIC MODE
TRUE IF MAIN POWER
IS ON
TRUE ON LOW
PRESSURE
TRUE IF THE AUTORANGE FUNCTION HAS
SWITCHED THE
ANALYZER INTO HIGH
RANGE.
TRUE IF NO ALARM
CONDITIONS EXIST
10
11
19,20
21,22
RESERVED
SOURCE
WARNING
12
23,24
RESERVED
TRUE IF THE
ANALYZER SOURCE
INTENSITY IS OUT OF
LIMITS.
TABLE 1.1 STATUS OUTPUTS
1.6.4 RS-232
The RS-232 connection is a male, 9-pin D-sub connector at the location shown in Figure
1.2.
1.6.5 Pneumatic system
The Model 300 is equipped with a vacuum pump capable of pulling 800 cc/min across a
critical flow orifice. This allows a smooth, stable flow of sample through the Analyzer.
Sample enters the Analyzer through a 5 micron TFE particulate filter element (37 mm
diameter) mounted immediately behind the front panel. The sample then enters directly
into the sample cell. Please see Figure 1.3 for a flow diagram and Figure 1.4 for
pneumatic connections.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 11
A critical flow orifice is used to control the sample flow. The orifice is a precisiondrilled sapphire jewel protected by a 20 micron sintered filter. The critical flow orifice
never needs adjustment and maintains precise flow control as long as the ratio of the upstream to down-stream pressures is greater than .53 (sonic flow conditions).
1.6.6 Sample gas connection (see Figure 1.4)
A 2 m section of 1/4" O.D. PTFE tubing is needed to connect the sample source to the
Analyzer.
NOTE
USE PTFE, GLASS, STAINLESS STEEL OR
NON-REACTIVE MATERIALS FOR SAMPLE GAS
CONNECTIONS.
NOTE
USE VENT LINE WHEN SAMPLING FROM
PRESSURIZED MANIFOLDS - SAMPLE PRESSURE
SHOULD NOT EXCEED ±1" H2O
1.6.7 Zero/span valve connections (see Figure 1.4)
Zero air and span gas manifolds should supply their respective gases in excess of
800cc/min demand of the Analyzer. The manifold should be vented to the outside
atmosphere and be of sufficient length and diameter to prevent back diffusion and
pressure effects.
Adequate zero air can be supplied by the M300 using the IZS option or by using a
commercial calibrator.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 12
1.6.8 Exhaust connections (see Figure 1.4)
A single 1/4" O.D. tube should be connected from the Analyzer sample exhaust to an
area outside of the room the Analyzer occupies. The maximum length of the exhaust line
should not exceed 30 feet.
CAUTION
Connect the exhaust fitting on the rear panel (See Fig. 1.4) to a
suitable vent outside the analyzer area.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 13
FLOW DIAGRAM
FIGURE 1.3
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 14
REAR PANEL PNEUMATIC CONNECTIONS
FIGURE 1.4
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 15
REAR PANEL
FIGURE 1.5
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 16
MODEL 300 ASSEMBLY LAYOUT
FIGURE 1.6
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 17
1.7 Operation verification
The Model 300 Analyzer is now ready for operation.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Read Sections 1.3 and all of Section 4 of the manual to understand the
Analyzer operation.
Turn on the power by pressing the on/off switch on the front panel (see
Figure 2.1). The display should turn on and green (sample) status LED
should be energized. The green LED should blink indicating the
instrument has entered the HOLD-OFF mode. Sample mode can be
entered immediately by pressing the EXIT button on the front panel. The
red "fault" light will also be on until the flows, temperatures and voltages
are within operating limits. Clear the fault messages.
After a 60 minute warm-up, review the TEST function values in the front
panel display by pushing the left most keyboard button labeled TEST.
Not every TEST function is a diagnostic of correct analyzer operation,
therefore TEST functions not covered below can be ignored for now.
CO REF, CO MEAS - TEST function values should be between 3200 mV
and 4700 mV.
Pressure - 29 to 30 Inches-Mercury-Absolute at sea level. Other values
will be displayed depending on altitude of Analyzer.
Sample Flow - 800 cc/min ±10 %
Sample Temp - Ambient temperature ± 10 °C
Optical Bench Temp - 48°C ±1° The computer drives the temp to this
setpoint.
Filter Wheel Temp - 68°C ±2° The computer drives the temp to this
setpoint.
Box Temp - Ambient ±10 °C
DC Power Supply - 2500 mV ± 50 mV - This is a composite of all of the
DC voltages in the instrument. The value is not important but it should be
within the range indicated.
If the TEST functions are within the limits given above, chances are very
good the instrument will function correctly. If there is a problem, please
read the manual and check your set-up. The Model 300 is now ready for
calibration (see Section 3.5).
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 18
FINAL TEST AND CALIBRATION VALUES
TEST VALUES
INSTALLED OPTIONS
RANGE
_______PPM
CO MEAS
_______mV
CO REF
_______mV
MR RATIO
_______
SAMPLE PRESS
_______IN HG-A
SAMPLE FLOW
_______SCC/MIN
SAMPLE TEMP
_______C
OPTICAL BENCH TEMP _______C
WHEEL TEMP
_______C
BOX TEMP
_______C
DC POWER SUPPLY
_______mV
TIME
_______HH:MM:SS
ZERO-SPAN VALVES
RACK MOUNTS/SLIDES
POWER ____/____ VOLTS/Hz
4-20mA OUTPUT
IZS
OTHER ____________
CALIBRATION VALUES
SETUP VALUES
CO SPAN SETTING
CO ZERO SETTING
_______PPM
_______PPM
ELECTRIC TEST
_______PPM
CO SLOPE
CO OFFSET
_______
_______
DARK MEAS
DARK REF
_______mV
_______mV
CONFIGURATION DATA
PROM REV
____________________
TECHNICIAN ______________________
ANALYZER SERIAL #
_______
DATE
_______
TABLE 1.1
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 19
1.8 Options
1.8.1 Rack mount with slides
This option, including slides and rack mounting ears, permits the Analyzer to be mounted
in a standard 19" wide x 30" deep RETMA rack.
NOTE
A 1¾" MINIMUM SEPARATION BETWEEN EACH
INSTRUMENT MUST BE MAINTAINED TO ALLOW FOR
AIR CIRCULATION. BLOCKING THE AIR INLET VENT
ON THE BOTTOM OF THE ANALYZER WILL RESULT
IN INTERNAL OVERHEATING.
1.8.2 Zero/span valves
The Zero/Span Valve option consists of three stainless steel solenoid valves mounted
inside the Analyzer connected to admit sample gas or customer-generated zero air or span
gas.
The valves are controlled from the front panel push-buttons, the auto-timer via the
RS-232 interface, or by remote contact closure.
A Zero air manifold should supply gas in excess of the 800 cc/min +10% demand of the
Analyzer. The zero manifold should be connected at the IZS/Zero Air fitting on the rear
of the Analyze and should be vented to the outside atmosphere.
A Span gas manifold can be connected to the analyzer in either of two ways.
1.
If it is desired to use span gas directly from a pressurized source (e.g. a gas
cylinder) the connection can be made directly to the Pressure Span port on
the analyzer rear panel. In this case the Vent/Span port at the rear panel
should be vented to a suitable exhaust manifold at ambient atmosphere
pressure. The pressure regulator on the gas source (cylinder should be
sent to provide 30-35 PSI delivery pressure.
2.
If it is desired to use span gas from a source which delivers gas at
atmosphere pressure (e.g. a calibrator), the span gas manifold should be
connected at the Vent/Span port at the Analyzer's rear panel, and the
Pressure/Span port should be capped.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 20
1.8.3 Internal zero/span
The IZS option includes the valves and connection parts described above, and in addition,
includes an internal zero air scrubber. This scrubber operates by catalyticly converting
CO in the gas stream to CO2. If the Analyzer is equipped with the IZS option, Span gas
connections should be made as described above and a source of clean air at ambient
pressure should be connected to the IZS/Zero Air Port on the Analyzer's rear panel.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 21
2.0 OPERATION
2.1 Key features
The important features of the Teledyne API Model 300 CO Analyzer are listed below.
2.1.1 CO readout
The Teledyne API Model 300 CO Analyzer constantly displays the current Carbon
Monoxide reading (in PPM) in the upper right hand corner of the alphanumeric display.
2.1.2 CO analog output
The Teledyne API CO Analyzer provides a buffered analog output of the current CO
readings on each of two pairs of outputs on the rear panel (see Figure 1.2) for DAS and
recorder reporting. The analog outputs provide for 20% overrange. For example, on the
50 ppm range the M300 will correctly report concentrations up to 60 ppm and output up
to 6.00 volts to the DAS and recorder outputs.
In addition TEST function values can be routed to a third analog output.
2.1.3 E2 ROM backup of software configuration
The Teledyne API CO Analyzer has a few jumpers that need to be set by the operator.
Configuration of the Analyzer is done under software control and the configuration
options are stored in electrically erasable (E2) ROM. Thus, configuration options are
saved even when the Analyzer is powered off.
There is one exception to this. The analog output voltage ranges are set by jumpers on
the A/D-I/O board as shown in Section 10.6.3.
2.1.4 Adaptive filter
The Teledyne API CO Analyzer is able to provide a smooth, stable output by means of an
adaptive filter. During conditions of constant or nearly constant concentration the filter is
allowed to grow to 600 samples (2 minutes) in length, providing a smooth, stable
reading. If a rapid change in concentration is detected, the filter is cut to 50 samples to
allow the Analyzer to quickly respond to rapidly varying signals.
2.1.5 Data acquisition
The Teledyne API CO Analyzer contains a built-in data acquisition system which keeps
track of the average CO readings and the last 100 averages. This data is made available
to other systems via the RS-232 interface. The Analyzer can be programmed to
automatically output a 1 minute to 60 minute average. The last 100 averages can be
called up through the remote RS-232 I/O or viewed on the display through keyboard
call-up.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 23
2.1.6 RS-232 interface
The Teledyne API CO Analyzer features an RS-232 interface which can output the
instantaneous and/or average CO data to another computer. It can also be used as a
command and status channel to allow another computer to control the Analyzer. Refer to
Figure 1.3 for details on using the RS-232 interface. Tips on connecting the RS-232 port
can be found in Appendix B.
2.1.7 Password protection
The Teledyne API CO Analyzer provides password protection of the calibration and
setup functions to prevent incorrect adjustments to the Analyzer. There are three levels
of passwords which correspond to operator, supervisor/maintenance, and analyzer
configuration functions. When prompted for a password, any of the valid passwords can
be entered, but the CPU will limit access to the functions allowed for that password level.
Each level allows access to the functions of all the levels below plus some additional
functions. Table 2.1 lists the password levels and the functions allowed for each level.
PASSWORD LEVELS
Password
No password
Level
0
Operator (512)
1
Setup (818)
2
Supervisor
(101)
3
Functions Allowed
TEST
MSG
CLR
CALZ
CALS
CAL
SETUP
SETUP-VARS
SETUP-DIAG
ALL
TABLE 2.1
NOTE
THE OPERATOR AND SETUP PASSWORDS CAN BE
DISABLED. TO DO THIS, ENTER SETUP-PASSWORD AND
TOGGLE “ON” TO “OFF”. PUSH “ENTR” AND THE
PASSWORDS WILL BE DISABLED
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 24
2.2 Front panel
This section describes the operator interface from the point of view of the front panel.
The front panel consists of a 2-line by 40-character alphanumeric display, 8 push buttons,
and 3 status LED’s. Each of these features is described below.
2.2.1 Front panel display
The display is divided into 4 main "fields": the mode field in the upper left, the message
field in the top center, the sample concentration field consisting of the most recent
instantaneous carbon monoxide value field in the upper right, and the MENU field which
occupies the entire bottom line of the display. A typical display is shown in Figure 2.1.
MODEL 300 FRONT PANEL
FIGURE 2.1
The mode field indicates the current mode of the Analyzer. Usually, it shows "SAMPLE
A", indicating that the instrument is in the sample mode and that automatic span checking
is enabled. Manual span checking or calibration can only be performed by pressing the
buttons on the front panel labeled "CALZ", "CALS", or "CAL". Automatic span check
only occurs at the preset time. Dynamic span adjust can be performed during automatic
or remote span checks. Remote span adjustment is performed via a command from the
RS-232 or the external contact closure inputs. Calibration and span adjustments are
discussed in greater detail in Section 3.6. Table 2.2 below lists all the possible modes in
the Analyzer and their meanings.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 25
SYSTEM MODES
Mode
SAMPLE x (1)
SAMPLE x (1)
ZERO CAL x (2)
SPAN CAL x (2)
MP CAL
SETUP xxx (3)
DIAG DAS (4)
DIAG I/O (4)
DIAG AOUT (4)
DIAG D/A (4)
DIAG TCHN (4)
Meaning
Sampling normally
Flashing indicates adaptive filter is on
Doing a zero check or adjust
Doing a span check or adjust
Doing a multi-point calibration
Configuring analyzer (sampling continues)
Data Acquisition configuration
Test digital I/O signals
Test analog output channels
Configure and Calibrate Digital to Analog converters
Configure Test Channel output
(1) x = A (auto)
(2) x = M (manual), A (auto), R (remote)
(3) xxx = software revision (e.g. A.9)
(4) diagnostic test modes
TABLE 2.2
The message field shows test measurements or warning messages. Tables 2.3 and 2.4
summarize the test measurements and warning messages and their meanings. Refer to
Sections 4.0 and 5.0 for detailed information on viewing test measurements and warning
messages and clearing warnings.
TEST MEASUREMENTS
Test Message
TIME=xx:xx:xx
RANGE=xxxx PPM
STABIL=x.xxx PPM
CO MEAS=xxxxx MV
CO REF=xxxxx MV
MR RATIO=X.XXX
PRES=xxx IN-HG-A
SAMPLE FL=xxx CC/M
SAMPLE TEMP=xxx C
BENCH TMP=xxx C
WHEEL TMP=xxx C
BOX TEMP=xxx C
DCPS=xxxxxx MV
SLOPE=x.xxx
OFFSET=xx.x MV
Meaning
Current time-of-day (HH:MM:SS)
Analog output full-scale range
Standard Deviation of CO readings
Current V/F measure channel (mV)
Current V/F reference channel (mV)
Ratio of the Reference and Measure values
Absolute sample pressure - inches Hg
Sample flow through Analyzer (cc/min)
Temperature in the absorption cell
Optical Bench Temperature
Filter Wheel Temperature
Internal box temperature (degrees C)
DC power supply (mV)
Internal formula - Slope
Internal formula - Offset
TABLE 2.3
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 26
WARNING MESSAGES
Warning Message
SYSTEM RESET
RAM INITIALIZED
SOURCE WARNING
BENCH HEAT SHUTDOWN
SAMPLE FLOW WARNING
SAMPLE PRESSURE WARN
SAMPLE TEMP WARNING
BOX TEMP WARNING
BENCH TEMP WARN
WHEEL TEMP WARN
CANNOT DYN ZERO
CANNOT DYN SPAN
V/F NOT INSTALLED
SYNC ERROR
Meaning
Issued whenever Analyzer is powered on
RAM was erased (incl. DAS reports)
IR source < 2500 OR >= 5000 mV
Optical bench temp control not working
Sample flow < 500 cc/m or > 1000 cc/m
Sample pressure < 15 or > 35 In-Hg-A
Sample temperature < 10°C or > 50°C
Box temp. < 12°C or > 48°C
Optical Bench < 43°C or > 53°C
Filter Wheel < 63°C or > 73°C
CO offset < -1500 or > +1500 mV
CO slope < 0.5 or > 2.0
A/D - I/O card not installed or bad
No modulation on detector output
TABLE 2.4
The menu field changes depending on the mode of the Analyzer and the buttons that have
been pressed. It indicates the current function of each of the 8 push buttons below the
display. See Section 2.2.2 for information on using the push buttons.
2.2.2 Programmable push buttons
The 8 push buttons below the display are programmable by the CPU in that their
functions change depending on the mode of the Analyzer or the operations being
performed. The legend above a button identifies its current function. If there is no
legend above a button, it has no function and will be ignored if pressed.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 27
ILLUSTRATION OF NORMAL DISPLAY
FIGURE 2.2
If TEST is pushed, the upper center display cycles through the menu of test parameters,
e.g. Sample flow (see Table 2.3). If CALZ is pushed, the sequence of operations for
setting the Analyzer zero is initiated(see Section 3.1).
If CALS is pushed, the sequence of operations for setting SPAN is initiated (see Section
3.1).
CAL is used to initiate span setting using sample gas, such as during a formal
calibration.
Pushing MSG will cause a message to appear on the upper center display.
Pushing CLR will erase a message, provided the condition causing the message has
ceased.
Pushing SETUP changes the function of the push buttons and is used for setting basic
parameters as described in Section 4.0.
