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User Manual Models T200H and T200M Nitrogen Oxides Analyzers with NumaView™ software © TELEDYNE API (TAPI) 9970 CARROLL CANYON ROAD SAN DIEGO, CALIFORNIA 92131-1106 USA Toll-free Phone: Phone: Fax: Email: Website: Copyright 2019 Teledyne API + 800-324-5190 +1 858-657-9800 +1 858-657-9816 [email protected] http://www.teledyne-api.com/ 083730210A DCN8164 14 August 2019 NOTICE OF COPYRIGHT © 2019 Teledyne API (TAPI). All rights reserved. TRADEMARKS All trademarks, registered trademarks, brand names or product names appearing in this document are the property of their respective owners and are used herein for identification purposes only. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software i SAFETY MESSAGES Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage. Please read these messages carefully. Each safety message is associated with a safety alert symbol and is placed throughout this manual; the safety symbols are also located inside the instrument. It is imperative that you pay close attention to these messages, the descriptions of which are as follows: WARNING: Electrical Shock Hazard HAZARD: Strong oxidizer GENERAL WARNING/CAUTION: Read the accompanying message for specific information. CAUTION: Hot Surface Warning Do Not Touch: Touching some parts of the instrument without protection or proper tools could result in damage to the part(s) and/or the instrument. Technician Symbol: All operations marked with this symbol are to be performed by qualified maintenance personnel only. Electrical Ground: This symbol inside the instrument marks the central safety grounding point for the instrument. CAUTION This instrument should only be used for the purpose and in the manner described in this manual. If you use this instrument in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences. NEVER use any gas analyzer to sample combustible gas(es)! For Technical Assistance regarding the use and maintenance of this instrument or any other Teledyne API product, contact Teledyne API’s Technical Support Department: Telephone: +1 800-324-5190 Email: [email protected] or access any of the service options on our website at http://www.teledyne-api.com/ ii Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CONSIGNES DE SÉCURITÉ Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes suivantes : AVERTISSEMENT : Risque de choc électrique DANGER : Oxydant puissant AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne complémentaire pour des renseignements spécifiques MISE EN GARDE : Surface chaude Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou sans les outils appropriés pourrait entraîner des dommages aux pièces ou à l’instrument. Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent être effectuées uniquement par du personnel de maintenance qualifié. Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central de la mise à la terre sécuritaire de l’instrument. MISE EN GARDE Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce manuel. Si vous utilisez cet instrument d’une autre manière que celle pour laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible et entraîner des conséquences dangereuses. NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz combustibles! 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software iii WARRANTY WARRANTY POLICY (02024J) Teledyne API (TAPI), a business unit of Teledyne Instruments, Inc., provides that: Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should equipment failure occur, TAPI assures its customers that prompt service and support will be available. (For the instrument-specific warranty period, please refer to the “Limited Warranty” section in the Terms and Conditions of Sale on our website at the following link: http://www.teledyne-api.com/terms_and_conditions.asp). COVERAGE After the warranty period and throughout the equipment lifetime, TAPI 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 are to be performed by the customer. NON-TAPI MANUFACTURED EQUIPMENT Equipment provided but not manufactured by TAPI is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturer’s warranty. PRODUCT RETURN 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. The complete Terms and Conditions of Sale http://www.teledyne-api.com/terms_and_conditions.asp can be reviewed at CAUTION – Avoid Warranty Invalidation Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration may void your warranty. For anti-ESD handling and packing instructions please refer to the manual, Fundamentals of ESD, PN 04786, in its “Packing Components for Return to Teledyne API’s Customer Service” section. The manual can be downloaded from our website at http://www.teledyne-api.com. RMA procedures can also be found on our website. iv Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ABOUT THIS MANUAL This manual is comprised of multiple documents, in PDF format, as listed below. Part No. Name/Description 083730210 T200M and T200H Nitrogen Oxides Analyzers Manual with NumaView™ software (this manual) n/a MODBUS Registers, Appendix A 069110000 Interconnect Diagram, Appendix B Support manuals, such as electrostatic discharge (ESD) prevention, are available on the TAPI website http://www.teledyne-api.com. We recommend that all users read this manual in its entirety before operating the instrument. Note CONVENTIONS USED In addition to the safety symbols as presented in the Safety Messages page, this manual provides special notices related to the careful and effective use of the instrument and related, pertinent information. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY This special notice provides information to avoid damage to your instrument and possibly invalidate the warranty. Important IMPACT ON READINGS OR DATA Provides information about that which could either affect accuracy of instrument readings or cause loss of data. Note Provides information pertinent to the proper care, operation or maintenance of the instrument or its parts. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software v TABLE OF CONTENTS Safety Messages ...................................................................................................................................... ii Warranty .................................................................................................................................................. iv Table of Contents .................................................................................................................................... vi List of Figures .......................................................................................................................................... xi List of Tables .......................................................................................................................................... xiii 1. INTRODUCTION, SPECIFICATIONS, APPROVALS, & COMPLIANCE ............................................... 14 Specifications .................................................................................................................................. 14 Safety .............................................................................................................................................. 16 EMC ................................................................................................................................................ 16 Other Certifications ......................................................................................................................... 16 2. GETTING STARTED .............................................................................................................................. 17 Unpacking ....................................................................................................................................... 17 Ventilation Clearance ........................................................................................................... 18 Instrument Layout ........................................................................................................................... 19 Front Panel ........................................................................................................................... 19 Rear Panel ........................................................................................................................... 20 Internal Chassis ................................................................................................................... 22 Connections and Startup................................................................................................................. 23 Electrical Connections ......................................................................................................... 23 Connecting Power ................................................................................................. 23 Connecting Analog Outputs ................................................................................... 24 Current Loop Analog Outputs (Option 41) Setup .................................................. 25 Connecting the Status Outputs (Digital Outputs) .................................................. 26 Connecting the Control Inputs (Digital Inputs) ....................................................... 27 Concentration Alarm Relay (Option 61) ................................................................ 28 Connecting Communications Interfaces ................................................................ 28 Pneumatic Connections ....................................................................................................... 34 Critical Tubing, Pressure, Venting and Exhaust Requirements ............................ 34 Basic Connections from Calibrator ........................................................................ 35 Connections w/Ambient Zero/Ambient Span Valves (OPT 50A) .......................... 37 Connections for Calibration with O2 Sensor Option .............................................. 39 Pneumatic Flow Diagrams ................................................................................................... 40 Startup, Functional Checks and Calibration ........................................................................ 45 Startup ................................................................................................................... 46 Alerts: Warnings and Other Messages .................................................................. 47 Functional Checks ................................................................................................. 48 Calibration.............................................................................................................. 48 Menu Overview ............................................................................................................................... 49 Home Page .......................................................................................................................... 50 Dashboard ............................................................................................................................ 52 Alerts .................................................................................................................................... 53 Calibration ............................................................................................................................ 54 Utilities .................................................................................................................................. 55 Setup .................................................................................................................................... 55 Setup Menu: Features/Functions Configuration ............................................................................ 55 Setup>Data Logging (Data Acquisition System, DAS) ........................................................ 56 Configuring Trigger Types: Periodic ...................................................................... 58 Configuring Trigger Types: Conditional ................................................................ 59 Downloading DAS (Data Acquisition System) Data .............................................. 59 Setup>Events ....................................................................................................................... 60 Editing or Deleting Events ..................................................................................... 62 vi Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Using Events as Triggers for Data Logging ........................................................... 63 Setup>Dashboard ................................................................................................................ 63 Setup>AutoCal (with Valve Option) ..................................................................................... 64 Setup>Vars .......................................................................................................................... 64 Setup>Homescreen ............................................................................................................. 65 Setup>Digital Outputs .......................................................................................................... 66 Setup>Analog Outputs ......................................................................................................... 67 Manual Calibration of Voltage Range Analog Outputs .......................................... 69 Manual Adjustment of Current Range Analog Outputs ......................................... 70 Setup>Instrument................................................................................................................. 71 Setup>Comm (Communications) ....................................................................................... 72 COM1/COM2 ....................................................................................................... 72 TCP Port1 ............................................................................................................ 73 TCP Port2 ............................................................................................................ 73 TCP Port3 ............................................................................................................ 73 Network Settings ................................................................................................. 73 Transferring Configuration to Other Instruments ............................................................................ 75 3. COMMUNICATIONS AND REMOTE OPERATION ............................................................................... 76 Data Terminal/Communication Equipment (DTE DCE) .................................................................. 76 Modes, Baud Rate and Serial Communication ............................................................................... 76 Serial Communication: RS-232............................................................................................ 77 Serial Communication: RS-485 (Option) ............................................................................. 77 Ethernet ........................................................................................................................................... 77 Communications Protocols ............................................................................................................. 78 MODBUS ............................................................................................................................. 78 MODBUS Com Port Configuration ........................................................................ 78 Hessen ................................................................................................................................. 80 Hessen Com Port Configuration ............................................................................ 80 Hessen Settings Configuration .............................................................................. 81 Hessen Gas List Configuration .............................................................................. 83 4. CALIBRATION ........................................................................................................................................ 84 Important Precalibration Information ............................................................................................. 84 Calibration Requirements .................................................................................................... 84 Zero Air ................................................................................................................................ 85 Calibration (Span) Gas ........................................................................................................ 85 Span Gas for Multipoint Calibration ..................................................................................... 85 Physical Range Measurements ........................................................................................... 86 Interferents ........................................................................................................................... 86 Data Recording Devices ...................................................................................................... 87 NO2 Conversion Efficiency (CE) .......................................................................................... 87 Calibration Procedures .................................................................................................................... 87 Calibration and Check Procedures for Basic Configuration ................................................ 88 Zero Calibration Check and Actual Calibration ..................................................... 89 Span Calibration Check and Actual Calibration .................................................... 89 Calibration and Check Procedures with Valve Options Installed ......................................... 90 Use of Zero/Span Valve with Remote Contact Closure ........................................ 91 Calibration and Check Procedures with O2 Sensor Option Installed .................................. 91 O2 Zero Calibration ................................................................................................ 92 O2 Span Calibration ............................................................................................... 92 Automatic Zero/Span Cal/Check (Auto Cal) ................................................................................... 92 Calibration Quality Analysis ............................................................................................................ 95 Conversion Efficiency (CE) Check .................................................................................................. 96 Simplified GPT Data Sheet.................................................................................... 97 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software vii 5. MAINTENANCE AND SERVICE ............................................................................................................ 98 Maintenance Schedule .................................................................................................................... 98 Predictive Diagnostics ................................................................................................................... 100 Operational Health Checks ........................................................................................................... 101 Software/Firmware Updates .......................................................................................................... 102 Remote Updates ................................................................................................................ 102 Manual Reload/Update Procedures ................................................................................... 102 Instrument Display Calibration (for earlier instruments)..................................................... 103 Time Zone Changes ...................................................................................................................... 104 Hardware Maintenance Procedures ............................................................................................. 105 Replacing the Sample Particulate Filter ............................................................................. 105 Changing the O3 Dryer Particulate Filter............................................................................ 106 Maintaining the External Sample Pump (Pump Pack) ....................................................... 107 Rebuilding the Pump ........................................................................................... 107 Replacing the Inline Exhaust Scrubber ............................................................... 107 Changing the External Zero Air Scrubber Option (T200H) ................................................ 