2.2.3 Status LED’s
The three status LED’s to the right of the display indicate the general status of the Model
300 Analyzer. The green SAMPLE LED indicates the sampling status. The yellow
CAL LED indicates the calibration status. The red FAULT LED indicates the fault
status. Table 2.5 summarizes the meanings of the status LED’s.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 28
STATUS LED’s
LED
Green
State
Off
On
Blinking
Meaning
Not monitoring, DAS Disabled
Monitoring normally, taking DAS data
Monitoring, HOLD-OFF mode on, no
data to DAS (1)
Yellow
Off
Auto Cal disabled
On
Auto Cal enabled
Blinking
Calibrating
Red
Off
No warnings exist
Blinking
Warnings exist
(1) This occurs during calibration holdoff, power-up holdoff and when in Diagnostic
mode
TABLE 2.5
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 29
3.0 PERFORMANCE TESTING
Zero/span checking and calibration of the Teledyne API CO Analyzer is divided into two
sections. Chapter 3 discusses the different methods by which the Analyzer's zero and
span settings may be checked and adjusted. The emphasis in Chapter 3 is on the
operation of the buttons and the internal adjustments they make in the instrument.
3.1 Manual zero/span check
Operators can manually check the zero and span setpoints of the Analyzer while in
sample mode by allowing the instrument to sample calibration gas and pressing the CAL
button. This is also referred to as a multi-point calibration.
NOTE
ZERO OR SPAN CHECKS CAN BE PERFORMED IN ANY
ORDER.
3.1.1 Zero Check
Allow the analyzer to sample zero air through the sample port. Press CAL button. After
a few minutes the CO reading should go to zero. If it doesn't, the operator may press the
ZERO button followed by ENTR. This will force the CO reading to go to zero and
modify the internal formulas used to compute the CO reading. If the ZERO button is not
displayed, this means that the zero reading is too far out of adjustment to do a reliable
calibration. The reason for this must be determined before the analyzer can be calibrated.
See Section 10.5 for troubleshooting calibration problems. Pressing EXIT will bring you
back to the Sample menu or you can leave the instrument in CAL mode if you are also
going to make a span check.
3.1.2 Span Check
Allow the analyzer to sample span gas through the sample port. Press CAL button. After
a few minutes the CO reading should be at the expected concentration. If the correct
concentration is not reached, then the instrument can be adjusted to read the correct
value. To do this, press CONC and enter the expected concentration for calibration. The
SPAN button should now be displayed on the front panel. Pressing SPAN and ENTER
will modify the internals formulas used to compute the CO reading. If the SPAN button
is not displayed, this means that the span reading is too far out of adjustment to do a
reliable calibration. The reason for this must be determined before the analyzer can be
calibrated. See Section 10.5 for troubleshooting calibration problems.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 31
3.1.3 Dual Range Calibration
If the analyzer is being operated in Dual Range mode or Auto-Ranging mode, then the
High and Low ranges must be independently calibrated. When the analyzer is in Dual or
Auto Range mode you will be prompted to enter the range to calibrate whenever you
enter a calibration command from the front panel. Press HIGH or LOW followed by the
ENTR button to proceed with the calibration. To calibrate the other range you must exit
to the sample menu and restart the calibration. See Section 4.6 for more information on
the Range Modes. The following procedure shows an example of how to calibrate the
two ranges with calibration gas coming in through the sample port:
Step
1.
Action
Press CAL
2.
3.
4.
Press LOW-ENTR
Wait 15 min.
Press ZERO-ENTR
5.
6.
7.
8.
9.
Press CONC
Key in span
concentration
Press ENTR
Wait 15 min.
Press SPAN-ENTR
10.
Press EXIT
Comment
Analyzer enters M-P calibration mode. Calibration gas
source should be set to deliver zero gas to the sample port.
Select range to calibrate
Wait for CO reading to stabilize at zero value.
Changes calibration equations for Low range so analyzer
will read zero.
Enter span gas concentration for Low range.
Enter span gas concentration for Low Range. Set
calibration gas source to deliver span concentration
Wait for CO reading to stabilize at span value
Changes calibration equations for Low range so analyzer
will read span value.
Exits back to sample menu
Repeat steps 1-10 for High range.
3.2 IZS zero/span check (Option)
If the IZS (Internal Zero Scrubber) option has been installed and a source of CO span gas
has been connected, the operator can check the zero and span setpoints of the analyzer at
any time by pressing the CALZ or CALS button.
Pressing CALZ switches the Sample/Cal valve and allows the analyzer to draw air
through the zero air scrubber. After a few minutes the CO reading should go to zero. If
it doesn't, the operator may press the ZERO button followed by ENTR.
CALS works like CALZ except that externally supplied span gas is drawn through the
analyzer. After a few minutes the CO reading should approach the span level (typically
40 PPM). If it doesn't, the operator may press the SPAN button, followed by ENTR.
The expected span gas concentration may be changed by pressing the CONC button.
The operator can exit the IZS calibration only by pressing the EXIT button. If either the
ZERO or SPAN buttons were pressed and ENTR was not pressed, the Analyzer will
beep once to indicate that no changes have been made.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 32
3.3 Zero/span valves (Option)
If the Zero/Span Valves option has been installed the operator can check the zero and
span setpoints of the analyzer at any time by pressing the CALZ or CALS button.
Zero and Span checks using the Zero/Span Valves option is identical to that described in
Section 3.2 except that external zero and span gas is supplied to the analyzer through a
zero/span valve located on the rear panel of the instrument.
3.4 Automatic zero/span check
Automatic zero/span checking (Z/S check) must be enabled in the setup mode. The
Teledyne API Model 300 Carbon Monoxide Analyzer with IZS or Zero/Span Valves option
offers capability to check the zero and span point automatically on a timed basis, or through
remote RS-232 operation(see Section 3.7).
Under the SETUP-ACAL menu, there are three separate auto-sequences called SEQ1,
SEQ2, and SEQ3. Under each SEQ, there are eight setup parameters that affect zero/span
checking: the mode, the starting date of the check, the time of day for check, the number
of delay days, time delay, the duration of the check, the range to check and whether to
calibrate as well as check the range. These are described individually below. Use the
PREV and NEXT buttons to scroll through the three sequences. The mode for each
sequence is displayed. To change the mode for any of the sequences, scroll to the desired
sequence and press the MODE button. Use the PREV and NEXT buttons to select one
of the modes shown below and press ENTR.
Mode:
1.
2.
3.
4.
DISABLED (Sequence is disabled)
ZERO
SPAN
ZERO-SPAN
To change the setup parameters for a sequence, press the SET button. Pressing the <SET
and SET> buttons allows you to scroll through the setup parameters and edit them by
pressing the EDIT button. The function of each setup parameter is described below:
Timer Enabled: When set to ON, the sequence will be executed based on the internal
timer, as specified in the following parameters. When set to OFF the sequence will be
executed only upon an external (RS-232) command.
Starting Date: The starting date for the sequence is entered in the format of
MM/DD/YY, where MM is the month, DD is the date, and YY is the year. Enter starting
date and press ENTR or EXIT to leave the date unchanged.
Starting Time: To set the time of day for the sequence, enter in the format HH:MM,
where HH is the hour in 24-hour format (i.e. hours range from 00 to 23) and MM is the
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 33
minute (00 - 59). Enter the time of day for calibration check and then press ENTR to
accept the new time or EXIT to leave the time unchanged.
NOTE
THE PROGRAMMED START TIME MUST BE A
MINIMUM OF 5 MINUTES LATER THAN THE REAL
TIME CLOCK (See Section 4.3 and 4.4 for setting real time
clock).
Delta Days: The number of delta days is the number of days between each autosequence. Enter desired number of delay days(0-365) and press ENTR.
Delta Time: The delta time allows the automatic Z/S check time-of-day to be delayed in
the format of HH:MM, where HH is the hour from 00 to 23 and MM is the minutes(0059). The delta days and delta time are added together to determine the total delay
between sequences. The delta time parameter allows you to advance or retard the starting
time by a fixed amount each time the sequence is run. For example: Setting the delta
days to 1 day and the delta time to 15 minutes will delay the starting time for the
sequence by 15 minutes each day. If you want to have the sequence run at the same time
every day, simply set the delta time to zero.
NOTE
Avoid setting two or more sequences at the same time of the
day. Any new sequence which is initiated whether from a
timer, the RS-232, or the contact closure inputs will override
any sequence which is in progress.
Duration: The duration of each step of the sequence. Enter the duration in minutes(1-60)
and press ENTR.
Calibrate: When set to ON, the sequence will adjust the internal formulas (slope and
offset) in the Analyzer to the value set in the span variable. If this feature is enabled
along with the automatic zero/span check, the Analyzer will re-adjust its formulas to
match the predetermined zero and span settings once each day.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 34
Range To Cal: This setup parameter is enabled only if the range mode is set to Dual or
Auto. This parameter determines which range the sequence will check.
NOTE
THE CALIBRATE FEATURE OF AUTO SEQUENCES
ALTERS THE FORMULAS USED TO COMPUTE THE
CARBON MONOXIDE READING. THIS METHOD OF
CALIBRATION IS NOT APPROVED BY USEPA AND IS
NOT INTENDED TO REPLACE THE USEPA APPROVED
CALIBRATION METHOD.
Examples of possible sequences are as following under any one of three available SEQx.
Example 1: to perform a 15 minute zero check once per day at 10:30 pm, 12/20/93.
1.
2.
3.
4.
5.
6.
7.
8.
MODE: ZERO
TIMER ENABLED: ON
STARTING DATE: 12/20/93
STARTING TIME: 22:30
DELTA DAYS: 1
DELTA TIME: 00:00
DURATION: 15
CALIBRATE: OFF
Example 2: to perform a 15 min zero span check once per day retarding 15 minutes
everyday starting at 11:30 pm, 12/20/93.
1.
2.
3.
4.
5.
6.
7.
8.
MODE: ZERO-SPAN
TIMER ENABLED: ON
STARTING DATE: 12/20/93
STARTING TIME: 23:30
DELTA DAYS: 0
DELTA TIME: 23:45
DURATION: 15
CALIBRATE: OFF
Example 3: to perform span check once per week starting at 11:30 pm, 12/20/93
1. MODE: SPAN
2. TIMER ENABLED: ON
3. STARTING DATE: 12/20/93
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 35
4.
5.
6.
7.
8.
STARTING TIME: 23:30
DELTA DAYS: 7
DELTA TIME: 00:00
DURATION: 15
CALIBRATE: OFF
Example 4: to perform zero check once per day at 10:30 pm and a span check once per
week starting at 11:30 pm, 12/20/93.
1. Select any one of SEQx and program as example 1.
2. Select any other SEQx and program as example 3. Avoid setting
two or more sequences at the same time of the day.
3.5 Summary of front panel check and calibration
controls
The calibration controls are summarized below in terms of the button sequences used to
access them.
CALIBRATION CONTROLS
Button Sequence
CALZ
CALZ-ZERO-ENTR
CALZ-EXIT
CALS
CALS-CONC-ENTR
CALS-SPAN-ENTR
CALS-EXIT
CAL
CAL-ZERO-ENTR
CAL-CONC-ENTR
CAL-SPAN-ENTR
CAL-EXIT
SETUP-ACAL-SEQ1
SETUP-ACAL-SEQ2
SETUP-ACAL-SEQ3
Function
Begin zero check
Adjust CO conc. to zero
Exit zero check
Begin span check
Expected CO span value
Adj. CO conc. to span val.
Exit span check
Begin M-P cal.
Adj. CO conc. zero value
Expected CO span value
Adj. CO conc. to span val.
Exit M-P cal.
Setup auto-cal SEQ1
Setup auto-cal SEQ2
Setup auto-cal SEQ3
Default
40 PPM
40 PPM
Disabled
Disabled
Disabled
Limits
1-1000 PPM
1-1000 PPM
-
TABLE 3.1
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 36
3.6 Remote zero/span check or adjustment
(contact closure)
In addition to adjustment via the front panel buttons, the Analyzer can be adjusted by
means of two contact closures called EXT_ZERO_CAL and EXT_SPAN_CAL. (See
Figure 1.2 for the location of the terminals for connection of the contacts on the rear
panel.) The CPU monitors these two contact closures every 1 second and looks for a
positive transition (i.e. 0 → 1) on either signal. If a positive transition occurs on
EXT_ZERO_CAL, the CPU will perform a zero check. If a positive transition occurs on
EXT_SPAN_CAL, the CPU will perform a span check. When a negative transition i.e. 1
→ 0) is detected, the CPU will go into hold-off.
Also, if a positive transition occurs on either signal while the M300 is in zero, span check
or hold off, it will immediately switch to the specified mode. For example, if the
analyzer is in zero check and a positive transition is detected on EXT_SPAN_CAL, then
the instrument will immediately go into span check. To perform a zero check followed
by a span check, first generate a positive transition on EXT_ZERO_CAL, and then when
you want to do the span check, generate a positive transition on EXT_SPAN_CAL.
The remote calibration signals may be activated in any sequence, providing a virtually
unlimited number of calibration types.
Remote adjustment is similar to automatic Z/S checking in that if dynamic calibration is
enabled, the internal CO formulas will be modified following calibration. To enable or
disable adjustment, press SETUP-MORE-VARS and press NEXT until the variable
DYN_ZERO or DYN_SPAN is displayed. To change the setting, toggle the value
between OFF - ON and press ENTR to store the new value or EXIT to leave the value
unchanged.
NOTE
TELEDYNE API RECOMMENDS THAT CONTACT
CLOSURES REMAIN CLOSED AT LEAST 10 MINUTES TO
ALLOW FOR AN ACCURATE AVERAGE ZERO OR SPAN
VALUE TO BE ESTABLISHED.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 37
NOTE
REMOTE ZERO AND SPAN ADJUSTMENT ALTER THE
FORMULAS USED TO COMPUTE THE CARBON
MONOXIDE READINGS IF DYN_ZERO OR DYN_SPAN ARE
ENABLED. THIS METHOD OF CALIBRATION IS NOT
APPROVED BY USEPA AND IS NOT INTENDED TO
REPLACE THE USEPA APPROVED CALIBRATION.
3.7 Remote zero/span check or adjustment
(RS-232)
Besides Z/S checking from the front panel, automatic Z/S checking, and remote Z/S
checking via the contact closure inputs, the Analyzer can also be checked via the RS-232
interface. Remote checking via the RS-232 interface supports zero, span, and zero
followed by span check, and is identical to remote check via the contact closure inputs.
This RS-232 control feature is provided mainly so that a host computer at another
location can control the Analyzer. See Section 7.0 for detailed information on using the
RS-232 interface to do a remote Z/S check.
3.8 Power-on hold off
Whenever the Model 300 is powered on it will go through a HOLD-OFF sequence (see
Section 3.10 below) like it does after a zero/span check.
3.9 Hold off
Every type of check or adjustment (zero, span, manual, remote, etc.) is followed by a
hold off period of from 1 to 20 minutes, during which time the internal data acquisition
system (DAS) does not accumulate CO readings into the DAS average. To set the hold
off time, press SETUP-MORE-VARS and press NEXT until the variable
HOLDOFF_TIME is displayed. To change the setting, enter a number from 1 to 20 and
then press ENTR to store the new value or EXIT to leave the hold off time unchanged.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 38
4.0 SETUP MODE
This section describes the setup variables which are used to configure the Analyzer.
4.1 Setup mode operation
ALL the setup variables are stored in the Analyzer's EEPROM and are retained during
power off and even when new software revisions are installed.
NOTE
IF A VARIABLE IS MODIFIED, BUT ENTR IS NOT
PRESSED, THE VARIABLE WILL NOT BE CHANGED AND
THE ANALYZER WILL BEEP WHEN EXIT IS PRESSED.
4.2 Examining the carbon monoxide formula
slope and offset
The slope and offset parameters can be examined by pressing the <TST or TST> buttons
until the slope and offset test functions appear. The slope and offset parameters are set
only during zero and span calibration routines. These parameters are used to adjust the
span and zero values to their exact values.
The current value of the carbon monoxide reading that is displayed on the front panel and
output on the D/A terminals on the back panel is computed as follows:
1.
Every 160 msec, the analyzer takes a CO MEAS reading (i.e. a reading of
the detector output with the IR beam passing through the N2 cell of the
Gas Filter Wheel) and a CO REF reading (i.e. a reading of the detector
output with the IR beam passing through the CO Cell of the Filter Wheel).
2.
A raw (uncorrected, un-linearized) CO concentration value is calculated
according to the following equation:
CONCENTRATION = GAIN_CONST x (1-CO_MEAS/CO_REF + ZERO_CONST)
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 39
3.
Slope and offset corrections are made to the CO concentration according
to the equation:
CORRECTED CONCENTRATION =
SLOPE x MEASURED CONCENTRATION + OFFSET
4.
The concentration value is linearized over the range of 0 to 1000 ppm by a
multi-point software look-up table and corrected for temperature and
pressure.
5.
An average of the last 750 samples is computed and converted to the
number displayed on the front panel. This is the carbon monoxide
concentration. The number is also routed to the D/A converter and the
resulting voltage is output to the back panel.
4.3 Setting the time-of-day
To set the current time-of-day, which is used for determining when to do an automatic
calibration and for time-stamping the RS-232 reports, press SETUP-CLK-TIME. The
CPU will display the current time-of-day as four digits in the format "HH:MM", where
"HH" is the hour in 24-hour format (i.e. hours range from 00 to 23) and "MM" the
time-of-day and then press ENTR to accept the new time, or press EXIT to leave the
time unchanged.
4.4 Setting the date
To set the current date, which is used for time-stamping the RS-232 reports, press
SETUP-CLK-DATE. The CPU will display the current date as "DD MMM YY". For
example, April 1, 1990 would be displayed as "0 1 APR 9 0". Change the date by
pressing the button under each field until the desired date is shown. Then press ENTR to
accept the new date or press EXIT to leave the date unchanged.