108 Changing or Cleaning the NO2 Converter.......................................................................... 110 Cleaning the Reaction Cell ................................................................................................ 112 Servicing Critical Flow Orifices .......................................................................................... 114 Checking for Light Leaks ................................................................................................... 116 Checking for Pneumatic Leaks .......................................................................................... 117 Simple Vacuum Leak and Pump Check .............................................................. 117 Detailed Pressure Leak Check ............................................................................ 117 Performing Flow Checks/Calibrations ................................................................. 118 Service and Troubleshooting ........................................................................................................ 120 Fault Diagnosis with Alerts ................................................................................................. 121 Fault Diagnosis With Dashboard Functions ....................................................................... 124 Using the Diagnostic Signal I/O Functions ........................................................................ 125 Using the Analog Output Channels.................................................................................... 126 Using the Internal Electronic Status LEDs ......................................................................... 127 CPU Status Indicator ........................................................................................... 127 Relay PCA Watchdog and Status LEDs .............................................................. 127 Flow Problems ................................................................................................................... 128 Sample Flow is Zero or Low ................................................................................ 129 Ozone Flow is Zero or Low.................................................................................. 130 High Flow ............................................................................................................. 131 Sample Flow is Zero or Low but Analyzer Reports Correct Flow........................ 131 Calibration Problems .......................................................................................................... 132 Negative Concentrations ..................................................................................... 132 Absence of Analyzer Response to Sample Gas ................................................. 133 Unstable Zero and Span...................................................................................... 134 Inability to Span - Deactivated SPAN Button ...................................................... 134 Inability to Zero - Deactivated ZERO Button ....................................................... 135 Non-Linear Response.......................................................................................... 135 Discrepancy Between Analog Output and Display .............................................. 136 Discrepancy Between NO and NOX Slopes ....................................................... 136 Other Performance Problems ............................................................................................ 136 Excessive Noise .................................................................................................. 136 Slow Response .................................................................................................... 137 Auto Zero Warnings ............................................................................................. 137 Subsystem Check for Troubleshooting .............................................................................. 138 AC Main Power .................................................................................................... 139 DC Power Supply ................................................................................................ 139 I2C Bus ................................................................................................................. 140 LCD/Display Module and Touchscreen ............................................................... 141 viii Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Relay PCA ........................................................................................................... 141 Motherboard ........................................................................................................ 141 Pressure / Flow Sensor Assembly ...................................................................... 143 CPU ..................................................................................................................... 144 RS-232 Communications ..................................................................................... 144 NO2 à NO Converter ........................................................................................ 145 Photomultiplier Tube (PMT) Sensor Module ..................................................... 147 PMT Preamplifier Board .................................................................................... 147 High Voltage Power Supply (HVPS) ................................................................. 148 PMT Temperature Control PCA ........................................................................ 149 O3 Generator ..................................................................................................... 149 Valve Options .................................................................................................... 150 Temperature Sensor.......................................................................................... 150 Service Procedures .......................................................................................................... 151 Disk-On-Module Replacement Procedure......................................................... 152 O3 Generator Replacement ............................................................................... 153 Sample and Ozone Dryer Replacement............................................................ 153 PMT Sensor Hardware Calibration .................................................................... 154 Replacing the PMT, HVPS or TEC .................................................................... 156 Removing / Replacing the Relay PCA from the Instrument .............................. 159 Frequently Asked Questions ......................................................................................................... 160 Technical Assistance .................................................................................................................... 161 6. PRINCIPLES OF OPERATION ............................................................................................................ 162 Measurement Principle ................................................................................................................. 162 Chemiluminescence Creation in the Reaction Cell ............................................................ 162 Chemiluminescence Detection in the Reaction Cell .......................................................... 163 The Photo Multiplier Tube (PMT) ........................................................................ 164 Optical Filter......................................................................................................... 164 NOX and NO2 Determination .............................................................................................. 165 Auto Zero ........................................................................................................................... 166 Measurement Interferences ............................................................................................... 168 Direct Interference ............................................................................................... 168 Third Body Quenching ......................................................................................... 169 Light Leaks .......................................................................................................... 169 Reaction Cell Temperature Control ..................................................................... 170 Pneumatic Operation .................................................................................................................... 171 Sample Gas Flow ............................................................................................................... 171 Vacuum Manifold ................................................................................................. 172 Sample Gas Flow Valves and Routing ................................................................ 173 Flow Rate Control - Critical Flow Orifices .......................................................................... 173 Critical Flow Orifice .............................................................................................. 174 Locations and Descriptions of Critical Flow Orifices ........................................... 175 Ozone Gas Generation and Air Flow ................................................................................. 177 The O3 Generator ................................................................................................ 178 Ozone Generator Dry Air Supply (Permeation Dryer) ......................................... 178 Ozone Supply Air Filter ........................................................................................ 180 Ozone Destruct .................................................................................................... 180 Pneumatic Sensors ............................................................................................................ 181 Vacuum Manifold ................................................................................................. 181 Sample Pressure Sensor ..................................................................................... 182 Vacuum Pressure Sensor .................................................................................... 182 O3 Supply Air Flow Sensor .................................................................................. 