4.5 Adjusting the clock speed
In order to compensate for clocks which run a little bit fast or slow, there is a variable to
speed up or slow down the clock by a fixed amount every day. To change this variable,
press SETUP-MORE-VARS. Press NEXT until the CLOCK_ADJ variable is
displayed. To change the setting, press the EDIT key and enter the value from the
keyboard.. Press ENTR to accept the change. This variable is set to the number of
seconds per day by which to speed up or slow down the clock. It should only need to be
set once for each Analyzer. For example, if the clock is running 10 seconds fast each
day, set the variable to -10 and press ENTR. (Note that -10 indicates that we want the
clock to run 10 seconds slower each day.) If the clock is running 10 seconds slow each
day, set the variable to +10, indicating that we want the clock to run 10 seconds faster
each day.
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If the clock speed adjust variable has already been set to a value other than 0 and the
speed is still too fast or too slow, ADD the required adjustment to the current value of the
variable. For example if the clock speed adjustment is already set to +10 and the clock is
5 seconds too slow per day, add +5 to the current value, yielding +15 as the new value.
4.6 Setting the CO concentration range
The CO concentration range is the concentration value that corresponds to the maximum
voltage output at the rear panel (usually 5 volts). The M300 can operate in one of three
analog output Range Modes. The Range Mode can be changed through the SETUPRNGE-MODE menu. The modes are described below:
4.6.1 Single range mode (SNGL)
In this mode, both analog outputs (REC and DAS) are set to the same range. This range
can be set to any value between 1 and 1,000 ppm and is accessed through the SETUPRNGE-SET menu. This is the default range mode for the analyzer.
4.6.2 Dual range mode(DUAL)
Selecting dual range mode will allow you to select different ranges for the REC and DAS
analog outputs. The two ranges are called Low and High. The REC output at the rear
panel is used for the Low range and the DAS output is used for the High range. To set
the ranges press SETUP-RNGE-SET and select which range you want to edit followed
by ENTR.
The High and Low ranges have separate slopes and offsets for computing the carbon
monoxide concentration. Therefore, the two ranges must be independently calibrated.
See Section 3.1.2 for details on calibrating the two ranges.
4.6.3 Auto range mode(AUTO)
In auto range mode, the analyzer automatically switches between the Low and High
range depending on the concentration. When the CO concentration increases to 98% of
the Low range value, the analyzer will switch to the High range. The analyzer will
remain in the High range until the CO concentration drops to 75% of the Low range
value. It will then switch back to the Low range. Auto ranging changes the range for the
REC and DAS outputs simultaneously. To set the ranges press SETUP-RNGE-SET and
select which range you want to edit followed by ENTR.
The High and Low ranges have separate slopes and offsets for computing the carbon
monoxide concentration. Therefore, the two ranges must be independently calibrated.
See Section 3.1.2 for details on calibrating the two ranges.
4.7 Setting the analog output offset
In order to permit the Analyzer to connect to a wider variety of strip chart recorders and
other instruments, the analog output of the carbon monoxide readings can be adjusted by
up to +500 mV for 0-5V range (or +10% of current analog output range) in software.
The default output offset is 0 mV. To change it, press SETUP-MORE-DIAG, press
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 41
NEXT until D/A CALIBRATION is displayed and press ENTR. Press CFG to enter the
D/A configuration menu. Use the NEXT and PREV buttons to select the desired analog
output and press SET. Enter a value of from -500 mV to +500 mV (other ranges will
ratio accordingly), followed by ENTR to accept the change, or EXIT to leave it
unchanged. The offset will be reflected immediately on the strip chart recorder or other
instrument.
4.8 Setting the RS-232 baud rate
To set the baud rate for the RS-232 channel, press SETUP-MORE-COMM-BAUD.
Press 300, 1200, 2400, 4800, 9600, or 19.2 followed by ENTR to accept the new baud
rate, or EXIT to leave the baud rate unchanged.
4.9 Setting the analyzer I.D.
Each Analyzer may be programmed with a unique I.D. number which appears on all RS232 messages. To set the Analyzer I.D., press SETUP-MORE-COMM-ID. Enter a 4digit number from 0000 to 9999, followed by ENTR to accept the new I.D., or EXIT to
leave the I.D. unchanged. If changed, the new I.D. number will appear on all RS-232
reports from this Analyzer.
4.10 Disabling the calibration password
Normally, operators are required to enter the calibration password when doing a manual
calibration via the CALZ, CALS, or CAL buttons. To allow calibration without entering
the password, press SETUP-PASS and set it to OFF, and then press ENTR to accept the
change, or EXIT to leave it unchanged. To enable the calibration password, set the
variable to ON.
4.11 Data acquisition system (DAS)
The Model 300 contains a flexible and powerful built in data acquisition system (DAS)
that enables the analyzer to store concentration data as well as many diagnostic
parameters in its battery backed memory. This information can be viewed from the front
panel or printed out through the RS-232 port. The diagnostic data can be used for
performing “Predictive Diagnostics” and trending to determine when maintenance and
servicing will be required.
The logged parameters are stored in what are called “Data Channels.” Each Data
Channel can store multiple data parameters. The Data Channels can be programmed and
customized from the front panel. A set of default Data Channels has been included in the
Model 300 software. These are described Section 4.11.1. For more information on
programming custom Data Channels, a supplementary document containing this
information can be requested from Teledyne API.
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4.11.1 Data Channels
The function of the Data Channels is to store, report, and view data from the analyzer.
The data may consist of carbon monoxide concentration, or may be diagnostic data, such
as the sample flow or detector output.
The M300 comes pre-programmed with a set of useful Data Channels for logging carbon
monoxide concentration and predictive diagnostic data. The default Data Channels can
be used as they are, or they can be changed by the user to fit a specific application. They
can also be deleted to make room for custom user-programmed Data Channels.
The data in the default Data Channels can be viewed through the SETUP-DAS-VIEW
menu. Use the PREV and NEXT buttons to scroll through the Data Channels and press
VIEW to view the data. The last record in the Data Channel is shown. Pressing PREV
and NEXT will scroll through the records one at a time. Pressing NX10 and PV10 will
move forward or backward 10 records. For Data Channels that log more than one
parameter, such as PNUMTC, buttons labeled <PRM and PRM> will appear. These
buttons are used to scroll through the parameters located in each record.
The function of each of the default Data Channels is described below:
CONC:
Samples carbon monoxide concentration (Low Range) at one minute
intervals and stores an average every hour with a time and date
stamp. Readings during calibration and calibration hold off are not
included in the data. The last 800 hourly averages are stored.
PNUMTC: Collects sample flow and sample pressure data at five minute
intervals and stores an average once a day with a time and date
stamp. This data is useful for monitoring the condition of the pump
and critical flow orifice(sample flow) and the sample filter(clogging
indicated by a drop in sample pressure) over time to predict when
maintenance will be required. The last 360 daily averages (about 1
year) are stored.
CALDAT: Logs new slope and offset every time a zero or span calibration is
performed. This Data Channel also records the instrument reading
just prior to performing a calibration. Note: this Data Channel
collects data based on an event(a calibration) rather than a timer.
This Data Channel will store data from the last 200 calibrations.
This does not represent any specific length of time since it is
dependent on how often calibrations are performed. As with all Data
Channels, a time and date stamp is recorded for every data point
logged.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 43
4.11.2 Setting-up Data Channels
To setup a new data channel or modify an existing data channel, press SETUP-DASEDIT to get into the DAS edit mode.
Once in the DAS edit mode, definitions of data channels may be created or modified by
using the MENU buttons described in the following table:
Button
PREV
NEXT
INS
DEL
EDIT
PRNT
Data Channel Edit Menu
Description
Moves to the previous data channel
Moves to the next data channel
Inserts a new data channel in front of the current
one (allowed up to 20 data channels)
Deletes the current data channel (prompts first)
Edits the properties of the current data channel
Prints a summary of all of the data channel on the
RS-232 port
The creation or modification of data channel definitions is accomplished by modifying
the properties of existing (or default) channel definitions. The table below lists all of the
properties defined for data channels.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 44
Property
NAME
EVENT
Data Channel Properties
Description
Initial
Setting
“NONE”
The data channel’s
name (primarily used
for RS-232 access and
reports)
ATIMER
The event which
triggers this data
channel to record a
sample or issue a
report
PARAMETER
S
REPORT
PERIOD
The number of
parameters sampled
The amount of time
between each report
NUMBER OF
RECORDS
How many reports
will be stored in the
data file
Indicates whether or
not a report will be
printed on the RS-232
channel
RS-232
REPORT
CHANNEL
ENABLED
CAL. HOLD
OFF
1
000:01:00
Setting
Range
Up to 6
letters or
numbers
Any of the
events listed
in the table
of triggering
events shown
above
1 to 10
100
000:00:01 to
366:23:59
(Days:Hours:
Minutes)
1 to 1000
OFF
OFF or ON
ON
ON or OFF
ON
ON or OFF
NAME
This property is primarily for the user’s convenience, and the user should select
meaningful names (you can give a data channel any name you want, up to six characters
long). When you edit this property you should see a display like the following:
Blank names (all dashes) or duplicate names should be avoided because they won’t be
accessible from the RS-232 interface.
EVENT
This property designates the event that will trigger data collection. Since this could be a
diagnostic tool, it might be useful to read the parameter that is associated with the events
such as the calibration. A data channel can be triggered by only one event. If you must
trigger collection of the same data by multiple events, then you can create multiple data
channels and trigger each one with a different event. The list of available triggering
events is shown in following table.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 45
Name
ATIMER
EXITZR
EXITSP
EXITMP
SLPCHG
Triggering Events
Description
Automatic timer expired
Exit zero calibration
Exit span calibration
Exit multi-point calibration
Slope changed
REPORT PERIOD
This property specifies the period between reports (DAS entries). Enter the number of
days and press ENTR. Then enter the number of hours (the leftmost digits) and minutes
and press ENTR.
NUMBER OF RECORDS
This property specifies how many records you want to store in this data channel. Each
record consists of a time stamp and the sampled measurements from each parameter. The
memory of the M300 has capacity for a total of about 8,000 records (for all data
channels). When the specified number of records for a data channel has been reached,
the channel will “wrap around”, with the oldest records being overwritten with the newest
records.
NOTE
Changing this property requires that any existing data records
be deleted because memory must be re-initialized.
Enter the number of records desired and press ENTR. Only when you press ENTR is
the data file actually deleted. If you press EXIT the property will not be modified and
data file will not be deleted.
RS-232 REPORT
This property controls printing of reports on the RS-232 channel. If set to ON then every
time a new report is stored it’s also printed on the RS-232 channel. If this property is set
to OFF, the reports are still stored in the data file, but not printed on the RS-232 channel.
PARAMETERS
This property shows the number of parameters being sampled. Each data channel can
sample up to 10 parameters, each with a separate sampling mode.
This parameter also specifies the mode of data collection. When sampling a reading such
as a concentration at periodic intervals, it is desirable to use the AVG mode to generate an
average of the readings during the interval. But when sampling the concentration when
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 46
exiting calibration it is desirable to take a single instantaneous reading using the INST
mode. The table below summarizes the available sampling modes.
Mode
INST
AVG
MIN
MAX
Sampling Modes
Description
Records instantaneous reading
Records average reading during reporting interval
Records minimum reading during reporting interval
Records maximum reading during reporting interval
Each parameter in this list can refer to a different (or the same) point, and can use a
different (or the same) sampling mode. For instance, you could create three parameters
which all measure the CO concentration for range 1 (the CONC1 parameter), but which
use the MIN, AVG, and MAX sampling modes. This permits you to record not only the
average concentration during the reporting interval, but the maximum excursions as well.
Like data channels, parameters also have properties which are listed in the table below.
Property
PARAMETER
SAMPLE
MODE
PRECISION
Parameter Properties
Description
Initial
Setting
The parameter to sample
CONC1
The sampling mode to use
when reading this
parameter
Number of decimal digits
AVG
1
Setting Range
Any of the parameters
listed in the table of
parameters shown
above
Any one of the INST,
AVG, MIN, and MAX.
0-3
The table below lists the data parameters initially defined. The entries in the Name and
Units columns are visible when editing and printing the data channel properties.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 47
Name
NONE
COMEAS
COREF
SLOPE1
SLOPE2
OFSET1
OFSET2
ZSCNC1
ZSCNC2
CONC1
CONC2
STABIL
BENCHTMP
WHEELTMP
SMPFLW
SMPPRS
BOXTMP
DCPS
Data Parameters
Description
CO Measure signal
CO Reference signal
Slope of Range #1
Slope of Range #2
Offset of Range #1
Offset of Range #2
Range1 zero/span measured
concentration
Range2 zero/span measured
concentration
Concentration of Range #1
Concentration of Range #2
Stability
Optical bench temperature
Filter wheel temperature
Sample flowrate
Sample pressure
Box temperature
DC power supply composite voltage
Units
mV
mV
mV
mV
PPM
PPM
PPM
PPM
PPM
o
C
o
C
cc/min
in-Hg
o
C
mV
Example:
Sample the CO concentration (Range #1) once per minute (default) and issue a report
once per 5 minutes, and print the report on the RS-232 channel.
1. Press SETUP-DAS-EDIT-ENTR-INS to create a new data channel and begin
editing its properties.
2. Edit the NAME property and give it any name you want, but do not set the blank
name (all dashes) or duplicate names because they won’t be accessible from the RS232 interface.
3. For each of the remaining properties, press the SET> to view the current setting, and
then press EDIT to change the property if necessary. The table below lists the proper
settings for all of the properties for this example:
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Property
NAME
EVENT
Setting
“CO5MIN”
ATIMER
PARAMETERS
REPORT PERIOD
CONC1,AVG
000:00:05 (i.e. 5 minutes)
DESCRIPTION
Sample when automatic
timer is expired
SO2 Range #1 concentration
Average of 5 minutes*
reported every 5 minutes
Stores 4032 of Report
Period (5 minutes average)
RS-232 is enabled
Data channel is enabled
NUMBER OF
4032 (i.e. two weeks)
RECORDS
RS-232 REPORT
ON
CHANNEL
ON
ENABLED
CAL. HOLD OFF
ON
Hold off is enabled
*
Sample measurement period of filtered CO concentration is 1 minute by default.
4.11.3 RS-232 reporting
Automatic RS-232 reporting can be independently enabled and disabled for each Data
Channel. For all default data channels, RS-232 reporting is initially set to “OFF.” If this
property is turned on, the Data Channel will issue a report with a time and date stamp to
the RS-232 port every time a data point is logged. The report format is shown below:
D 31:10:06 0412 CONC : AVG COCNC1=6.8 PPB
The report consists of the letter “D” follow by a time/date stamp(“31:10:06”) followed by
the instrument ID number(“0412”). Next is the Data Channel name(“CONC”) and the
sampling mode (“AVG” indicates that the data point is an average of more than one
sample as opposed to a instantaneous reading, “INST”). Finally, the name of the
parameter and its value(“COCNC1=6.8 PPB”) are printed. For Data Channels that
sample more than one parameter, such as PNUMTC and CALDAT, each parameter is
printed on a separate line.
To enable RS-232 reporting for a specific Data Channel:
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Step
1.
2.
3.
4.
Action
Press SETUP-DASEDIT
Press PREV/NEXT
Press EDIT
Press SET> (5 times)
5.
6.
7.
8.
Press EDIT
Toggle OFF to ON
Press ENTR
Press EXIT (4 times)
Comment
Enter DAS menu to edit Data
Channels
Select Data Channel to edit
Edit selected Data Channel
Scroll through setup properties until
RS-232 REPORT: OFF is displayed
Edit selected setup property
Change RS-232 REPORT property
Accepts change
Exits back to sample menu
See Section 7.3.1 for more information on DAS reporting through the RS-232 interface.
4.12 Software configuration
The software configuration can be displayed by entering the button sequence
SETUP-CFG-LIST. For example the M300 could display:
"CO MACHINE"
"SBC40 CPU"
Stating that the instrument was an Carbon Monoxide Analyzer using the SBC40
computer. This feature is useful for showing any special features that are present in the
currently installed PROM.
4.13 Summary of setup functions
The setup functions are summarized in Table 4.1 in terms of the button sequences used to
access them.