182 O3 Supply Air Flow Sensor .................................................................................. 183 O2 Sensor Option Measurement Principle .................................................................................... 183 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software ix Electronic Operation ...................................................................................................................... 185 Overview ............................................................................................................................ 185 CPU .................................................................................................................................... 187 Motherboard ....................................................................................................................... 188 A to D Conversion ............................................................................................... 188 Sensor Inputs....................................................................................................... 188 Thermistor Interface ............................................................................................ 189 Analog Outputs .................................................................................................... 189 External Digital I/O ............................................................................................... 189 Internal Digital I/O ................................................................................................ 189 I2C Data Bus ........................................................................................................ 190 Power-Up Circuit ................................................................................................. 190 Relay PCA .......................................................................................................................... 190 Status LED’s ........................................................................................................ 192 Watchdog Circuitry .............................................................................................. 192 Valve Control ....................................................................................................... 192 Heater Control ..................................................................................................... 193 Thermocouple Inputs and Configuration Jumper (JP5) ...................................... 193 Sensor Module .............................................................................................................................. 195 Photo Multiplier Tube (PMT) ......................................................................................................... 195 PMT Preamplifier ............................................................................................................... 196 PMT Cooling System ......................................................................................................... 198 TEC Control Board .............................................................................................. 199 Pneumatic Sensor Board .............................................................................................................. 200 Power Supply/Circuit Breaker ....................................................................................................... 200 AC Power Configuration .................................................................................................... 202 AC Configuration – Standard Heaters (JP2) ....................................................... 203 AC Configuration – Heaters for Option Packages (JP6) ..................................... 204 Front Panel Touchscreen/Display Interface .................................................................................. 205 LVDS Transmitter Board .................................................................................................... 206 Front Panel Touchscreen/Display Interface PCA .............................................................. 206 Software Operation ..................................................................................................................... 206 Adaptive Filter .................................................................................................................. 207 Temperature/Pressure Compensation (TPC) .................................................................. 207 Calibration - Slope and Offset .......................................................................................... 208 Glossary ............................................................................................................................................... 209 x Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 LIST OF FIGURES Figure 2-1. Front Panel Layout ................................................................................................................... 19 Figure 2-2. Rear Panel Layout, Base Unit (options include additional pneumatic ports) ........................... 20 Figure 2-3. T200H/M Internal Chassis Layout ............................................................................................ 22 Figure 2-4. Analog Output Connector ......................................................................................................... 24 Figure 2-5. Current Loop Option Installed on the Motherboard .................................................................. 25 Figure 2-6. Status Output Connector for Digital Outputs ............................................................................ 26 Figure 2-7. Energizing the Control Inputs ................................................................................................... 27 Figure 2-8. Concentration Alarm Relay....................................................................................................... 28 Figure 2-9. Rear Panel Connector Pin-Outs for RS-232 Mode .................................................................. 29 Figure 2-10. Default Pin Assignments for CPU COM Port Connector (RS-232) ........................................ 30 Figure 2-11. Jumper and Cables for Multidrop Mode ................................................................................. 32 Figure 2-12. RS-232 Multidrop PCA Option Host/Analyzer Interconnect Diagram .................................... 33 Figure 2-13. Gas Line Connections from Calibrator – Basic Configuration ................................................ 35 Figure 2-14. Gas Line Connections from Bottled Span Gas – Basic Configuration ................................... 36 Figure 2-15. Rear Panel Layout with Z/S Valve Options (OPT 50A) .......................................................... 37 Figure 2-16. Gas Line Connections with Z/S Valves Option (OPT 50A) .................................................... 38 Figure 2-17. Gas Line Connections for Calibration when O2 Sensor Option Installed ............................... 39 Figure 2-18. T200H Pneumatics, Basic Configuration ................................................................................ 40 Figure 2-19. T200M Pneumatics, Basic Configuration ............................................................................... 41 Figure 2-20. T200H Pneumatics with Zero/Span Valves Option ................................................................ 42 Figure 2-21. T200M Pneumatics with Zero/Span Valves Option ................................................................ 43 Figure 2-22. T200H Pneumatics with O2 Sensor Option ............................................................................ 44 Figure 2-23. T200M Pneumatics with O2 Sensor Option ............................................................................ 45 Figure 2-24. Status Screens at Startup ....................................................................................................... 46 Figure 2-25. Home Page Example .............................................................................................................. 46 Figure 2-26. Viewing Active Alerts Page ..................................................................................................... 47 Figure 2-27. Sample Dashboard Page ....................................................................................................... 48 Figure 2-28. User Interface Orientation ...................................................................................................... 50 Figure 2-29. Concentration and Stability Graph (top) and Meter Graph (bottom) ...................................... 51 Figure 2-30. Dashboard Page ..................................................................................................................... 52 Figure 2-31. Navigating to the Active Alerts Page ...................................................................................... 53 Figure 2-32. Active Alerts Cleared .............................................................................................................. 54 Figure 2-33. Utilities>Alerts Log of Active and Past Alerts and Events ...................................................... 54 Figure 2-34. Datalog Configuration, New Log Page ................................................................................... 56 Figure 2-35. Datalog Configuration, Existing Log ....................................................................................... 56 Figure 2-36. Creating a New Data Log ....................................................................................................... 57 Figure 2-37. Datalog Periodic Trigger Configuration .................................................................................. 58 Figure 2-38. Datalog - Conditional Trigger Configuration ........................................................................... 59 Figure 2-39. DAS Download Page .............................................................................................................. 59 Figure 2-40. Events List .............................................................................................................................. 60 Figure 2-41. Event Configuration ................................................................................................................ 61 Figure 2-42. Configured Event Sample....................................................................................................... 