SETUP FUNCTIONS
Button Sequence
SETUP-CFG-LIST
Default
CO Mach
Limits
N/A
Disabled
Zero, Span,
Zero-Span
SETUP-DAS-VIEW
SETUP-RNGE-MODE
Function
List Software
Configuration
Define/Change
AutoCal Sequences
Define/Change DAS
Data Channels
View DAS Data
Set Range Mode
N/A
Single
SETUP-RNGE-SET
Set D/A output range
50 ppm
N/A
Single,
Dual, Auto
1-1000ppm
SETUP-ACAL-MODE
SETUP-DAS-EDIT
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SETUP-RNGE-UNIT
Set Measurement Units
ppm
SETUP-PASS
SETUP-CLK-TIME
SETUP-CLK-DATE
SETUP-MORE-COMM-BAUD
Password Enable
Set Time-of-Day
Set Current Date
RS-232 baud rate
ON
00:00
01 JAN 00
2400 baud
SETUP-MORE-COMM-ID
SETUP-MORE-VARSDAS_HOLD_OFF
SETUP-MORE-VARSDYN_ZERO
Analyzer ID number
Set Hold-Off Interval
0000
15 min
ppb. ppm.
mg/m3,
ug/m3
OFF-ON
00:00-23:59
31 DEC 99
300, 1200,
2400, 4800,
9600, 19.2
0000-9999
1 - 60 min
Enable Remote
Dynamic Zero
Adjustment
Enable Remote
Dynamic Span
Adjustment
Set RS-232 Mode
OFF
OFF-ON
OFF
OFF-ON
Set Clock Adjustment
Rate
View Dark Offset
0
-15 to +15
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
125mV
75-175mV
SETUP-MORE-VARSDYN_SPAN
SETUP-MORE-VARSRS232_MODE
SETUP-MORE-VARSCLOCK_ADJ
SETUP-MORE-DIAG-DARKVIEW
SETUP-MORE-DIAGSIGNAL I/O
SETUP-MORE-DIAGANALOG OUTPUT
SETUP-MORE-DIAGD/A CALIBRATION
SETUP-MORE-DIAGELECTRICAL TEST
SETUP-MORE-DIAGDARK-CAL
SETUP-MORE-DIAGTEST CHAN OUTPUT
SETUP-MORE-DIAGRS-232 OUTPUT
View the state of
internal signals
Generate Analog
Output Test Pattern
Calibrate D/a\A and
A/D Converters
Generate Electrical
Test Output
Adjust Dark Offset
Select TEST to Analog
Output
Generate RS-232
Output Test Pattern
8
None
N/A
N/A
TABLE 4.1
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5.0 DIAGNOSTICS
The Teledyne API carbon monoxide analyzer contains two levels of diagnostics: test
measurements which can be viewed at all times (except when in setup) by pressing
TEST, and lower level diagnostic operations which can only be performed by pressing
SETUP-DIAG.
5.1 Test measurements
As stated, test measurements can be viewed at any time except when in setup. To view a
different test measurement, simply press the TEST button. Table 2.3 lists the test
measurements which are available. Viewing these test measurements does not interfere
with the operation of the Model 300 or the carbon monoxide reading in any way, so they
may be viewed freely.
NOTE
IF THE VALUE OF ANY TEST FUNCTION IS DISPLAYED
AS “XXXX”, THIS INDICATES THAT THE READING IS OFF
SCALE OR OTHERWISE NON-VALID.
Additionally, the values of most TEST functions can output as an analog voltage at the
instrument's rear panel (see Figure 1.2). The TEST function to be output is selected by
pressing SETUP-MORE-DIAG. Press NEXT until TEST CHANNEL OUTPUT
appears. Press ENTR. Select test channel function and press ENTR. Table 5.1 below
lists the Test functions available for analog output.
In addition to outputting a value to the analog output channel, these tests activate a new
test measurement which displays the analog voltage reading on the front panel as:
"TEST=XXXXX.X MV".
When you exit the diagnostics, this test measurement is removed.
5.2 Diagnostic tests
The diagnostic tests are used to help diagnose a problem in the Analyzer and should only
be used by skilled maintenance people since they can potentially interfere with the carbon
monoxide reading. Table 5.1 below lists the low level diagnostic tests which are
available. To get into the diagnostic test mode, press SETUP-DIAG. When the
diagnostic mode is entered, a message is sent to the RS-232 channel indicating entry into
the diagnostic mode. The buttons which are available to the operator are described
below.
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The TEST button is used to scroll through the test measurements until the one of interest
is displayed. To turn the test on press the OFF/ON button. Viewing test measurements
in the diagnostic mode is especially useful for viewing the results of a diagnostic test.
The PREV button goes to the previous diagnostic test. When pressed, the CPU turns the
current diagnostic test OFF if it is ON. The NEXT button goes to the next diagnostic test.
When pressed, the CPU turns the current diagnostic test OFF if it is ON. The EXIT
button exits the diagnostic mode and turns all the diagnostic tests OFF. This ensures that
a diagnostic test is not accidentally left ON. A message is also sent to the RS-232
channel to indicate that the diagnostic mode has been exited.
DIAGNOSTIC TESTS
Test #
1
2
3
Name
NONE
CO MEASURE
CO REFERENCE
4
5
6
7
8
9
10
11
SAMP PRESS
SAMP FLOW
SAMP TEMP
BENCH TEMP
WHEEL TEMP
CHASSIS TEMP
DCPS VOLT
DAS AVERAGE
Signal
No output
CO detector measure value
CO detector reference
value
Sample pressure
Sample flow
Sample temperature
Optical bench temperature
Outputs filter wheel temp.
Outputs Chassis temp
Outputs DC power
Current DAS average
Nominal Value
0 mV
4500 mV
4200 mV
125 mV
3000 mV
3000 mV
3900 mV
3900 mV
2740 mV
2500 mV
Any
TABLE 5.1
5.2.1 Signal I/O
The signal I/O diagnostic mode gives the user access to the digital and analog inputs and
outputs on the V/F board. The digital outputs can be controlled through the keyboard.
Any signals manually changed through the signal I/O menu will remain in effect until
you leave the signal I/O menu. At that time the analyzer will regain control of these
signals. To enter the signal I/O test mode, press SETUP-MORE-DIAG-ENTR. When
the diagnostic mode is entered, a message is sent to the RS-232 channel indicating entry
into the diagnostic mode. Use the PREV and NEXT buttons to scroll through the signals.
Edit buttons will appear for the signals that can be controlled by the user. Press JUMP to
skip to a specific I/O Signal.
Table 5.2 below lists the I/O signals available for the M300:
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#
Signal
0
DISP_BROWNOUT
Contro
l
NO
1
EXT_ZERO_CAL
NO
2
EXT_SPAN_CAL
NO
3
SYNC_OK
NO
4
SPAN_VALVE
YES
5
CAL_VALVE
YES
6
BENCH_HTR
YES
7
WHEEL_HTR
YES
8
DARK_CAL
YES
9
ELEC_TEST
YES
10
BROWNOUT_RST
YES
11
ST_ZERO_CAL
YES
12
ST_SPAN_CAL
YES
Description
Display brownout is used to keep the
display from getting corrupted during
low line voltage conditions. Circuitry
on the Power Supply board (00015)
senses low line voltage and sets this
bit. The CPU reads this and generates
the
BROWNOUT_RST
signal
described below.
Shows state of status input bit to cause
the M300 to enter Zero Calibration
mode. Use to check external contact
closure circuitry.
Shows state of status input bit to cause
the M300 to enter the Span Calibration
mode. Use to check external contact
closure circuitry.
Indicates that demodulation circuitry
on the Sync/Demod Board (00798) is
able to lock-in on the detector signal.
Switches the Zero/Span valve. Use
this bit to test the valve function.
Switches the Sample/Cal valve. Use
this bit to test the valve function.
Shows the status of the optical bench
heater. This has the same function as
the LED in the power supply module.
Shows the status of the filter wheel
heater. This has the same function as
the LED in the power supply module.
Turns off the detector input to the
Sync/Demod board for electronics
calibration.
Activates the Electric Test diagnostic
circuitry.
Resets
the
DISP_BROWNOUT
circuitry described above.
Status Bit - Zero Calibration mode
Logic high = M300 in Zero cal mode
Logic low = Not in Zero cal mode
Status Bit - Span Calibration mode
Logic high = M300 in Span cal mode
Logic low = Not in Span cal mode
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 55
13
ST_FLOW_ALARM
YES
14
ST_TEMP_ALARM
YES
15
ST_DIAG_MODE
YES
16
ST_POWER_OK
YES
17
ST_PRESS_ALARM
YES
18
ST_HIGH_RANGE
YES
19
ST_SYSTEM_OK
YES
20
ST_BENCH_ALARM
YES
21
ST_SOURCE_ALARM
YES
22
ST_WHEEL_ALARM
YES
23
CO_MEASURE
NO
24
CO_REFERENCE
NO
25
SAMPLE_PRES
NO
26
27
SAMPLE_FLOW
SAMPLE_TEMP
NO
NO
Status Bit - Flow alarm
Logic High = Sample flow out of spec
Logic Low = Flows within spec
Status Bit - Temperature alarm
Logic High = One or more temps out
of spec
Logic Low = Temps within spec
Status Bit - In Diagnostic mode
Logic High = M100A in Diagnostic
mode
Logic Low = Not in Diag mode
Status Bit - Power OK
Logic High = Instrument power is on
Logic Low = Instrument power is off
Status Bit - Flow alarm
Logic High = Sample pressure out of
spec
Logic Low = pressure within spec
Status Bit - Autorange High Range
Logic High = M300 in high range
Logic Low = M300 in low range
Status Bit - System OK
Logic High = No instrument warning
present
Logic Low = 1 or more alarm present
Status Bit - Bench Temperature Alarm
Logic High = Bench Temp out of spec
Logic Low = Bench Temp in spec
Status Bit - IR Source Alarm
Logic High = IR Source output too
low
Logic Low = IR Source output
normal
Status Bit - Wheel Temperature Alarm
Logic High = Wheel Temp out of spec
Logic Low = Wheel Temp in spec
IR detector reading during measure
phase. Typically 2500-4500 mV
IR detector reading during reference
phase. Typically 2500-4500 mV
Sample pressure in mV. Typical sea
level value = 4300mV for 29.9" HGA.
Sample flow in mV.
Sample temp in mV
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 56
28
BENCH_TEMP
NO
29
WHEEL_TEMP
NO
30
31
BOX_TEMP
DCPS_VOLTAGE
NO
NO
32
33
34
35
36
37
38
DAC_CHAN_0
DAC_CHAN_1
DAC_CHAN_2
DAC_CHAN_3
CO_CONC_1
CO_CONC_2
TEST_OUTPUT
NO
NO
NO
NO
YES
YES
YES
Optical Bench temp. Typically 2270
mV for 48 C
Filter Wheel temp. Typically 4770
mV for 68 C
Internal analyzer temp in mV
DC power supply composite voltage
output. Typically 2500 mV.
Output of DAC 0(REC) in mV.
Output of DAC 1(DAS) in mV.
Output of DAC 2(TEST) in mV.
Output of DAC 3(Spare) in mV.
CO Reading (REC) in mV
CO Reading (DAS) in mV
Test Channel in mV
TABLE 5.2 I/O SIGNALS
5.2.3 D/A output
This test cycles 3 of the analog output channels from 0% to 100% of Full Scale in 20%
FS steps. It starts by outputting 0 volts to all four channels and displaying a 0% button.
Then, every five seconds, the output is increased 20% FS and the button is changed
accordingly. Thus, the button (and the analog outputs) will cycle through the following
value
0%, 20%, 40%, 60%, 80%, 100%, 0%, ...
To pause the output at the current voltage, press the n% button. To resume automatic
cycling, press the n% button again.
5.2.4 Electric Test
This test activates a diagnostic circuit located on the Synchronous Demodulator board
which generates an artificial signal which simulates the output of the IR detector. This
signal is injected in place of the detector output.
When activated, Electric Test will automatically switch the analyzer into a 50 ppm range
and result in the Analyzer producing a constant, stable output (i.e. CO reading) of about
40 ppm. This test is particularly useful in isolating problems, since it exercises
essentially all electronic sub-systems of the Analyzer but does not depend on the proper
function of Optical or Pneumatic subsystems.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 57
6.0 HANDLING WARNINGS
When a system warning occurs, a warning message is displayed and the FAULT LED
blinks. A warning indicates that something in the system needs to be checked or
adjusted. Failure by the operator to respond to a warning may result in poor system
performance and/or less accurate data acquisition. Warnings should be taken seriously.
When a warning is displayed, the MSG and CLR buttons will appear on the menu line
(when not in setup mode). Pressing MSG will scroll through the warning messages if
there is more than one. CLR will clear the currently displayed warning message, and if
there are no more warning messages remaining, the MSG and CLR buttons will
disappear and the FAULT LED will be turned OFF. If after pressing CLR, warning
messages still exist, the FAULT LED will continue to blink and the MSG and CLR
buttons will remain on the menu line.
If after clearing a message, the warning condition for that message still exists, the
message will reappear after a period of time which depends on how frequently the
condition is checked by the CPU (usually every few seconds). If a warning message
reappears every time after CLR is pressed, the problem should be solved and the
Analyzer restarted. Some problems may be temporary and may not reappear after CLR
is pressed (e.g. temperature too high, too low, etc.).
To ignore the warning messages and display the test measurement again, simply press
TEST. The warning messages will remain active and may be viewed again by pressing
MSG.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 59
7.0 RS-232 COMMUNICATIONS
The Model 300 features a powerful RS-232 interface which is used both for reporting test
results and for controlling the Analyzer from a host computer. Because of the dual nature
of the RS-232 interface, the message format has been carefully designed to accommodate
both printers and host computers.
All message outputs from the Model 300 have the following format:
"X DDD:HH:MM IIII MESSAGE<CRLF>"
The "X" is a character indicating the message type (see table below).
RS-232 MESSAGE TYPES
Character
W
C
D
T
V
?
Message Type
Warning
Control/status
Diagnostic
Test measurement
Variable value
HELP screen
TABLE 7.1
The "DDD:HH:MM" is a time-stamp indicating the day-of-year ("DDD") as a number
from 1 to 366, the hour of the day ("HH") as a number from 00 to 23, and the minute
("MM") as a number from 00 to 59.
The "IIII" is a 4-digit Analyzer I.D. number.
The "MESSAGE" field contains variable information such as warning messages, test
measurements, DAS reports, etc.
The "<CRLF>" is a carriage return-line feed combination which terminates the message
and also makes the messages appear neatly on a printer.
The uniform nature of the output messages makes it easy for a host computer to spare
them.
Input messages to the Model 300 have a format which is similar to that for output
messages:
"X COMMAND<CRLF>"
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 61
The "X" indicates the message type as shown above in Table 7.1 and "COMMAND" is
the command type, each of which is described individually below.
The "<CRLF>" is used to terminate the command. Typing "<CRLF>" a few times by
itself is a good way to clear the input buffer of any extraneous characters.
7.1 DAS reporting
Data from individual Data Channels in the DAS system can be retrieved through the RS232 interface. The command format for printing the data for a Data Channel is shown
below:
D [id] REPORT “name” [RECORDS=number] [COMPACT|VERBOSE]
parameters in [ ] are optional
id is the analyzers ID number (SETUP-MORE-COMM-ID)
name is the Data Channel name(must be enclosed in quotes)
number is the number of records to print, beginning with the most recent(if this
parameter is not specified then all available records for the Data Channel are printed)
COMPACT|VERBOSE refers to the report format.
Verbose Data Report Format
There are two kinds of data reports: verbose (with a lot of detail) and compact
(with just the data point values). The verbose format looks like the following:
D
31:10:06
0412
CONC
: AVG
COCNC1=6.8 PPM
This report uses the format of a leading first character (“D” in this example), a
time stamp (“31:10:06”), and the instrument ID (“0412”).
The other fields in the report are the data collector name (“CONC”), the sampling
mode (“AVG”), the data point (“COCNC1”), the data point value (“6.8”), and the
units (“PPM”). Due to the length of the message, only one data point may be
printed per line.
Compact Data Report Format
The compact format looks like the following:
D
31:10:06
0412
CONC
: 1
6.8
The fields up to the colon are the same as for the verbose format, but the next
fields are different. The fields following the colon are the line number (“1” in the
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 62
example), and the data point value (“6.8”). Presumably the user (or remote
computer) knows all of the other information about the data point value.
This report format is particularly useful when you are sampling more than one
data point because up to five data points may be printed per line. The line number
field is necessary because a single report may span multiple lines. A compact
report with two data points, such as the PNUMTC Data Channel, looks like this:
D
31:10:06
0412 PNUMTC: 1
800.0 29.7
Example 1: To report the last 100 records from the CONC Data Channel in Verbose
format type:
D REPORT “CONC” RECORDS=100 VERBOSE
Example 2: To report all the records from the PNUMTC Data Channel in Compact
format type:
D REPORT “PNUMTC” COMPACT
7.2 Warnings
Whenever a warning message is displayed on the display, it is also sent to the RS-232
output. See Table 2.4 for a list of the warning messages. These messages are very
helpful when trying to track down a system problem and for determining whether or not
DAS average data is actually valid. The message format is:
"W DDD:HH:MM IIII WARNING MESSAGE<CRLF>"
An example of an actual warning message is:
"W 194:11:03 0000 SAMPLE FLOW WARN<CRLF>"
Warnings may be cleared via the RS-232 interface by issuing a command of the form:
"W COMMAND<CRLF>"
where "COMMAND" indicates which warning message to clear. For example, to clear
the "SAMPLE FLOW WARN" message, the host computer can issue the command:
"W WSMPFLOW<CRLF>".
Attempting to clear a warning which is not active has no effect. The table below lists the
command to use to clear each possible warning message.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 63
WARNING MESSAGE CLEAR COMMANDS
Command
"W WSYSRES<CRLF>"
"W WRAMINIT<CRLF>"
"W WSOURCE<CRLF>"
"W WBHEAT<CRLF>"
"W WWHLTEMP<CRLF>"
"W WSMPFLOW<CRLF>"
"W WSMPRES<CRLF>"
"W WSMPTEMP<CRLF>"
"W WBOXTEMP<CRLF>"
"W WBNCHTEMP<CRLF>"
"W WDYNZERO<CRLF>"
"W WDYNSPAN<CRLF>"
"W WVFINS<CRLF>"
Warning Message Cleared
SYSTEM RESET
RAM INITIALIZED
SOURCE WARNING
BENCH HEAT SHUTDOWN
WHEEL TEMP WARNING
SAMPLE FLOW WARNING
SAMPLE PRESSURE WARNING
SAMPLE TEMP WARNING
BOX TEMP WARNING
BENCH TEMP WARNING
CANNOT DYN ZERO
CANNOT DYN SPAN
V/F NOT INSTALLED
TABLE 7.2
7.3 Status/control
This subset of messages is concerned with reporting the status of the Analyzer and
controlling the Analyzer remotely. Whenever the Analyzer does a calibration it issues a
report to the RS-232 output. The table on the following page summarizes the status
reports.
STATUS REPORTS
"C DDD:HH:MM
"C DDD:HH:MM
"C DDD:HH:MM
"C DDD:HH:MM
"C DDD:HH:MM IIII
"C DDD:HH:MM IIII
"C DDD:HH:MM
"C DDD:HH:MM
Report
IIII START ZERO CALIBRATION"
IIII FINISH ZERO CALIBRATION"
IIII START SPAN CALIBRATION"
IIII FINISH SPAN CALIBRATION"
START MULTI-POINT CALIBRATION"
FINISH MULTI-POINT CALIBRATION"
IIII START CALIBRATION HOLD"
IIII FINISH CALIBRATION HOLD"
TABLE 7.3
To do a remote adjustment via the RS-232 interface, the host computer should issue a
message with the following format:
"C COMMAND<CRLF>
The commands are summarized in the table below:
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 64
CONTROL COMMANDS
Command Message
Meaning
”C ZERO<CRLF>”
Do a zero check
”C COMPUTE ZERO<CRLF>”
Calibrate Zero point1
”C SPAN<CRLF>”
Do a span check
”C COMPUTE SPAN<CRLF>”
Calibrate Span point1
”C ASEQ1<CRLF>”
Do a auto-cal sequence2
”C ASEQ2<CRLF>”
Do a auto-cal sequence2
”C ASEQ3<CRLF>”
Do a auto-cal sequence2
”C ABORT<CRLF>”
Aborts auto-cal sequence
”C EXITZ<CRLF>”
Exit zero cal only
”C EXITS<CRLF>”
Exit span cal only
”C EXIT<CRLF>”
Exit zero span or hold
1
Executed only if the instrument is in the proper calibration mode and concentration
is within calibration limits. This command adjusts slope and offset values.
2
Initiated only If automatic calibration sequence setup is programmed and enabled.
TABLE 7.4
NOTE
THE COMMANDS IN TABLE 7.4 CAN ONLY
BE ENTERED VIA THE RS-232 PORT WHEN
THE ANALYZER IS IN THE SAMPLE MODE.
When a control command is issued, the CPU will respond by issuing a status report. For
example if the host computer issues the command
"C CALZ<CRLF>"
to do a zero check, the CPU will send the status report
"C DDD:HH:MM IIII START ZERO CALIBRATION<CRLF>"
to the RS-232 output.
7.4 Diagnostics
The diagnostics mode can be entered from the RS-232 port as well as from the front
panel. The diagnostics commands available are listed below.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 65
NOTE
THE DIAGNOSTICS MODE MAY ONLY BE
ENTERED VIA THE RS-232 PORT WHEN
THE ANALYZER IS IN SAMPLE MODE.
DIAGNOSTIC COMMANDS
Command
D ENTER SIG
D EXIT
D LIST
D name[=value]
D RESET
D RESET RAM
D RESET EEPROM
Function
Enter diagnostic Signal I/O mode
Exit diagnostics mode
Prints all Signal I/O values. See Table
5.2 for Signal Definitions
Examines or sets I/O signal. See
Table 5.2 for a list of signals. Must
issue D ENTER SIG before using this
command.
Reset analyzer(same as power on)
Resets analyzer and erases RAM.
Erases all DAS data. Keeps setup
variables and calibration
Resets analyzer and erases RAM and
EEPROM. Erases all DAS data.
Resets all setup variables to factory
default. Resets calibration values.
TABLE 7.5
These commands may be used whether the diagnostics have been entered from the
keyboard (SETUP-DIAG) or the RS-232 ("D ENTER <CRLF>"). However, when the
diagnostics are entered via the keyboard, no feedback is sent to the RS-232 channel. This
prevents the RS-232 output from getting unnecessarily cluttered with diagnostic data.
Whenever the diagnostic mode is entered or exited, a report is issued to the RS-232
output. The table below summarizes the diagnostic reports.
DIAGNOSTIC REPORTS
Report
"C DDD:HH:MM IIII ENTER DIAGNOSTIC MODE"
"C DDD:HH:MM IIII EXIT DIAGNOSTIC MODE"
TABLE 7.6
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 66
7.5 Test measurements
All the test measurements which can be displayed by pressing the TEST button are also
available to the host computer via the RS-232 interface. The host computer should issue
a request for a test measurement, and then the CPU will send the current value of the test
measurement to the RS-232 output. The format of the test measurement message is:
"T DDD:HH:MM IIII TEST MEASUREMENT<CRLF>"
For example, the format of the DC Power Supply output in millivolts would be:
"T 194:11:29 0000 DCPS= 2500 MV<CRLF>"
To request a test measurement, the host must issue a command of the form:
"T MEASUREMENT<CRLF>"
For a summary of all test functions issue the command "T LIST". The table below lists
the commands and the corresponding test measurements which will be returned.
TEST MEASUREMENT REQUEST COMMANDS
Command
"?<CRLF>"
"T LIST<CRLF>"
"T CO<CRLF>"
"T COMEAS<CRLF>"
"T COREF<CRLF>"
"T MRRATIO<CRLF>"
"T SPRESS<CRLF>"
"T SFLOW<CRLF>"
"T STEMP<CRLF>"
"T BNCHTEMP<CRLF>"
"T WHEELTEMP<CRLF>"
"T BOXTEMP<CRLF>"
"T DCPS<CRLF>"
"T COSLOPE<CRLF>"
"T COFFSET<CRLF>"
"T CLKTIME<CRLF>"
Test measurement
RS-232 HELP screen
Summary of all TEST's
Current CO reading
Current CO MEAS mV
Current CO REF mV
Current MR RATIO
Sample pressure
Sample flow rate
Sample temperature
Optical Bench temperature
Filter Wheel temperature
Internal box temperature
DC power supply output
Slope value
Offset value
Current time-of-day
TABLE 7.7
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 67
7.6 Viewing and modifying variables
The most powerful feature of the RS-232 interface is the ability of a host computer to
view and modify the Analyzer's internal variables. Just as the operator modifies the
variables by means of the setup mode, the host computer modifies them by means of the
RS-232 interface.
To view a variable's value, the host computer issues a command of the following format:
"V VARIABLE<CRLF>"
The CPU will respond by sending a message of the following format to the RS-232
output:
"V VARIABLE=VALUE WARNLO WARNHI <DATALO-DATAHI> <CRLF>"
In both cases "VARIABLE" is the name of the variable that is being viewed. "VALUE"
is the current value of the variable. "WARNLO" and "WARNHI" are the low and high
warning limits, respectively, but may not appear for all variables since some variables do
not have warning limits. "DATALO" and "DATAHI" are the low and high data entry
limits, respectively, and are given for all variables. The CPU will not set a variable's
value or warning limits to values which are outside of the data entry limits.
For example, to see the optical bench temperature set point, the host computer would
issue the command:
"V BENCH_SET<CRLF>"
and the CPU would respond with something like:
"V DDD:HH:MM IIII BENCH_SET=48 43 53 <0-100><CRLF>",
indicating that the current set point is 40 degrees, the warning limits are 43 to 53 degrees,
and the data entry limits are 0 to 100 degrees.
To modify a variable's value, almost the same format of command is used:
"V VARIABLE=VALUE WARNLO WARNHI<CRLF>"
The "VARIABLE" field is the name of the variable being modified, and the "VALUE"
field is the new value. "WARNLO" and "WARNHI" are the low and high warning
limits, respectively, and may only be given if the variable uses warning limits. They are
optional for variables which use warning limits and, if not given, the warning limits are
not changed.
After changing the variable's value, the CPU will respond with:
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 68
"V VARIABLE=VALUE WARNLO WARNHI [DATALO-DATAHI] <CRLF>"
which should reflect the new value. The values in square brackets are not required for all
variables. If needed, the values are included on the command line, separated by spaces.
For example, to change the instrument ID, the host computer would issue a command like
this:
"V MACHINE_ID=1234<CRLF>"
and the CPU should respond with:
"V DDD:HH:MM IIII MACHINE_ID = 1234 (0-9999)<CRLF>"
Table 7.9 lists the variable names which are variable through the RS-232 interface and
their corresponding button sequences.
RS-232 VARIABLE NAMES
Var. Name
CO_SPAN
FILT_ADAPT
REPORT_FREQ
MACHINE_ID
BAUD_RATE
CURR_TIME
CURR_DATE
CLOCK_ADJ
FAULT_TIME
Button Sequence
SETUP-IZSC-SPAN
SETUP-MISC-FILT-ADAPT
SETUP-DAS-FREQ
SETUP-COMM-ID
SETUP-COMM-BAUD
SETUP-MISC-CLK-TIME
SETUP-MISC-CLK-DATE
SETUP-MISC-CLK-ADJ
SETUP-MISC-MORE-FLT
Legal Values
0-1000
OFF, ON
1-60
0000-9999
300,1200,2300
00:00-23:59
01/01/00-12/31/99
-60 - +60
0-300
TABLE 7.9
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 69
8.0 CALIBRATION
This section describes a method of performing a multi-point calibration of the Model 300
CO Analyzer and a method of performing a zero-span check.
8.1 REQUIRED EQUIPMENT AND GAS
STANDARDS
Zero air must be free of CO (less than 0.1 ppm of CO).
CAUTION
BE CAREFUL WHEN PULLING IN OUTSIDE AIR
PARTICULARLY IF OUTSIDE HUMIDITY AND
TEMPERATURE ARE HIGH. CONDENSATION
MAY RESULT WHICH CAN LEAD TO
UNSTABLE OPERATION, OR, AT WORST,
WATER CONTAMINATION IN THE CELL.
Calibration gas concentrations must be generated from an NIST-traceable cylinder of
CO-in-air, such as manufactured by Scott-Marrin. Carrier air for transporting the CO
must be the same as the zero air. A suggested calibration gas generating system is shown
in Figure 8.1.
The materials in the calibration gas delivery system should be stainless steel, TFE and
FEP (Teflon). The system must be clean.
The calibration gas delivery system (or manifold) must be properly vented near the
Analyzer inlet to avoid imposing a pressure or vacuum at the inlet. The recommended
venting method is shown in Figure 8.2.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 71
GAS GENERATION SYSTEM
FIGURE 8.1
INLET VENTING RECOMMENDATIONS
FIGURE 8.2
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 72
For minimum back-diffusion through the vent and for minimum back-pressure in the
manifold, the following relationship should be met:
Qv x L
⎯⎯⎯⎯ = 500
Qa x D
Where Qv is the vent flow in cc/min
Qa is the Analyzer flow in cc/min
L is the vent line length in inches
D is the ID of the vent line in inches
For
Qv of 1000 cc/min
Qa of 800 cc/min
D of .188 inches
L = approximately 72”
8.2 MULTI-POINT CALIBRATION
Multi-point calibration requires seven approximately equally-spaced calibration points,
including zero, using an NIST-traceable CO source.
The calibration must be carried out:
a.
Prior to field operation as an EPA-DESIGNATED REFERENCE METHOD
b.
After maintenance
c.
Every three months (recommended)
NOTE
THE TEST GAS MUST BE INTRODUCED INTO THE
ANALYZER THROUGH THE SAMPLE INLET PORT.
ALL FLOW MEASUREMENT DEVICES MUST BE
CALIBRATED AGAINST AN NIST-TRACEABLE
STANDARD SUCH AS A BUBBLE-FLOW-METER WHICH
HAS BEEN CALIBRATED AGAINST AN NISTTRACEABLE VOLUME STANDARD.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 73
There are two acceptable methods of generating accurate CO concentrations for
calibrating the Model 300.
One method uses a single cylinder of CO-in-air and a means of accurately diluting the
cylinder gas with zero air. This is illustrated in Figure 8.1.
Alternatively, several cylinders of CO-in-air, of appropriate concentrations, may be used
without dilution.
The cylinder concentrations must be traceable to NIST standards.
Flow correction for standard temperature and pressure (STP) is not required with either
method. With dilution, the correction is self-canceling. With the multi-cylinder method,
the correction is not applicable.
8.2.1 PROCEDURE
1.
Set the Analyzer to the desired range. (The EPA-approved ranges are any
range between 0-10 ppm and 0-50 ppm.)
2.
Set the calibration system to deliver a flow of at least 1500 cc/min. The
Model 300 draws approximately 800 cc/min. (See Section 8.1 and Figure
8.2 for vent flow calculation.)
3.
Pre-calculate the calibrator flow to be sure that a CO concentration of 80%
of URL (upper range limit) can be produced with enough surplus flow to
provide an adequate vent flow.
4.
Connect the Analyzer REC (recorder) terminals to a calibrated strip-chart
recorder. For best accuracy, connect a DVM to the same terminals or to
the DAS (Data Acquisition System) terminals.
The standard output voltage of 0-5.0 VDC.
If, in service, data is to be collected from a device (printer) connected to
the RS-232 port, then the calibration data must be collected from the RS232 port.
5.
Set the calibrator to deliver zero air to the manifold.
6.
Push “CAL” on the Analyzer front panel.
7.
Enter password. (If Enabled)
8.
Wait 15 minutes for the Analyzer to stabilize.
9.
Push “ZERO” and “ENTR” on the front panel. The Analyzer is now
“zeroed.”
10.
Push “EXIT,” “EXIT.” (Return to sample mode.)
11.
Record the DVM reading and the percentage chart reading or the RS-232
output.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 74
12.
Set the calibrator to produce 75% to 85% of the URL (upper range limit).
This will be 40 ppm ±2.5 ppm on the 50 ppm range.
13.
Allow the Analyzer to sample the CO concentration.
14.
Push “CAL”
15.
Enter password. (If enabled)
16.
Push “CONC”
17.
Change the span value in the display to the calculated CO concentration in
the manifold in ppm units, and push “ENTR”.
18.
Wait 15 minutes for the Analyzer to stabilize.
19.
Push “SPAN” and “ENTER.” The Analyzer is now spanned. Record the
calculated CO concentration, the DVM reading and the percentage chart
reading, or the RS-232 output.
20.
Push “EXIT,” “EXIT.” The Analyzer is now returned to the normal
Sample mode.
21.
Introduce at least five (5) more approximately evenly spaced CO
concentrations into the manifold to complete the manual calibration.
22.
Record all calculated CO concentrations, DVM reading and strip-chart
recorder readings or RS-232 output readings.
23.
Plot the calculated CO concentrations (X-axis) versus output voltages
and/or percentage chart readings (Y-axis).
Calculate the curve equations:
[CO] ppm = (Volts - b) / m
where b is the offset (should be within ± 0.05 volts of zero setting)and m
is the slope (should be .098 to .102 based on 0-5V full scale)
or
[CO] = (% chart - b) / m
(b should be within ± 1% of chart and m should be 1.96 to 2.04)
The correlation coefficient r should be 0.998 or higher.
The Analyzer is now calibrated. All CO concentration data should be obtained by
reading the Analyzer output in volts or percentage of chart and converting to ppm
from the appropriate equation or curve.
If poor correlation exists, check for
1.
Flow calculation errors,
2.
Concentration calculation errors,
3.
Leaks in manifold,
4.
Dirt in the manifold,
5.
Proper manifold venting,
6.
Zero air system.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 75
If none of these help, see the TROUBLESHOOTING SECTION 10.0.
Record all the Analyzer setup data from the display.
Range
DCPS
Box Temp
Wheel Temp
Bench Temp
Sample Temp
Sample Flow
Pressure
MR ratio (Measure/reference ratio)
CO Reference
CO Measure
These data can be useful in future troubleshooting.
8.3 ZERO/SPAN CHECKING
It is recommended that the Model 300 be checked daily for zero and span drift.
The EPA requires that the Analyzer be zero and span checked at least once every two
weeks.
With the Automatic Zero/Span Check and Remote Zero/Span Check features of the
Model 300, daily zero and span checks are easy.
For Automatic Zero/Span Check and Remote Zero/Span Check to be effective, it is
necessary that the Analyzer have the Zero/Span valve option. This option includes the
two three-way stainless steel valves and requires user-supplied sources of zero air and
span gas.
Operating instructions for Automatic Zero/Span Check and Remote Zero/Span Check
are described in Sections 3.4 through 3.7.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 76
9.0 ADJUSTMENTS
NOTE
THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE
PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL
ONLY!
All adjustments to the Model 300 are easy to make. Pots and test points are readily
accessible without removing any components.
Figure 1.6 is a plan view of the Model 300 CO Analyzer showing all the major
components.
Figure 9.1 is an electrical diagram of Model 300 CO Analyzer.
9.1 Power supply board adjustment
The power supply board provides +/-15v +12v and +5v DC power to the Analyzer. Four
temperature linearization circuits, for the Analyzer main lamp, Sample temp, Box temp,
and IZS carbon monoxide generator are also located on the power supply board.