62 Figure 2-43. Edit or Delete an Event ........................................................................................................... 62 Figure 2-44. Dashboard Display and Configuration .................................................................................... 63 Figure 2-45. Homescreen Configuration ..................................................................................................... 65 Figure 2-46. Digital Outputs Setup .............................................................................................................. 66 Figure 2-47. Analog Output Configuration Example ................................................................................... 67 Figure 2-48. Analog Outputs Group Calibration Screen ............................................................................. 68 Figure 2-49. Analog Outputs Manual Calibration Screen (AOUT2 Example) ............................................. 68 Figure 2-50. Setup for Checking / Calibrating DCV Analog Output Signal Levels ..................................... 69 Figure 2-51. Setup for Checking / Calibration Current Output Signal Levels ............................................. 70 Figure 2-52. Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ............. 71 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software xi Figure 2-53. Communications Configuration, Network Settings ................................................................. 73 Figure 2-54. Configuration Transfer ............................................................................................................ 75 Figure 3-1. MODBUS via Ethernet .............................................................................................................. 78 Figure 3-2. MODBUS via Serial Communication (example) ....................................................................... 79 Figure 3-3. Serial Communication, Setting Hessen Protocol...................................................................... 80 Figure 3-4. Hessen Gas List Configuration ................................................................................................. 83 Figure 4-1. Multi-Point Calibration Page ..................................................................................................... 88 Figure 4-2. Zero and Span Calibration Screens ......................................................................................... 90 Figure 4-3. O2 Sensor Calibration Screens ................................................................................................. 91 Figure 4-4. Auto Cal Page........................................................................................................................... 93 Figure 5-1: Report Generation Page ......................................................................................................... 101 Figure 5-2. Remote Update Page ............................................................................................................. 102 Figure 5-3. Manual Update Page (and other utilities) ............................................................................... 102 Figure 5-4. Touchscreen Calibration Page ............................................................................................... 103 Figure 5-5. Time Zone Change Requirements ......................................................................................... 104 Figure 5-6. Replacing the Particulate Filter............................................................................................... 105 Figure 5-7. Particle Filter on O3 Supply Air Dryer ..................................................................................... 106 Figure 5-8. Zero Air Scrubber Assembly................................................................................................... 109 Figure 5-9. NO2 Converter Assembly........................................................................................................ 111 Figure 5-10. Reaction Cell Assembly........................................................................................................ 113 Figure 5-11. Critical Flow Orifice Assembly .............................................................................................. 114 Figure 5-12. Flow Calibration Menu .......................................................................................................... 119 Figure 5-13. CPU Status Indicator ............................................................................................................ 127 Figure 5-14. Relay PCA Status LEDS Used for Troubleshooting ............................................................. 128 Figure 5-15. Location of DC Power Test Points on Relay PCA ................................................................ 140 Figure 5-16. Typical Set Up of Status Output Test ................................................................................... 142 Figure 5-17. Pressure / Flow Sensor Assembly........................................................................................ 143 Figure 5-18. Pre-Amplifier Board Layout .................................................................................................. 155 Figure 5-19. Sensor Assembly .................................................................................................................. 157 Figure 5-20. Relay PCA with AC Relay Retainer In Place........................................................................ 159 Figure 5-21. Relay PCA Mounting Screw Locations ................................................................................. 159 Figure 6-2. Reaction Cell with PMT Tube and Optical Filter ..................................................................... 164 Figure 6-3. Sensitivity Spectrum ............................................................................................................... 165 Figure 6-4. NO2à NO Conversion ............................................................................................................ 165 Figure 6-5. Reaction Cell during the Auto Zero Cycle .............................................................................. 167 Figure 6-6. Vacuum Manifold, Standard Configuration ............................................................................. 172 Figure 6-7. Flow Control Assembly & Critical Flow Orifice ....................................................................... 174 Figure 6-8. Location of Flow Control Assemblies for T200H .................................................................... 175 Figure 6-9. Location of Flow Control Assemblies for T200M .................................................................... 176 Figure 6-10. Ozone Generator Principle ................................................................................................... 178 Figure 6-11. Semi-Permeable Membrane Drying Process ....................................................................... 179 Figure 6-12. Sample Dryer ........................................................................................................................ 179 Figure 6-13. Vacuum Manifold .................................................................................................................. 181 Figure 6-14. Dilution Manifold ................................................................................................................... 183 Figure 6-15. Oxygen Sensor - Principle of Operation ............................................................................... 184 Figure 6-16. Electronic Block Diagram ..................................................................................................... 185 Figure 6-17. CPU Board............................................................................................................................ 187 Figure 6-18. Relay PCA Layout (P/N 045230100) .................................................................................... 191 Figure 6-19. Relay PCA P/N 045230100 with AC Relay Retainer in Place .............................................. 192 Figure 6-20. Heater Control Loop Block Diagram. .................................................................................... 193 Figure 6-21. Thermocouple Configuration Jumper (JP5) Pin-Outs .......................................................... 194 Figure 6-22. Basic PMT Design ................................................................................................................ 196 Figure 6-23. PMT Preamp Block Diagram ................................................................................................ 197 Figure 6-24. Typical Thermo-Electric Cooler ............................................................................................ 198 Figure 6-25. PMT Cooling System Block Diagram ................................................................................... 199 xii Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 6-26. Power Distribution Block Diagram ........................................................................................ 201 Figure 6-27. Location of AC power Configuration Jumpers ...................................................................... 202 Figure 6-28. Typical Set Up of AC Heater Jumper Set (JP2) ................................................................... 203 Figure 6-29. Typical Jumper Set (JP2) Set Up of Heaters ...................................................................... 204 Figure 6-30. Front Panel and Display Interface Block Diagram................................................................ 205 Figure 6-31. Basic Software Operation ..................................................................................................... 206 LIST OF TABLES Table 1-1. Specifications ............................................................................................................................. 14 Table 2-1. Ventilation Clearance ................................................................................................................. 18 Table 2-2. Rear Panel Description .............................................................................................................. 21 Table 2-3. Analog Output Pin Assignments ................................................................................................ 24 Table 2-4. Status Output Pin Assignments ................................................................................................. 27 Table 2-5. Control Input Pin Assignments .................................................................................................. 