Each circuit is a whetstone bridge with the measuring thermistor being one leg. A
feedback circuit performs the required linearization. Zero adjust pots have been factory
set and no field adjustment should be required.
9.1.1 Box temperature limits
The box temperature is measured by a thermistor located on the motherboard. The box
temp is not controlled in the Model 300. The temperature is measured and displayed as a
TEST function on the front panel (see Section 5.1). The alarm limits can be set via an
RS-232 port command.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 77
M300 ELECTRICAL BLOCK DIAGRAM
FIGURE 9.1
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 78
9.2 A/D - D/A Calibration procedure
Due to the stability of modern electronics, this procedure should not have to be
performed more than once a year or whenever a major sub-assembly is exchanged or
whenever analog output voltage range is changed .
To calibrate the ADC, do the following:
1. Press SETUP-MORE-DIAG.
2. Enter Diagnostic password and press NEXT until D/A CALIBRATION
appears in the display and press ENTR.
3. Press ADC to perform the A/D Cal.
4. The M300 display will read "ADJUST ZERO:A/D=xx.x MV.” Put the probe
of a voltmeter between TP3(AGND) and TP9(DAC #0) on the top of the V/F
card (See Drawing 00514, Appendix C)
5. The value displayed by the voltmeter should be close(+/- 20 mV) to the value
on the M300 display. If they are not close then the V/F card has probably
been configured improperly.
6. Adjust the Zero pot(R27) on the V/F card until the value on the M300 display
matches the value on the voltmeter to within +/- 2 mV. Note that when
adjusting R27, the value on the M300 display will change, the value on the
voltmeter will remain constant.
7. Press ENTR.
8. The M300 display will now read "ADJUST GAIN:A/D=xx.x MV.”
9. Adjust the Span pot(R31) on the V/F card until the value on the M300 display
matches the value on the voltmeter to within +/- 2 mV.
10. Press ENTR.
11. The ADC is now calibrated and the M300 will automatically calibrate all the
DAC’s. This process takes only a few seconds
12. Press EXIT 4 times to return to the sample menu.
9.3 Dark current signal adjust procedure
The detector dark current changes little as the detector ages. Therefore this procedure
should not need to be performed more than once per year or whenever a major
sub-assembly is changed
To calibrate the dark current signal, press
SETUP-MORE-DIAG-DARK-CAL and the analyzer will automatically do the
following:
1.
Disconnect the detector output from the processing electronics
2.
Wait 2 minutes for electronics to stabilize at the dark value
3.
Average CO MEAS and CO REF reading for 1 minute
4.
Reconnect the detector output to the processing electronics to the
processing electronics.
The average CO MEAS and CO REF dark reading are stored as offsets which are
subtracted from all future CO detector readings.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 79
To view the current dark offset, press SETUP-MORE-DARK-VIEW. Press EXIT
when finished. No password is required to view the dark offset, only to change it.
9.4 Output voltage range changes
Output voltage ranges are set by DIP Switch settings on the V/F board. To change the
range for the analog outputs:
1.
Turn off instrument power. Remove the instrument cover. Locate the V/F
board near the top of the drawing using Figure 1.6.
2.
Locate switches S1, S2, and S3 along the top edge of the card. Select the
desired range by setting the switches as shown in Table 9.1, below.
V/F BOARD SWITCH SETTINGS - RANGES FOR ANALOG OUTPUT
Switch
S1 (Recorder Output)
S2 (DAS Output)
S3 (Test Output)
100 mV
Full Scale
1, 6
1, 6
1, 6, 7
1V
Full Scale
1, 5
1, 5
1, 5, 7
5V
Full Scale
1, 4
1, 4
1, 4, 7
10 V
Full Scale
1, 3
1, 3
1, 3, 7
TABLE 9.1
NOTE
TO ADJUST ANALOG RECORDER OFFSET,
SEE SECTION 4.7.
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9.5 Flow readout adjustment
The sensor module in the M300 consists of a flow
sensor and a pressure sensor. See Figure 9.2 for a
diagram of this module. From these three sensors
two values are displayed on the front panel TEST
function area. These are:
•
Sample flow
•
Sample cell pressure
In order to adjust the flow or pressure read
out, select the desired test function on the
front panel and adjust the appropriate pot
for the desired value per Figure 9.2.
FLOW AND PRESSURE READOUT
ADJUSTMENT
FIGURE 9.2
9.6 DC power supply
Overall performance of the DC power supply may be checked by observing the value
displayed during test DCPS. If this value, a composite of the five (5) regulator outputs,
deviates by more than 10% from the value recorded in Table 1.1 of this manual under
Test Values, the outputs of the individual regulators should be measured.
Test points 1, 2, 3 and 4 provide connection to the temperature outputs on drawing no.
00016 in Appendix C.
9.7 CPU
If the display is operating and the green sample light is on, the CPU should be operating.
If not, check for +5v to the CPU.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 81
10.0 TROUBLESHOOTING
NOTE
THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE
PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL
ONLY!
CAUTION
DO NOT DISCONNECT CPU OR OTHER DIGITAL
CARDS WHILE UNDER POWER.
10.1 Overview
The Model 300 has been designed to rapidly detect possible problems and allow their
quick evaluation and repair. During operation, the analyzer continuously performs
self-check diagnostics and provides the ability to monitor the key operating parametersof
the instrument without disturbing monitoring operations. These capabilities will usually
allow the quick isolation and resolution of a problem.
A systematic approach to troubleshooting will generally consist of the following four
steps, performed in order:
1.
2.
3.
4.
Confirm the proper operation of Fundamental Instrument sub-systems
(Power Supplies, CPU, Display).
Note any warning messages and take corrective action as required.
Examine the values of all TEST functions and compare to Factory values.
Note any major deviations from the factory values and take correction
action as required;
Address any Dynamic (Sample related) problems.
The following sections provide a guide for performing each of these steps. Figure 1.6 in
this manual shows the general layout of components and sub-assemblies in the analyzer
and can be referenced in performing the checks described in the following sections.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 83
10.2 Troubleshooting fundamental analyzer
operation
When the Analyzer is turned on, several actions will normally occur which indicate the
proper functioning of basic instrument sub-systems. These actions are:
1.
2.
3.
The sample pump should start.
The green sample light on the front panel should turn on.
The Display should energize and display a log-on message followed by a
standard “Sample" display (See Fig. 2.2 for illustration of a normal
display).
If these actions all occur, it is probable that the Analyzer's Power Supplies, CPU, and
Display are working properly.
If any of these actions fail to occur, power and/or CPU operation should be checked as
follows:
10.2.1 Checking the power sub-systems
WARNING
HAZARDOUS VOLTAGES EXIST WITHIN THE INSTRUMENT
CHASSIS - USE CAUTION!
1.
2.
3.
4.
5.
Check incoming line power for proper Voltage and Frequency.
Check the Circuit breaker on the Analyzer's rear panel.
Check the 3-wire safety power-input plug on the Analyzer's rear panel.
Check for proper internal AC power by confirming that the
Red(right-most) LED on the Power Supply Module is lit. If this LED is
not lit, replace the fuse at the bottom center of the Power Supply Module.
Check for proper DC Voltages by measuring for the following voltages on
the V/F Board:
+5V between TP4 and TP5
+15V between TP1 and TP3
-15V between TP2 and TP3
If any of these voltages are incorrect, check the DC Power Supply as
described in Section 10.6.4.
10.2.2 Checking the CPU and display
When the analyzer is turned on, the front panel display should energize and the green
"Sample" LED should light. If proper DC power is present (see Section 10.2.1), the
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 84
absence of these actions will usually indicate either a CPU or Display failure. To
determine which module is defective, perform the following procedure:
1.
2.
3.
4.
Turn off power.
Remove the ribbon cable from the CPU board to the Display;
Turn Power on.
A cursor character should appear in the upper left corner of the display. If
it does not, the display is defective and should be replaced. If the cursor
does appear, it is probable that the CPU is faulty.
10.2.3 Checking the keyboard
During normal Analyzer operation, depressing the right most key of the keyboard should
cause a change of display modes. If it does not, check:
- Cable connections;
- CPU and Display operation (see Section 10.2.2)
If these checks are satisfactory, it is probable that the keyboard is defective and should be
replaced.
10.3 Troubleshooting using warning messages
The most common and/or serious instrument failures will result in a warning message (or
messages) being displayed on the front panel. Table 10-1 below lists the warning
messages which the Analyzer may display, along with their meaning and the
recommended corrective action. It should be noted that if multiple (more than 2 or 3)
warning messages occur at the same time, it is often an indication that some fundamental
analyzer sub-system (power supply, V/F board, CPU) has failed rather than an indication
of the multiple failures referenced by the warnings. In this situation, it is recommended
that proper operation of power supplies (see Section 10.6.4) and the V/F Board (see
Section 10.6.3) be confirmed before addressing the specific warning messages.
WARNING MESSAGES
Warning Message
SOURCE WARNING
Meaning
The CO REF value is
greater than 5000 mV or
less than 2500 mV
SYNC ERROR
No modulation is present
on the output of the IR
detector.
Corrective Action
Check and adjust the
Sync Demodulator and
optical alignment as
described in Section
10.6.6 and 10.6.8
Check IR source, IR
detector/pre-amp, and
Opto interrupter
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BENCH HEAT
SHUTDOWN
Temperature control of
the Optical bench cannot
be maintained at its
48oC set point
Check Optical Bench
heater and thermistor as
described in Section 9.10
SAMPLE PRESSURE
WARNING
The Sample Pressure is
less than 15"Hg or is
greater than 35"Hg
SAMPLE FLOW
WARNING
The sample flow is less
than 500 cc/min or
greater than 1000
cc/min.
BOX TEMP
WARNING
The inside chassis temp
is less than 10oC or is
Check for pressure
transducer problems as
described in Sect 10.6.5
and Sect 10.6.1
Check for pneumatic
system problems as
described in Section
10.6.1 Check for flow
transducer problems as
described in Sect 10.6.5
See Section 10.6.2
SAMPLE TEMP
WARNING
greater than 50oC
The Sample
Temperature is less than
10oC or is greater than
CANNOT DYN ZERO
CANNOT DYN SPAN
V/F NOT
INSTALLED
SYSTEM RESET
RAM INITIALIZED
50oC
An offset of more than
+5 ppm would be
required to Zero adjust
the analyzer
A slope of less than 0.5
or greater than 2.0 would
be required to Span
adjust the analyzer
The CPU is unable to
communicate with the
V/F Board
A power Off-On cycle
has occurred
Dynamic memory has
been re-initialized in
response to the
installation of a new
PROM or memory chip
See Section 10.6.2
See Section 10.5.5
See Section 10.5.6
Check and re-seat CPU
and V/F board. See
Sect. 10.6.3
None required
None required
TABLE 10.1
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10.4 Troubleshooting using test function values
The Model 300 provides the capability to display, on operator demand, the values of Test
Functions which allow the observation of key analyzer operating parameters. These Test
Functions can be accessed by depressing the TEST Button on the instrument's front
panel, with each depression of the button causing the next test function to be displayed.
By comparing the values of Test Functions to acceptable operating limits, it is possible to
quickly isolate and correct most problems.
NOTE
IF THE VALUE OF ANY TEST FUNCTION IS DISPLAYED
AS “XXXX”, THIS INDICATES THAT THE READING IS
OFF SCALE OR OTHERWISE NON-VALID.
Table 10-2 provides a list of available Test Functions along with their meaning, their
range of acceptable values, and the recommended corrective actions if the value is not in
the acceptable range. Additionally, Table 1-1 in this manual provides a list of the values
of all Test Functions at the time the analyzer left the factory.
TEST FUNCTION VALUES
Test Function
Meaning
Acceptable Values
RANGE
The Current Full
Scale Range Setting
of the analyzer's
analog outputs
The most recent
detector reading
taken in Measure
mode
Any
CO MEAS
2000-4800 CNTS
CO REF
The most recent
detector reading
taken in Reference
mode
2000-4800 mV
MR RATIO
The ratio of the CO
MEAS value to CO
REF value
1.00-1.25
Corrective Action
for Unacceptable
Values
None required
Check and adjust IR
source and Sync
Demodulator and
optical alignment as
described in Sect.
10.6.6 and 10.6.8
Check and adjust IR
source and Sync
Demodulator and
optical alignment as
described in Sect.
10.6.6 and 10.6.8
Check CO REF and
CO MEAS values as
described above.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 87
PRES
The absolute
pressure of the
sample gas in the
absorption cell
0"-1.0" Hg below
ambient pressure
SAMPLE FLOW
Sample mass flow
rate
720-880 scc/min
SAMPLE TEMP
The temperature of
the sample gas in
the absorption cell
The temperature of
the Optical Bench
48o-50o C (After
warm-up)
BENCH TEMP
WHEEL TEMP
The temperature of
the Gas Filter Wheel
BOX TEMP
The temperature
inside the analyzer
chassis
DC Power Supply
reference - A
composite of all
voltages provided
by the DC Power
Supply
DCPS
Check for
pneumatic system
problems. See Sect.
10.6.1. Check for
pressure transducer
problems. See Sect.
10.6.5
Check for
pneumatic system
problems. See
Section 10.6.1.
Check for
flowmeter
problems. See
Section 10.6.5
See Section 10.6.2
48oC (After warmup)
68oC (After warm-
See Section 10.6.2
See Section 10.6.2
up)
o
o
1 -5 C above
See Section 10.6.2
ambient
2250-2750 mV
See Section 10.6.4
TABLE 10.2
10.5 Troubleshooting dynamic problems
Dynamic problems (i.e. problems which only manifest themselves when the analyzer is
monitoring sample gas) can be the most difficult and time consuming to isolate and
resolve. Additionally, analyzer behavior which appears to be a dynamic problem is often
a symptom of a seemingly unrelated static problem. For these reasons, it recommended
that dynamic problems not be addressed until all static problems and warning conditions,
as described in the preceding sections, have been isolated andresolved.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 88
If all the checks described in the preceding sections have been successfully performed,
the following will provide an itemization of the most common dynamic problems with
recommended troubleshooting checks and corrective actions:
10.5.1 Noisy or unstable readings at zero
1.
2.
3.
4.
Check for leaks in the pneumatic system as described in Section 11.2.
Confirm that the Zero gas is free of Carbon Monoxide.
Check for a dirty particulate filter and replace as necessary as described in
Section 11.1.
Check for dirty Sample Cell and/or pneumatic lines. Clean as necessary
as described in Section 11.3.
10.5.2 Noisy, unstable, or non-linear span readings
1.
2.
3.
4.
5.
Check for leaks in the pneumatic systems as described in Section 11.2.
Check for a dirty particulate filter and replace as necessary as described in
Section 11.1.
Check for dirty pneumatic system components and clean or replace as
necessary as described in Section 11.3.
Check for proper adjustment of DAC and ADC electronics by performing
the adjustment procedure in Section 9.2.
Confirm the Sample Temperature, Sample Pressure, and Sample Flow
readings are correct. Check and adjust as required.
10.5.3 Slow response to changes in concentration
1.
2.
3.
Check for dirty pneumatic components and clean or replace as necessary
as described in Section 11.3.
Check for pneumatic leaks as described in Section 11.2.
Check for improper materials in the inlet manifold.
10.5.4 Analog outputs do not agree with front panel readings
1.
2.
Confirm that the DAC offset (SETUP-MISC-D/A-OFFS) is set to zero.
Perform a DAC/ADC adjustment and Dark Signal adjustment by
following the procedure described in Sections 9.2 and 9.3.
10.5.5 Cannot zero or cannot dynamic zero
1.
2.
3.
Check for leaks in the pneumatic system as described in Section 11.2.
Confirm that the Zero gas is free of Carbon Monoxide.
Check for a dirty particulate filter and replace as necessary as described in
Section 11.1.
10.5.6 Cannot span or cannot dynamic span
1.
2.
Check for leaks in the pneumatic systems as described in Section 11.2.
Check for a dirty particulate filter and replace as necessary as described in
Section 11.1.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 89
3.
4.
5.
Check for dirty pneumatic system components and clean or replace as
necessary as described in Section 11.3.
Check for proper adjustment of DAC and ADC electronics by performing
the adjustment procedure in Section 9.2
Confirm the Sample Temperature, Sample Pressure, and Sample Flow
readings are correct. Check and adjust as required.
10.6 Troubleshooting individual sub-assemblies
and components
The following sections provide troubleshooting/check-out methods for the
specific sub-assemblies and components of the Analyzer.
10.6.1 Troubleshooting flow problems
When troubleshooting flow problems, it is a good idea to first confirm that the
actual flow and not the flow-meter is in error. If available, use an independent
flow meter rotameter or mass flow meter) to measure flow(s). Sample flow can
be measured at the sample inlet port at the instrument's rear panel. If no
independent flow meter is available, placing a finger over an inlet port and feeling
for a vacuum will at least give an indication whether flow is present.
If the independent flowmeter shows the flow to be correct, check the Pneumatic
Sensor Board as described in Section 10.6.5.
In general, flow problems can be divided into 3 categories:
- Flow in zero (no flow)
- Flow is greater than zero, but is too low, and/or unstable
- Flow is too high
Figure 1.3 in this Manual provides a schematic diagram of the Flow in a Model
300 and its optional IZS subsystem.
Flow is zero:
WARNING
HAZARDOUS VOLTAGES PRESENT - USE CAUTION!
1.
Confirm that the sample pump (sample flow) and/or IZS pump, (IZS flow)
is operating (turning). If not, check the 115V power to the pump. If the
pump does not operate with 115V present at its terminal, replace the
pump. Check for plugged pneumatic lines, filters, or orifices.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 90
Low Flow:
1.
2.
3.
Check for leaks as described in Section 11.2. Repair and re-check.
Check for dirty sample filter or dirty orifice filter(s).
Check for partially plugged pneumatic lines, orifices, or valves.
High Flow:
1.
The most common cause of high flow is a leak around an orifice. To
correct, remove the orifice as described in Section 11.5, replace O-rings,
and re-assemble.
10.6.2 Troubleshooting temperature problems
The Model 300 has been designed to operate at ambient temperatures between 5oC and
40oC. As a first step in troubleshooting temperature problems, confirm the ambient
temperature is within this range and that the air inlet slots on the sides of the cover and
the fan exhaust on the rear panel are not obstructed.
The instrument monitors four temperatures:
•
•
•
•
Sample Temperature
Inside Chassis Temperature
Optical Bench Temperature
Gas Filter Wheel Temperature
and controls the temperatures of two components by heating:
•
•
Optical Bench
Gas Filter Wheel
If any of the temperature readings appear to be incorrect, check for proper thermistor
operation by measuring the resistance of the thermistor(s). This resistance should be in
the range of 7.6K ohms to 95 ohms. If it is not, the thermistor is defective and should be
replaced. Points for measuring thermistor resistance are as follows:
Sample Temperature:
Unplug the connector at Motherboard J2 and measure across the leads.
Optical Bench Temperature:
Unplug the connector at Motherboard J4 and measure across the leads.
Gas Filter Wheel Temperature:
Unplug the connector at Motherboard J5 and measure across the leads.
Chassis Temperature:
Turn the analyzer off and remove the DC Power Supply Board.
Motherboard J21 pins A30 and C30.
Measure across
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 91
If thermistor resistance(s) are within the proper range, check the temperature linearzation
circuits on the DC Power Supply Board as described in Section 10.6.4.
If temperature sensor readings appear accurate but control temperatures are not being
maintained at their proper value, check the operation of the heaters as follows:
1.
Observe the indicator LED's on the Power Supply Module and confirm
that the red (right-most) LED is lit, and that the "CEL HTR" LED is lit or
cycling (turning off and on). If these indicators are not correct, it is
probably that the Power Supply Module, or the V/F Board is at fault.
Check as described in Sections 10.2 and 10.6.3.
2.
Unplug the heater element from Power Supply Module and confirm that
115 VAC is present. If 115 VAC is present, the heater element has failed
and should be replaced.
WARNING
HAZARDOUS VOLTAGES PRESENT - USE CAUTION!
10.6.3 Checking the V/F card
A schematic and physical diagram of the V/F card are shown on Drawings 514 and 515
in Appendix C. The V/F is a multi-function I/O card which connects to the
micro-processor via a STD Bus interface, and acts as the primary I/O interface between
the micro-processor and the rest of the analyzer. All functions of the board are performed
under control of the micro-processor.
The primary functions of the board can be divided into three areas:
- 16 Channels of Multiplexed Analog input to an Analog to Digital converter
- 4 independent Digital to Analog converters
- 32 Digital I/O Lines configured as 24 outputs and 8 inputs
The following sections describe each of these functional areas.
10.6.3.1 Analog Inputs
16 Analog channels (0-5 VDC) are multiplexed under micro-processor control by IC U26
and transmitted via buffer amp U29 to the V/F converter section of the board for A-D
conversion.
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Analog to Digital (A/D) conversion is accomplished by performing a Voltage to
Frequency (V/F) conversion on the input signal at IC U17 and running the frequency
output to a counter comprised of IC's U20, U21, U22.
The full scale digital output of the counter section is 80,000 counts, giving an A/D
resolution of 1 part in 80,000.
The combination of V/F converter and counter inherently provides an integrating Analog
to Digital conversion. The time base for this integration is controlled by the
micro-processor using the clock oscillator, U36. Jumper B15 allows the selection of
either a 4.0 MHz or 4.8 MHz frequency to minimize electrical pick-up at the operating
line frequency. The time duration of integration is selectable over the range of 67 msec
to 2.067 seconds. In the Model 300 an integrate period of 1.033 records is used for
reading the photo-detector outputs, a 133 msec integrate period is used for all other
signals.
Pots R27 and R31 provide offset and gain adjust respectively to the analog input of the
V/F converter, allowing the A/D section to be adjusted to match an external voltage
standard.
10.6.3.2 Digital to Analog Converters
Four Independent Digital to Analog Converters (DAC's) are contained in IC's U10 and
U11 and are used to generate the instrument's analog outputs. These DAC's have 12 bit
resolution and are fully buffered by OpAmps at U8 and U9. The outputs of the DAC's
are jumper selectable for full scale range at jumpers B6, B7, B8 and B9. The Full Scale
Ranges supported are:
•
•
•
•
0-100 mV
0-1 V
0-5 V
0-10 V
In the M300 the use of these four DAC's is:
DAC
CHANNEL
0
1
2
3
SIGNAL
Strip Chart Analog Output
DAS Analog Output
Spare
Test Function Analog Output
The DAC's are operated in bipolar mode allowing a "live zero" on all output. In addition,
DAC's 0 and 1 (Strip Chart and DAS) physically provide a Full Scale of 120% of the
nominal selected value with the micro-processor providing pre-scaling to achieve the
nominal value.
This combination provides 20% over-range capability.
The
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 93
micro-processor is also used to adjust for offset and gain needed to match DAC outputs
to external voltage standards, and no on board adjustments are needed or provided
for
this function.
The outputs of all DAC's are "looped-back" to Analog input (via the Mother Board)
channels. This loop back allows for automatic micro-processor checking of A/D
10.6.3.3 Digital I/O lines
32 Digital Lines are used to provide the primary means for the micro-processor to control
various analyzer functions(valves, heaters, etc.) and to send and receive status conditions
to/from external equipment. These lines are configured as 8 digital inputs and 24 digital
outputs. The convention for all Digital I/O Lines is High (+5V)-True, Low (0V)-False.
10.6.3.4
Proper operation of the V/F board can be confirmed by performing an ADC calibration
procedure as described in Section 9.2. If this calibration procedure can be performed
correctly, it is highly probable that the V/F card is functioning properly.
If the V/F does not function properly, check the following:
1.
Confirm the presence of appropriate power by checking for:
•
•
•
2.
+5V between TP 4 and TP 5
+15V at TP 1 and TP 3
-15V at TP 2 and TP 3
If any of these voltages are incorrect, check the DC Power Supply as
described in Section 10.6.4.
Confirm that all jumpers and switches on the V/F board are set properly,
as follows:
V/F BOARD JUMPERS - FACTORY SETTINGS
Factory Set Jumpers
Jumper
JP1
JP2
B12
B14
B15
Setting
1-2
1-2
3-4
ON
Set to match input line frequency
TABLE 10.3
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 94
V/F BOARD SWITCH SETTINGS - RANGES FOR ANALOG OUTPUT
Switch
S1 (Recorder Output)
S2 (DAS Output)
S3 (Test Output
S4 (Spare)
User Set Switches
100 mV
1V
Full Scale
Full Scale
1, 6
1, 5
1, 6
1, 5
1, 6, 7
1, 5, 7
1, 6, 7
1, 5, 7
5V
Full Scale
1, 4
1, 4
1, 4, 7
1, 4, 7
10 V
Full Scale
1, 3
1, 3
1, 3, 7
1, 3, 7
TABLE 10.4
3.
If Voltages and Jumper settings are correct, the V/F card is faulty and
should be replaced.
10.6.4 Checking the DC power supply board
A schematic and physical diagram of the DC Power Supply Board are shown on
Drawings 015 and 016 in Appendix C.
The overall performance of the DC Power Supply Board can be checked by observing the
value of the DCPS test functions. If this value, a composite of five regulator value
recorded in Table 1-1 of this manual under Test Values, the outputs of the individual
regulators should be checked by measuring for the following voltages:
1.
Remove Plugs J8, J6, and J13 from the front of the Power Supply Module.
Verify that the following voltages are present:
•
+24VDC between J8 pins 2 and 4
•
+24VDC between J6 pins 12 and 13
•
25VAC between J13 pins 4 and 5
•
15VAC between J13 pins 3 and 2
•
38VAC between J13 pins 6 and 7
If any of these voltages is not present, the Power Supply Module is
defective and should be replaced.
2.
Confirm that the following voltages are present on the V/F Board:
•
+5V between V/F TP 4 and V/F TP 5
•
+15V between V/F TP 1 and V/F TP 3
•
-15V between V/F TP 2 and V/F TP 3
•
+12V between Mother Board Pad J13,6 and J13,7
If any of these voltages is incorrect, it is probable that the DC Power
Supply Board is faulty and should be replaced.
Four Temperature linearization circuits are contained on the DC Power Supply board.The
outputs of these circuits can be checked by measuring the voltages at test points on
the
board as follows:
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 95
TP1 Sample Temp
TP2 Optical Bench
TP3 Filter Wheel Temp
TP4 Chassis Temp
30oC=2.5 V, ±.125 V/oC
50oC=2.5 V, ±.125 V/oC
50oC=2.5 V, ±.125 V/oC
20oC=2.5 V, ±.125 V/oC
If any of these voltages is incorrect, check thermistor operation as described in Section
10.6.2. If thermistors are operating correctly, it is probable the DC Power Supply Board
is defective and should be replaced.
10.6.5 Checking the pneumatic sensor board
A schematic and physical diagram of the Pneumatic Sensor Board are shown on
Drawings 402 and 403 in Appendix C. Proper operation of the pneumatic sensor board
can best be determined by comparing the values of Flow and Pressure Test functions to
measurements obtained with independent flow and pressure meters. Flow and pressure
readings can be adjusted as described in Section 9.5.
If it is not possible to adjust the pneumatic sensor board to agree with independent flow
and pressure measurements, confirm the presence of +15V at connector J1 pin 6. If this
voltage is not present, check the DC Power Supply Board as described in Section 10.6.4.
If +15V is present, it is probable that the Pneumatic Sensor Board is defective and should
be replaced.
10.6.6 Checking the Synchronous Demodulator Board
A schematic and physical diagrams of the Synchronous Demodulator Board are shown in
drawings 798 and 799 in Appendix C.
Proper operation of the Synchronous Demodulator can best be confirmed by performing
the Electric Test Diagnostic as described in Section 5.2.4.
When activated, the Electric Test Diagnostic should produce a constant, stable analyzer
output of approximately 50 ppm. If this stable output is produced it is probably that the
Synchronous Demodulator is functioning properly.
If Electric Test does not produce a stable output, check the following:
1.
Confirm proper operation of the V/F Board as described in Section 10.6.3.
2.
Confirm that during Electric Test the values of the CO MEAS and CO
REF test functions are between 2500mV and 4500mV. If they are not,
adjust the signal levels by turning Pot R7 on the Synchronous
Demodulator Board.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 96
10.6.7 Checking the Opto Interrupter
Correct operation of the Opto Interrupter on the gas filter wheel can be confirmed by
connecting an oscilloscope U6, Pin 11 on the Sync Demodulator board and comparing
the waveform to Figure 10.1. The waveform should be symmetrical and 5 Volts peak to
peak.
FIGURE 10.1 OPTO PICKUP
WAVEFORM
FIGURE 10.2 DETECTOR
WAVEFORM
10.6.8 Checking Optical Alignment
The mirrors used in the optical system of the Model 300 are designed to have their
alignment set permanently during the manufacturing process and no adjustment is
normally needed. If the optical system is disassembled or if failure of any of the optical
components is suspected, the instrument can be checked for proper optical alignment as
follows:
1.
Connect a source of zero air to the analyzer.
2.
Allow the analyzer to warm-up for 60 minutes.
3.
Confirm Optical System Energy through-put by:
4.
a)
Press the TST> or TST< button on the front panel until the CO
MEAS value is displayed.
b)
Increase the gain of the Synchronous Demodulation by turning Pot
R7 on the Sync Demodulator board clockwise. If a CO MEAS
value of 5000 mV can obtained, energy throughput is acceptable.
c)
Re-adjust Pot R7 on the Sync Demodulator Board to obtain a CO
MEAS reading of 4200 mV (±200).
Connect an oscilloscope to U7-Pin 1.
channel.
Sync the oscilloscope on this
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 97
5.
Confirm the wave from of the optical signal by attaching an oscilloscope
to the Sync Demodulator board a U2 Pin 7. The oscilloscope trace should
appear like those shown in Figure 10.2. In particular the wave form
should be symmetrical and should have distinct flat regions at the top and
bottom of the pulses.
6.
If unable to achieve 4200 mV on CO MEAS, then do the following:
7.
Adjust source for maximum signal strength. Typically source has no
effect on wave shape. (Not to exceed 27V peak to peak.)
8.
Adjust input mirror as needed to create a wave shape with distinct
flattening of the peaks and symmetrical “Knees” at the peaks. A smaller
waveform with nice symmetry is preferable to a larger one which is
asymmetrical.
9.
With zero air in, verify an MR RATIO of 1.18 to 1.22 is desired. If the
analyzer shows a significantly different value, slightly adjust the input
mirror.
10.
Adjust R7 for a CO MEAS reading of 4200 ±200 mV.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 98
10.7 Warranty/repair questionnaire
Organization:_____________________________________________________________
Contact: _________________________________________
Phone: ____________
Address _________________________________________________________________
________________________________________________________________________
Model 300 Serial Number: ______________
Are there any warning messages?
YES
NO
If YES, please list:_________________________________________________________
________________________________________________________________________
________________________________________________________________________
Please record the following values:
TEST VALUES
RANGE
_______PPM/PPB
CO MEAS @ ZERO
_______mV
CO REF @ ZERO
_______ mV
MR RATIO @ ZERO
_______
CO MEAS @ SPAN
_______ mV
CO REF @ SPAN
_______ mV
MR RATIO @ SPAN
_______
SAMPLE PRESS
_______IN HG-A
SAMPLE FLOW
_______SCC/MIN
SAMPLE TEMP
_______°C
BENCH TEMP
_______°C
WHEEL TEMP
_______°C
BOX TEMP
_______°C
DC POWER SUPPLY
_______mV
TIME
_______HH:MM:SS
Has the unit been leak checked?
YES
CALIBRATION VALUES
CO SPAN SETTING
CO SLOPE
CO OFFSET
_______PPM/PPB
_______
_______
SETUP VALUES
ELECTRIC TEST
_______PPM
DARK MEAS
DARK REF
_______mV
_______mV
NO
What are failure symptoms? _________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
If possible, please include a portion of a strip chart pertaining to the problem. Circle
pertinent data.
Do Opto Interrupter and Detector wave forms match those shown in Figures 10.1 and
10.2?
YES
NO
Thank you for providing this information. Your assistance enables Teledyne API to
respond faster to the problem that you are encountering.
Teledyne API Customer Service
Phone: (858) 657-9800
Toll Free:(800) 324-5190 FAX: (858) 657-9816
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 99
11.0 ROUTINE MAINTENANCE
NOTE
THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE
PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL
ONLY!
11.1 Model 300 maintenance schedule
The following are the recommended periodic maintenance items for the Teledyne API
Model 300 CO Analyzer:
Date Instrument Was Recieved: ___________________
J
A
N
ITEM
F
E
B
M A
A P
R R
M J
A U
Y N
J
U
L
A
U
G
S
E
P
O
C
T
N
O
V
Particulate
filter element
Pump
diaphragms
Sample flow
D
E
C
RECOMMENDED
ACTION
Repalce weekly or as
needed.
Replace every 6
months.
Check for proper flow
(800cc/min ±10%)
annually.
Examine and clean as
necessary.
Leak Check after
maintenance and at
least annually.
As needed.
Pneumatic
lines
Leak Check
Clean optical
bench
TABLE 11.1
11.2 Replacement of sample filter
a.
Turn off the Analyzer. This will stop the pump and eliminate the
possibility of sucking debris into the Analyzer while changing the filter
element.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 101
b.
c.
d.
e.
f.
g.
h.
i.
Open the front panel and remove the transparent filter cover and knurled
retaining ring.
Remove the teflon hold-down O-ring.
Remove the old filter element and discard.
Install a new filter element in the filter cavity. Be careful with the
element, it is fragile.
Replace the hold-down O-ring on top of the filter element.
Replace the filter top and re-tighten.
Leak check.
Turn on the Analyzer.
11.3 Leak checking
There are two methods of leak checking:
11.3.1 Using a leak checker
Turn the power off. Disconnect the fittings from the pump and bypass the pump.
Connect the leak checker to the sample inlet of the Model 300. Cap the exhaust of the
analyzer. Set the leak checker to pressure mode.
CAUTION
DO NOT EXCEED 15 PSI OF PRESSURE.
Leave the checker on until 15 psi is achieved. Close the valve and ensure the pressure
remains at 15 psi for at least 5 minutes. If pressure drops more than 1 psi, there is a leak
and it must be repaired.
If there is a leak present, pressurize the Model 300 to 15 psi and put soap bubble
solution on pneumatic assemblies until the leak is found.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 102
CAUTION
BE CAREFUL USING THE BUBBLE
SOLUTION. IF THERE IS NO INTERNAL
PRESSURE, THE SOLUTION MAY ENTER
AND CONTAMINATE THE CELL.
DO NOT ATTEMPT TO USE THE BUBBLE SOLUTION
WHILE THE UNIT IS UNDER VACUUM. THIS MAY
CAUSE DAMAGE TO THE ANALYZER.
USE ONLY BUBBLES, NOT LIQUID.
11.3.2 leak self test
If only a Model 300 is available, the following alternate method for leak checking can be
used:
The power must be on and the pump must be in-line. Disconnect the power from the
pump. Check for the sample flow. If the sample flow does not read zero, record the
reading. Re-connect the power to the pump.
Cap the sample inlet. Check if the sample flow goes down to zero. If not, check the
sample flow exceeds the prerecorded value when the pump was disconnected. If the
sample flow is above zero or higher than the prerecorded value, the unit has the leak.
11.4 Changing the prom
1.
2.
3.
4.
5.
6
7.
Locate the CPU card by referring to Figure 1.6.
Remove the screws that hold the CPU card (SBC40 printed on the lever) top
corner to the A/D - I/O card, then remove the card from the STD-BUS backplane.
Remove the two cables attached to the SBC40, taking note of the polarity.
Remove the card, laying it down on an insulating surface such that the card edge
pins on the PCB are on the left. The PROM chip should be at the top center. The
current chip should be labeled with something like "API CO A.6 - - -". Gently
pry the chip from its socket and replace it with the new chip. Install the chip in
the left end of the socket with the notch facing to the right. Make sure that all of
the legs insert into the socket correctly.
Replace the CPU board and re-attach the connectors, making sure to observe the
polarity.
Re-attach the CPU card to the STD-BUS.
Move the power switch to the "ON" position and observe the front panel display.
As the analyzer goes through the setup the version number will be displayed on
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 103
8.
9.
the front panel. It should read the same as the version number that was located on
the top right corner of the label on the PROM.
Re-enter any non-default settings such as RANGE or ASEQ. Re-enter the CONC
value in the CAL menu. Check all settings to make sure that expected setup
parameters are present.
Re-calibrate the analyzer so that the default slope and intercept are overwritten
with the correct values.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 104
12.0 SPARE PARTS LISTS
12.1 SPARE PARTS FOR CE MARK UNITS
Note: Use of replacement parts other than those supplied by Teledyne API may
result in non-compliance with European Standard EN 61010-1.
PART NO. DESCRIPTION
00015
00094-10
00276-18
00329
00329-03
00329-06
00329-09
00369
00369-01
00402-05
00422-01
00514-03
00551-14
00551-18
00611-01
00611-02
00646
00690-01
00728
00798
00864
00953
009560001
00958-01
00960
00960-02
00960-03
00960-04
00969
POWER SUPPLY BOARD
ORIFICE, 13 MIL
CPU BOARD
THERMISTOR ASSY (885-071600)
THERMISTOR ASSY: SAMPLE TEE
THERMISTOR ASSY: SAMPLE TEE
THERMISTOR ASSY: SAMPLE TEE
FILTER, TFE, 37 MM, QTY 100 (872-006400)
FILTER, TFE, 37 MM, QTY 25 (872-006300)
PNEUMATIC SENSOR BOARD
CO PROM W/SOFTWARE
V/F BOARD
POWER SUPPLY MODULE (EU) - 230V/50Hz
POWER SUPPLY MODULE (UK) - 230V/50Hz
ASSY, THERMISTOR
ASSY, HEATER/THERMISTOR
SAMPLE FILTER ASSY
PADS
NEW DISPLAY
SYNC DEMODULATOR BOARD
ASSY, OPTICAL BENCH
PREAMP/DETECTOR ASSEMBLY
GAS FILTER WHEEL
M300 LEVEL 1 SPARES KIT FOR S/N ABOVE 320
M300 37 MM FILTER EXPENDABLES KIT - KNF
#MPU527-N79
M300 47 MM FILTER EXPENDABLES KIT - KNF
#MPU5247-N79
M300 37 MM FILTER EXPENDABLES KIT - KNF
#NO5ATI
M300 47 MM FILTER EXPENDABLES KIT - KNF
#NO5ATI
FILTER, TFE, 47 MM, QTY 100
PUMP MODEL
PUMP MODEL
PUMP MODEL
PUMP MODEL
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 105
00969-01
00982
00987
01037
01070
01077
01079
01080
01581
01595
01916-01
01930
01934-03
CB004
CH024
FA004
FL001
HE017
HE018
HW020
HW036
HW037
OP009
OR001
OR018
OR021
OR030
OR034
OR039
PU010
PU020
PU022
SW006
TU001
TU002
TU009
VA002
VA004
FILTER, TFE, 47 MM, QTY 25
ASSY, SYNCHRONOUS MOTOR
OPTO INTERRUPTER ASSEMBLY
CO/CO2 CONVERTER ASSEMBLY
INSTRUCTION MANUAL FOR M300
FIELD MIRROR
INPUT MIRROR
OUTPUT MIRROR
SOURCE ASSEMBLY (WITH ADAPTOR)
OBJECTIVE MIRROR
REAR PANEL BOARD, CE
KEYBOARD, CE
ASSY, SAMPLE THERMISTOR
FUSE, 3 AG 3 AMP 250V
CATALYST, CO/CO2 CONVERTER (1 OZ)
FAN
SINTERED FILTER (002-024900)
HEATER, CO/CO2 CONVERTER, 12W
HEATER, 50W (IZS)
SPRING, FLOW CONTROL
TFE THREAD TAPE (48 FT)
TIE, CABLE
WINDOW, SAPPHIRE
O-RING, FLOW CONTROL
O-RING, SAMPLE FILTER
O-RING, SCRUBBER
O-RING, 2-141 V
O-RING, INPUT/OUTPUT MIRROR/DETECTOR
O-RING, WINDOW
PUMP DIAPHRAM, KNF MODEL #MPU527N79
PUMP, 115V 50/60 Hz
PUMP REBUILD KIT, KNF MODEL #NO5ATI
OVERHEAT SW, CELL
TUBING: 6’, 1/8” CLR
TUBING: 6’, 1/8” BLK
TUBING: 6’, 1/4” TYGON
SOLENOID, SS, 3-WAY, 24V
SOLENOID, SS, 2-WAY, 24V
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 106
12.2 SPARE PARTS FOR NON-CE MARK UNITS
PART NO. DESCRIPTION
00015
00094-10
00276-13
00329
00329-03
00329-06
00329-09
00369
00369-01
00402-05
00422-01
00514-03
00551-02
00551-06
00551-10
00611-01
00611-02
00646
00690-01
00704
00728
00798
00864
00953
009560001
00958-01
00960
POWER SUPPLY BOARD
ORIFICE, 13 MIL
CPU BOARD
THERMISTOR ASSY (885-071600)
THERMISTOR ASSY: SAMPLE TEE
THERMISTOR ASSY: SAMPLE TEE
THERMISTOR ASSY: SAMPLE TEE
FILTER, TFE, 37 MM, QTY 100 (872-006400)
FILTER, TFE, 37 MM, QTY 25 (872-006300)
PNEUMATIC SENSOR BOARD
CO PROM W/SOFTWARE
V/F BOARD
POWER SUPPLY MODULE - 115V/60Hz
POWER SUPPLY MODULE - 220V/50Hz
POWER SUPPLY MODULE - 240V/50Hz
ASSY, THERMISTOR
ASSY, HEATER/THERMISTOR
SAMPLE FILTER ASSY
PADS
KEYBOARD
NEW DISPLAY
SYNC DEMODULATOR BOARD
ASSY, OPTICAL BENCH
PREAMP/DETECTOR ASSEMBLY
GAS FILTER WHEEL
M300 LEVEL 1 SPARES KIT FOR S/N ABOVE 320
M300 37 MM FILTER EXPENDABLES KIT - KNF PUMP MODEL
#MPU527-N79
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 107
00960-02
00960-03
00960-04
00969
00969-01
00982
00987
01037
01070
01077
01079
01080
01581
01595
01934-03
CB004
CH024
FA004
FL001
HE001
HE002
HW020
HW036
HW037
OP009
OR001
OR018
OR021
OR030
OR034
OR039
PU010
PU020
PU022
SW006
TU001
TU002
TU009
VA002
VA004
M300 47 MM FILTER EXPENDABLES KIT - KNF PUMP MODEL
#MPU5247-N79
M300 37 MM FILTER EXPENDABLES KIT - KNF PUMP MODEL
#NO5ATI
M300 47 MM FILTER EXPENDABLES KIT - KNF PUMP MODEL
#NO5ATI
FILTER, TFE, 47 MM, QTY 100
FILTER, TFE, 47 MM, QTY 25
ASSY, SYNCHRONOUS MOTOR
OPTO INTERRUPTER ASSEMBLY
CO/CO2 CONVERTER ASSEMBLY
INSTRUCTION MANUAL FOR M300
FIELD MIRROR
INPUT MIRROR
OUTPUT MIRROR
SOURCE ASSEMBLY (WITH ADAPTOR)
OBJECTIVE MIRROR
ASSY, SAMPLE THERMISTOR
FUSE, 3 AG 3 AMP 250V
CATALYST, CO/CO2 CONVERTER (1 OZ)
FAN
SINTERED FILTER (002-024900)
HEATER, CO/CO2 CONVERTER, 12W
HEATER, 50W (IZS)
SPRING, FLOW CONTROL
TFE THREAD TAPE (48 FT)
TIE, CABLE
WINDOW, SAPPHIRE
O-RING, FLOW CONTROL
O-RING, SAMPLE FILTER
O-RING, SCRUBBER
O-RING, 2-141 V
O-RING, INPUT/OUTPUT MIRROR/DETECTOR
O-RING, WINDOW
PUMP DIAPHRAM, KNF MODEL #MPU527N79
PUMP, 115V 50/60 Hz
PUMP REBUILD KIT, KNF MODEL #NO5ATI
OVERHEAT SW, CELL
TUBING: 6’, 1/8” CLR
TUBING: 6’, 1/8” BLK
TUBING: 6’, 1/4” TYGON
SOLENOID, SS, 3-WAY, 24V
SOLENOID, SS, 2-WAY, 24V
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 108
APPENDIX A - LIST OF AVAILABLE MODEL 300
OPTIONS
RS-232 & Status Outputs
Internal Zero/Span (IZS) with valves
Rack Mount and Slides
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 109
APPENDIX B: TIPS ON CONNECTING THE
TELEDYNE API ANALYZER RS-232 INTERFACE
Teledyne API analyzers use the RS-232 communications protocol to allow the instrument
to be connected to a variety of computer based equipment. RS-232 has been used for
many years and as equipment has become more advanced, connections between various
types of hardware have become increasingly difficult. Generally, every manufacturer
observes the signal and timing requirements of the protocol very carefully. Problems
arise when trying to specify connectors, and wiring diagrams that attach the analyzer to
various devices.
The problem centers around two areas. First is the physical incompatibility of
connectors. Second is the wiring of the connectors. This Note will attempt to provide
some guidelines for connecting the Teledyne API analyzers to a variety of other
equipment
Connectors:
There is a wide variety of connectors
and cables that are specified to
operate with the RS-232 protocol.
This is because electronics have
decreased in size over the years and
connectors have been downsized to
match the electronics.
Pin
1
2
3
4
5
6
7
8
9
Signal
Not Used
Transmit Data
Receive Data
Not Used
Signal Ground
Not Used
Data Set Ready (DSR)
Request to Send (RTS)
Not Used
Cables & Adapters come
in 4 general types
1. Cables - cables are provided in
various lengths from 6 to 50 feet. In
most cases they have a male
connector at one end and a female at
the other. Variations on this are
ones that provide both a cable and
adapter. For example the cable
provided with our analyzer adapts a
RS-232 PIN ASSIGNMENTS
female DB-9 to a male DB-25
FIGURE B.1
connector.
Most cables do not
contain a Null modem.
2. Gender changers - convert a male connector to a female connector or vice versa. They
do so WITHOUT changing the pin-to-pin wiring.
3. Adapters - these change from one type plug (DB-9) to another type plug (DB-25).
They do so WITHOUT changing the wiring.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 111
4. Null modems - here the connector changes the internal wiring so that DTE devices can
become DCE or vice versa. The main internal change is swapping pin 2 and 3 so that data
is transmitted and received on opposite pins.
NOTE
Null modems can also combine gender changer or adapter
features in the design. When making up an adapter cable be
careful to note what you are using especially with combination
null modem-adapter connectors.
Wiring:
The RS-232 is a point-to-point protocol and as such it specifies a two different wiring
schemes depending on if you are originating the transmission or receiving the
transmission. In the original spec, modems communicated with terminals and were wired
as "Data Communications Equipment" or DCE. Terminals or printers received data from
modems and thus were wired as "Data Terminal Equipment" or DTE. As technology has
progressed it has become more ambiguous who was DCE and DTE. Teledyne API
analyzers are wired as DTE (i.e. like a printer). As can be seen, this presents difficulties
if you a hook
a printer to the instrument that is likewise wired as a printer. To help understand the
different problems - 3 examples as shown below:
Example 1: Connecting the Teledyne API analyzer to an IBM-PC AT compatible
computer.
In this case the PC is wired as DCE and the analyzer is wired as DTE therefore a null
modem is not needed. The wiring is "straight through" i.e. pin 1 to pin 1, pin 2 to pin 2,
etc. Therefore all you have to do here is adapt the connector on the analyzer (male DB-9)
to whatever is on the PC. Make sure none of the adapters have null modems in them.
Example 2: Connecting the Teledyne API analyzer to a serial printer.
In this case both the analyzer and the printer are wired as DTE so a "Null Modem" will
have to be inserted in the line to change the wiring to make the analyzer look like a
modem (i.e. DCE). Make sure in using your adapters that ONLY ONE null modem
connector is used. Null modems can be purchased in DB-9 and DB-25 connectors at
each
end.
Example 3: Connecting the Teledyne API analyzer to a modem.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 112
The modem is configured as Data Communications Equipment (DCE), and may have
additional signal requirements to enable transmission. See modem troubleshooting
section below.
NOTE
Modems are especially difficult because they may have pins
that need to be at certain EIA RS-232 levels before the modem
will transmit data. The most common requirement is the
Ready to Send (RTS) signal must be at logic high (+5V to
+15V) before the modem will transmit.
The Teledyne API analyzer sets pin 8 (RTS) to 10 volts to
enable modem transmission..
Troubleshooting the modem connection:
First: Disconnect the RS-232 cable from the Analyzer and verify (use a DVM) that you
are getting a signal on Pin 2 of the RS232 port on the Analyzer. The signal will be
between -5V and -15V with respect to signal ground (pin 5). If not, there is a problem
with the CPU board or the cable. This is the transmit (TD) signal out of the Analyzer.
This should then be connected to TD input on the modem, normally Pin 2. If the
Analyzer is equipped with a DTE/DCE switch, you may need to change its setting so the
signal is on Pin 2.
Second: Go to the cable connected to the modem/terminal and verify (use a DVM) that
you are getting a -5V to -15V signal on Pin 3 of the cable. This pin should be connected
to Pin 3 of the Teledyne API Analyzer.
Third: (for modems) Check that the voltage level on Pin 8 of the Analyzer is between
+5V and +15V. This pin should be connected (through the cable) to Pin 4 of the modem.
Now set the baud rate of the Analyzer to the speed required by the modem and it should
work. If you are still experiencing problems, a cable adapter may be needed. Please
contact the factory for assistance.
Data Communications Software for a PC.
You will need to purchase a software package so your computer can transmit and receive
on its serial port. There are many such programs, internally we use PROCOMM. Once
you set up the variables in PROCOMM and your wiring connections are correct, you will
be able to communicate with the analyzers. Make sure the analyzer is set up for 2400
baud (SETUP-MORE-COMM-BAUD) and that PROCOMM is set up as described in
the "RS-232 Pin Assignments" Figure B.1.
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 113
APPENDIX C - ELECTRICAL DRAWING INDEX
Drawing Number
00015
00016
00402
00403
00514
00515
00532
00533
00551
00704
00705
00798
00799
00866
00867
00874
00875
01916
01917
01930
01931
02035
Title
Assembly, DC Power Supply PCA
Schematic, DC Power Supply PCA
Assembly, Pneumatic Sensor PCA
Schematic, Pneumatic Sensor PCA
Assembly, A/D - I/O Card PCA
Schematic, A/D - I/O Card PCA
Assembly, Power Supply Module PCA
Schematic, Power Supply Module PCA
Wiring Diagram, Power Supply Module
Assembly, Keyboard PCA
Schematic, Keyboard PCA
Assembly, Sync Demodulator
Schematic, Sync Demodulator
Assembly, Mother Board
Schematic, Mother Board
Assembly, Pre-Amp/Bias
Schematic, Pre-Amp/Bias
Assembly, Rear Panel PCA (CE Mark Units Only)
Schematic, Rear Panel PCA (CE Mark Units Only)
Assembly, Keyboard PCA (CE Mark Units Only)
Schematic, Keyboard PCA (CE Mark Units Only)
Assembly, XFMR PTC (CE Mark Units Only)
02036
Schematic, XFMR PTC (CE Mark Units Only)
P/N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual - Page 115