28 Table 2-6. Zero/Span Valves Option’s Operating States ............................................................................ 43 Table 2-7. Menu Overview .......................................................................................................................... 49 Table 2-8. Utilities Submenu Descriptions .................................................................................................. 55 Table 2-9. List of Variables with Descriptions ............................................................................................. 64 Table 2-10. Analog Output Voltage/Current Range .................................................................................... 68 Table 2-11. Voltage Tolerances .................................................................................................................. 69 Table 2-12. Current Loop Output Check ..................................................................................................... 71 Table 2-13. Setup>Instrument Menu .......................................................................................................... 71 Table 2-14. COM1/COM2 Configuration..................................................................................................... 72 Table 2-15. LAN/Ethernet Configuration Properties ................................................................................... 74 Table 3-1. Ethernet Status Indicators ......................................................................................................... 77 Table 3-2. Teledyne API's Hessen Protocol Response Modes .................................................................. 81 Table 3-3. Hessen Status Flags and Default Bit Assignments ................................................................... 82 Table 3-4. Hessen Gas List Definitions ....................................................................................................... 83 Table 4-1. AUTO CAL States ...................................................................................................................... 93 Table 4-2. Auto Cal Setup Combinations .................................................................................................... 94 Table 4-3. Auto Cal Programming Sequence Execution ............................................................................ 94 Table 4-4. Calibration Data Quality Evaluation ........................................................................................... 95 Table 5-1. Maintenance Schedule .............................................................................................................. 99 Table 5-2. Predictive Uses for Dashboard Functions ............................................................................... 100 Table 5-3. Warning Alerts, Fault Conditions and Possible Causes .......................................................... 121 Table 5-4. Dashboard Functions - Indicated Failures ............................................................................... 125 Table 5-5. Analog Outputs as Diagnostic Tools....................................................................................... 126 Table 5-6. Relay PCA Watchdog and Status LED Failure Indications ..................................................... 128 Table 5-7. DC Power Test Point and Wiring Color Codes ........................................................................ 139 Table 5-8. DC Power Supply Acceptable Levels ...................................................................................... 140 Table 5-9. Relay PCA Control Devices ..................................................................................................... 141 Table 5-10. Control Input Pin Assignments and Corresponding Signal I/O Functions ............................. 142 Table 6-1. List of Interferents .................................................................................................................... 168 Table 6-2. Valve Cycle Phases ................................................................................................................ 173 Table 6-3. T200H/M Critical Flow Orifice Diameters and Gas Flow Rates ............................................... 176 Table 6-4. Thermocouple Configuration Jumper (JP5) Pin-Outs.............................................................. 194 Table 6-5. Typical Thermocouple Settings ............................................................................................... 195 Table 6-6. Power Configuration for Standard AC Heaters (JP2) .............................................................. 203 Table 6-7. Power Configuration for Optional Heaters (JP6) ..................................................................... 204 Appendix A – MODBUS Registers Appendix B – Interconnect Wiring Diagram 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software xiii 1. INTRODUCTION, SPECIFICATIONS, APPROVALS, & COMPLIANCE Teledyne API’s Models T200H and T200M (also referred to in this manual as T200H/M when applicable to both models) use the proven chemiluminescence measurement principle, coupled with state-of-the-art microprocessor technology for monitoring high and medium levels of nitrogen oxides. User-selectable analog output ranges and a linear response over the entire measurement range make them ideal for a wide variety of applications, including extractive and dilution CEM, stack testing, and process control. Along with providing high accuracy and dependability, the T200H/M tracks operational parameters and issues warnings if they fall outside diagnostic limits, as well as stores easily retrievable data. Proprietary software allows configurable data acquisition capability that can be triggered conditionally or periodically, enabling operators to perform predictive diagnostics and enhanced data analysis by tracking parameter trends. Reports can be downloaded onto a USB flash drive or via the I/O ports. Operators can also view real-time graphing with one touch of the interface screen. SPECIFICATIONS Table 1-1. Specifications PARAMETER SPECIFICATION T200M: Min: 0-1 ppm Full scale Max: 0-200 ppm Full scale (selectable, independent NO, NO2, NOX ranges supported) Min/Max Range (Physical Analog Output) T200H: Min: 0-5 ppm Full scale Max: 0-5000 ppm Full scale (selectable, independent NO, NO2, NOX ranges supported) Measurement Units ppm, mg/m3 (user selectable) Zero Noise < 20 ppb (RMS) Span Noise < 0.2% of reading (RMS) above 20 ppm Lower Detectable Limit < 40 ppb (2x noise as per USEPA) Zero Drift (24 hours) < 20 ppb (at constant temperature and voltage.) Span Drift (24 hours) < 0.5% of reading (at constant temperature and voltage.) Response Time < 80 seconds to 95% Rise/Fall Time 95% in <60 s (in switching mode) Linearity 1% of full scale Precision 0.5% of reading above 5ppm 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 14 PARAMETER SPECIFICATION Gas Flow Rates T200H: AC Power T200M: Recorder Offset T200H: T200M: • 40 cm³/min sample gas 250 cm³/min sample gas through through NO2 converter & NO2 converter & sensor module sensor module ± 10% 3 • 250 cm /min ± 10% through bypass manifold • 290 cm³/min total flow ± 10% O2 Sensor option adds 80 cm³/min to total flow through T200H/M when installed. Rating Typical Power Consumption 110V-120V, 60 Hz 3.0A 175W 220V-240V, 50/60 Hz 3.0A 155W 110V-120V, 60 Hz 3.0A 55W 220V-240V, 50/60 Hz 3.0A 75W ± 10% Environmental Installation category (over-voltage category) II; Pollution degree 2 Intended for Indoor Use Only at Altitudes ≤ 2000m Analog Outputs 4 user configurable outputs Analog Output Ranges All Outputs: 0.1 V, 1 V, 5 V or 10 V Three outputs convertible to 4-20 mA isolated current loop. All Ranges with 5% under/over-range Analog Output Resolution 1 part in 4096 of selected full-scale voltage (12 bit) Status Outputs 8 Status outputs from opto-isolators, 7 defined, 1 spare Control Inputs 6 Control inputs, 4 defined, 2 spare Alarm outputs 2 relay alarms outputs (Optional equipment) with user settable alarm limits - 1 Form C: SPDT; 3 Amp @ 125 VAC Temperature Range 5 - 40 °C operating range Humidity Range 0-95% RH non-condensing Dimensions H x W x D 18 cm x 43 cm x 61 cm (7" x 17" x 23.6") Weight, Analyzer 40 lbs (18 kg) without options Weight, Ext Pump Pack 7 kg (16 lbs) Standard I/O 1 Ethernet: 10/100Base-T 2 RS-232 (300 – 115,200 baud) 2 USB device ports 8 opto-isolated digital outputs 6 opto-isolated digital inputs 4 analog outputs Optional I/O 1 USB com port 1 RS485 4 digital alarm outputs Multidrop RS232 3 4-20mA current outputs 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 15 SAFETY IEC/EN 61010-1:2010 (3rd Edition), Safety requirements for electrical equipment for measurement, control, and laboratory use. CE: 2006/95/EC, Low-Voltage Directive EMC IEC/EN 61326-1, Class A Emissions/Industrial Immunity FCC 47 CFR Part 15B, Class A Emissions CE: 2004/108/EC, Electromagnetic Compatibility Directive OTHER CERTIFICATIONS Please contact Teledyne API’s Technical Support Department for information about any other certifications: Toll-free Phone: +1 800-324-5190 Phone: +1 858-657-9800 Fax: +1 858-657-9816 Email: 16 [email protected] Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 2. GETTING STARTED This section addresses unpacking, connecting, and initializing the instrument, getting an overview of the menu system, and setting up/configuring the functions. UNPACKING CAUTION - GENERAL SAFETY HAZARD To avoid personal injury, always use two persons to lift and carry the analyzer. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Printed Circuit Assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use Electro-Static Discharge (ESD) protection when working with electronic assemblies will void the instrument warranty. Refer to the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.com. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Do not operate this instrument without first removing dust plugs from SAMPLE and EXHAUST ports on the rear panel. Note Teledyne API recommends that you store shipping containers and materials for future use if/when the instrument should be returned to the factory for repair and/or calibration service. See Warranty statement in this manual and Return Merchandise Authorization (RMA) on our Website at http://www.teledyneapi.com. Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne API. Included with your instrument is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet, is an important quality assurance and calibration record and should be placed in the quality records file for this instrument. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 17 With no power to the unit, carefully remove the top cover of the instrument and check for internal shipping damage by carrying out the following steps: 1. Carefully remove the top cover and check for internal shipping damage. a. Remove the screws located on the instrument’s sides. b. Slide the cover backward until it clears the instrument’s front bezel. c. Lift the cover straight up. 2. Inspect the interior of the instrument to ensure all circuit boards and other components are intact and securely seated. 3. Check the connectors of the various internal wiring harnesses and pneumatic hoses to ensure they are firmly and securely seated. 4. Verify that all of the optional hardware ordered with the unit has been installed. These are listed on the paperwork accompanying the instrument. WARNING – ELECTRICAL SHOCK HAZARD Never disconnect PCAs, wiring harnesses or electronic subassemblies while under power. VENTILATION CLEARANCE Whether the instrument is set up on a bench or installed in a rack, be sure to leave sufficient ventilation clearance. Table 2-1. Ventilation Clearance AREA 18 MINIMUM REQUIRED CLEARANCE Back of the instrument 10 cm / 4 in Sides of the instrument 2.5 cm / 1 in Above and below the instrument 2.5 cm / 1 in Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 INSTRUMENT LAYOUT Instrument layout includes front panel, rear panel connectors, and the internal chassis layout. FRONT PANEL The front panel (Figure 2-1) includes two USB ports for peripheral device connections, which can be used with mouse and keyboard as alternatives to the touchscreen interface, or with flash drive for uploads/downloads (devices not included). Figure 2-1. Front Panel Layout 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 19 REAR PANEL Figure 2-2 shows the layout of the rear panel. Figure 2-2. Rear Panel Layout, Base Unit (options include additional pneumatic ports) 20 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Table 2-2. Rear Panel Description COMPONENT FUNCTION cooling fan AC power connector Model/specs label Pulls ambient air into chassis through side vents and exhausts through rear. Connector for three-prong cord to apply AC power to the analyzer. CAUTION! The cord’s power specifications (specs) MUST comply with the power specs on the analyzer’s rear panel instrument and power label Identifies the analyzer model number and provides power specs TO CONV (not used) FROM CONV (not used) MULTI (not used) TO DRYER (not used) FROM DRYER SAMPLE EXHAUST SPAN 1 SPAN2/VENT ZERO AIR Outlet for internal sample gas dryer; connect to external zero air scrubber (for IZS options only). Connect a gas line from the source of sample gas here. Calibration gases are also inlet here on units without zero/span/shutoff valve options installed. Connect an exhaust gas line of not more than 10 meters long here that leads outside the shelter or immediate area surrounding the instrument. The line must be ¼” tubing or greater. On units with zero/span valves option installed, connect a gas line to the source of calibrated span gas here. On units with pressurized span valve option, used for venting. Internal Zero Air: On units with zero/span valves option installed but no internal zero air scrubber attach a gas line to the source of zero air here. RX TX LEDs indicate receive (RX) and transmit (TX) activity when blinking. COM 2 Serial communications port for RS-232 or RS-485. RS-232 Serial communications port for RS-232 only. DCE DTE STATUS ANALOG OUT CONTROL IN ALARM ETHERNET USB Label 083730210A DCN8164 Switch to select either data terminal equipment or data communication equipment during RS-232 communication. For outputs to devices such as Programmable Logic Controllers (PLCs). For voltage or current loop outputs to a strip chart recorder and/or a data logger. For remotely activating the zero and span calibration modes. Option for concentration alarms and system warnings. Connector for network or Internet remote communication, using Ethernet cable Connector for direct connection to laptop computer, using USB cable. Includes instrument information with voltage and frequency specifications Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 21 INTERNAL CHASSIS Figure 2-3 shows the internal chassis configuration. Figure 2-3. T200H/M Internal Chassis Layout 22 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CONNECTIONS AND STARTUP This section presents the electrical (Section 2.3.1) and pneumatic (Section 2.3.2) connections for setting up and preparing the instrument for operation (Section 2.3.3). ELECTRICAL CONNECTIONS Note To maintain compliance with EMC standards, cable length must be go greater than 3 meters for all I/O connections. WARNING – Electrical Shock Hazard High Voltages are present inside the instrument’s case. Power connection must have functioning ground connection. Do not defeat the ground wire on power plug. Turn off instrument power before disconnecting or connecting electrical subassemblies. • Do not operate with cover off. • • • • CAUTION – Avoid Damage to the Instrument Ensure that the AC power voltage matches the voltage indicated on the instrument’s model/specs label before plugging it into line power. CONNECTING POWER Attach the power cord between the instrument’s AC power connector and a power outlet capable of carrying at least the rated current at your AC voltage range and ensure that it is equipped with a functioning earth ground. It is important to adhere to all safety and cautionary messages. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 23 CONNECTING ANALOG OUTPUTS The rear panel Analog Output channels A1 through A4 can be mapped to reflect various operating values in the analyzer, including concentration values, temperatures, pressures, etc. These mappings are not configured by default and must be set by the user. An optional Current Loop output (Section 2.3.1.3) is available for A1, A2 and A3 only. To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output connections on the rear panel of the analyzer. Configure through the Setup>Analog Outputs menu (Section 2.5.8) ANALOG OUT + A1 - + A2 - + A3 - A4 + - Figure 2-4. Analog Output Connector Table 2-3. Analog Output Pin Assignments PIN 1 2 3 4 3 4 7 8 24 ANALOG OUTPUT A1 A2 A3 A4 SIGNAL OUT User-selected through the Setup>Analog Outputs menu. STANDARD VOLTAGE OUTPUT CURRENT LOOP OPTION V+ I Out + Ground I Out - V+ I Out + Ground I Out - V+ I Out + Ground I Out - V+ Not Available Ground Not Available Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP If your analyzer had this option installed at the factory, there are no further connections to be made. Otherwise, it can be installed as a retrofit for each of the analog outputs. This option converts the DC voltage analog output to a current signal with 0-20 mA output current, which can be scaled to any set of limits within that 0-20 mA range. However, most current loop applications call for either 2-20 mA or 4-20 mA range. All current loop outputs have a +5% over-range. Ranges with the lower limit set to more than 1 mA (e.g., 2-20 or 4-20 mA) also have a -5% under-range. Figure 2-5 provides installation instructions and illustrates a sample configuration of one current output combined with two voltage outputs. Next are instructions for converting current loop analog outputs to standard 0-to-5 VDC outputs. To calibrate or adjust these outputs use the Setup>Analog Outputs menu (Section 2.5.8). CAUTION – Avoid Invalidating Warranty Servicing or handling of circuit components requires electrostatic discharge protection, i.e. ESD grounding straps, mats and containers. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. For information on preventing ESD damage, refer to the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.com. Figure 2-5. Current Loop Option Installed on the Motherboard 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 25 CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation: 1. Turn off power to the analyzer. 2. If a recording device is connected to the output being modified, disconnect it. 3. Remove the top cover. • Remove the screws fastening the top cover to the unit (one per side). • Slide the cover back and lift the cover straight up. 4. Remove the screw holding the current loop option to the motherboard. 5. Disconnect the current loop option PCA from the appropriate connector on the motherboard (see Figure 2-5). 6. Each connector, J19 and J23, requires two shunts. Place one shunt on the two left most pins and the second shunt on the two adjacent pins (see Figure 2-5). 7. Return the top cover to the analyzer and secure. The analyzer can now have a voltage-sensing recording device attached to that output. CONNECTING THE STATUS OUTPUTS (DIGITAL OUTPUTS) The 12-pin STATUS connector allows the digital status outputs to report analyzer conditions (configured through the Setup>Digital Outputs menu) via optically isolated NPN transistors that sink up to 50 mA of DC current. These outputs can be used to interface with devices that accept logic-level digital inputs, such as Programmable Logic Controllers (PLCs). Each status bit is an open collector output that can withstand up to 40 VDC. All of the emitters of these transistors are tied together and available at pin D (see Figure 2-6). ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Most PLC’s have internal provisions for limiting the current that the input will draw from an external device. When connecting to a unit that does not have this feature, an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA. At 50 mA, the transistor will drop approximately 1.2V from its collector to emitter. STATUS 1 2 3 4 5 6 7 8 D + Map the digital outputs 1 thru 8 through the Setup>Digital Outputs menu. +5V to external device Figure 2-6. Status Output Connector for Digital Outputs 26 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Table 2-4. Status Output Pin Assignments PIN STATUS DEFINITION CONDITION 1-8 Configurable through the Setup>Digital Outputs menu Collector side of individual status output opto-isolators. D Emitter BUS The emitters of the transistors on pins 1 to 8 are bussed together. Blank NO CONNECTION + DC Power + 5 VDC, 300 mA source maximum The ground level from the analyzer’s internal DC power supplies. This connection should be used as the ground return when +5VDC power is used. Digital Ground CONNECTING THE CONTROL INPUTS (DIGITAL INPUTS) With zero and span valves option installed, two digital control inputs in the rear panel CONTROL IN connector, can be used to remotely activate the zero and span calibration modes (see Section 4.2.2.1). Energize the Control Inputs either by the internal +5V available from the pin labeled “+” (more convenient), or by a separate external 5 VDC power supply (ensures that these inputs are truly isolated). Refer to Figure 2-7. CONTROL IN CONTROL IN D E F U + A B C D Local Power Connections E F U + SPAN C ZERO B SPAN ZERO A 5 VDC Power Supply + External Power Connections Figure 2-7. Energizing the Control Inputs 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 27 Table 2-5. Control Input Pin Assignments A STATUS DEFINITION Remote Zero Cal The analyzer is placed in Zero Calibration mode. B Remote Span Cal The analyzer is placed in Lo Span Calibration mode. C, D, E &F Spare INPUT # Digital Ground U + External Power input 5 VDC output ON CONDITION The ground level from the analyzer’s internal DC Power Supplies (same as chassis ground). Input pin for +5 VDC is required to activate pins A – F. Internally generated 5V DC power. To activate inputs A – F, place a jumper between this pin and the “U” pin. The maximum amperage through this port is 300 mA (combined with the analog output supply, if used). CONCENTRATION ALARM RELAY (OPTION 61) The concentration relay option provides four (4) “dry contact” relays on the rear panel (Figure 2-8), each with 3 pins: Common (C), Normally Open (NO), and Normally Closed (NC). The Relays can be mapped to reflect various internal instrument conditions and states. Configure these outputs through the Setup>Digital Outputs menu (Section 2.5.7) under MB Relay [1 thru 4]. Figure 2-8. Concentration Alarm Relay CONNECTING COMMUNICATIONS INTERFACES ETHERNET CONNECTION For network or Internet communication with the analyzer, connect an Ethernet cable from the analyzer’s rear panel Ethernet interface connector to an Ethernet port. Although the analyzer is shipped with DHCP enabled by default, it should be manually configured with a static IP address. Configuration: Section 2.5.10.5 28 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 USB (OPTION) CONNECTION The rear panel USB option is for direct communication between the analyzer and a PC. Connect a USB cable between the analyzer and a computer USB port. Computer and instrument baud rates must match. Note If this option is installed, the rear panel RS232 (COM2) port cannot be used for anything other than RS-232 Multidrop communication. RS-232 CONNECTION For RS-232 communications with data terminal equipment (DTE) or with data communication equipment (DCE) connect either a DB9-female-to-DB9-female cable (Teledyne API part number WR000077) or a DB9-female-to-DB25-male cable (Option 60A), as applicable, from the analyzer’s RS-232 port (see Figure 2-9 for connector pin assignments) to the device. Adjust the rear panel DCE-DTE switch to select DTE or DCE as appropriate (Section 3.1). Configuration: Section 3.2.1 and Section 3.4.2 (for Hessen protocol) Important IMPACT ON READINGS OR DATA Cables that appear to be compatible because of matching connectors may incorporate internal wiring that makes the link inoperable. Check cables acquired from sources other than Teledyne API for pin assignments (Figure 2-9) before using. Figure 2-9. Rear Panel Connector Pin-Outs for RS-232 Mode The signals from these two connectors are routed from the motherboard via a wiring harness to two 10-pin connectors on the CPU card, J11 and J12 (Figure 2-10). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 29 Figure 2-10. Default Pin Assignments for CPU COM Port Connector (RS-232) Teledyne API offers two mating cables, one of which should be applicable for your use. • P/N WR000077, a DB-9 female to DB-9 female cable, 6 feet long. Allows connection of the serial ports of most personal computers. • P/N WR000024, a DB-9 female to DB-25 male cable. Allows connection to the most common styles of modems (e.g. Hayes-compatible) and code activated switches. Both cables are configured with straight-through wiring and should require no additional adapters. To assist in properly connecting the serial ports to either a computer or a modem, there are activity indicators just above the RS-232 port. Once a cable is connected between the analyzer and a computer or modem, both the red and green LEDs should be on. • If the lights are not lit, locate the small switch on the rear panel to switch it between DTE and DCE modes. • If both LEDs are still not illuminated, ensure that the cable properly constructed. Received from the factory, the analyzer is set up to emulate an RS-232 DCE device. (View these parameters in the Setup>Comm>COM1[COM2] menu). RS-232 (COM1): RS-232 (fixed) DB-9 male connector 30 • Baud rate: 115200 bits per second (baud) • Data Bits: 8 data bits with 1 stop bit • Parity: None Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 COM2: RS-232 (configurable to RS 485), DB-9 female connector • Baud rate:19200 bits per second (baud) • Data Bits: 8 data bits with 1 stop bit • Parity: None RS-232 MULTIDROP (OPTION 62) CONNECTION When the RS-232 Multidrop option is installed, connection adjustments and configuration through the menu system are required. This section provides instructions for the internal connection adjustments, then for external connections, and ends with instructions for menu-driven configuration. Note Because the RS-232 Multidrop option uses both the RS232 and COM2 DB9 connectors on the analyzer’s rear panel to connect the chain of instruments, COM2 port is no longer available for separate RS-232 or RS-485 operation. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Printed Circuit Assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. For information on preventing ESD damage, refer to the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.com under Help Center > Product Manuals in the Special Manuals section. In each instrument with the Multidrop option there is a shunt jumpering two pins on the serial Multidrop and LVDS printed circuit assembly (PCA), as shown in Figure 2-11. This shunt must be removed from all instruments except that designated as last in the multidrop chain, which must remain terminated. This requires powering off and opening each instrument and making the following adjustments: 1. With NO power to the instrument, remove its top cover and lay the rear panel open for access to the Multidrop/LVDS PCA, which is seated on the CPU. 2. On the Multidrop/LVDS PCA’s JP2 connector, remove the shunt that jumpers Pins 21 ↔ 22 as indicated in Figure 2-11. (Do this for all but the last instrument in the chain where the shunt should remain at Pins 21 ↔ 22). 3. Check that the following cable connections are made in all instruments (again refer to Figure 2-11): • J3 on the Multidrop/LVDS PCA to the CPU’s COM1 connector (Be aware that the CPU’s COM2 connector is not used in Multidrop) • J4 on the Multidrop/LVDS PCA to J12 on the motherboard • J1 on the Multidrop/LVDS PCS to the front panel LCD 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 31 Figure 2-11. Jumper and Cables for Multidrop Mode Note If you are adding an instrument to the end of a previously configured chain, remove the shunt between Pins 21 and 22 of JP2 on the Multidrop/LVDS PCA in the instrument that was previously the last instrument in the chain. 4. Close the instrument. 5. Referring to Figure 2-12 use straight-through DB9 male à DB9 female cables to interconnect the host RS232 port to the first analyzer’s RS232 port; then from the first analyzer’s COM2 port to the second analyzer’s RS232 port; from the second analyzer’s COM2 port to the third analyzer’s RS232 port, etc., connecting in this fashion up to eight analyzers, subject to the distance limitations of the RS-232 standard. 6. On the rear panel of each analyzer, adjust the DCE DTE switch so that the green and the red LEDs (RX and TX) of the COM1 connector (labeled RS232) are both lit. (Ensure you are using the correct RS-232 cables internally wired specifically for RS-232 communication; see Figure 2-10). 32 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Female DB9 Host Male DB9 RS-232 port Analyzer Analyzer Analyzer Last Analyzer COM2 COM2 COM2 COM2 RS-232 RS-232 RS-232 RS-232 Ensure jumper is installed between JP2 pins 21 ↔ 22 in last instrument of multidrop chain. Figure 2-12. RS-232 Multidrop PCA Option Host/Analyzer Interconnect Diagram 7. BEFORE communicating from the host, power on the instruments and check that the user-selectable Instrument ID is unique for each: in the Setup>Vars menu, check Instrument ID in the list of variables. To change, select the variable and press the Edit button; once changed, press the Enter button. 8. Next, in the Setup>Comm>COM1 menu (do not use the COM2 menu for multidrop), use the Edit button to set COM1 Quiet Mode and COM1 Multidrop to ENABLED; then press the Accept button. 9. Also check the COM1 Baud Rate to ensure it reads the same for all instruments (edit if needed and press the Accept button). Note The (communication) Host instrument can address only one instrument at a time, each by its unique ID (see step 7 above). Note Teledyne API recommends setting up the first link, between the Host and the first analyzer, and testing it before setting up the rest of the chain. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 33 PNEUMATIC CONNECTIONS This section provides pneumatic connection and setup instructions for basic and optional configurations. Pneumatic flow diagrams are shown in Section 2.3.3. Calibration instructions are provided in Section 4. Before making the pneumatic connections, carefully note the following cautionary and special messages: CAUTION – General Safety Hazard Do not vent calibration gas or sample gas into enclosed areas. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Vent Pressurized Gas: When any gas (span, zero air, sample) is received from a pressurized manifold, always provide a vent to equalize the pressure with the ambient atmosphere before it enters the instrument to ensure that the gases input do not exceed the instrument’s maximum inlet pressure, as well as to prevent back diffusion and pressure effects Remove Dust Plugs: Remove dust plugs from rear panel exhaust and supply line fittings before powering on the instrument. Keep dust plugs for reuse in future storage or shipping to prevent debris from entering the pneumatics. Important IMPACT ON READINGS OR DATA Sample and calibration gases should only come into contact with PTFE tubing. Run a leak check once the appropriate pneumatic connections have been made; check all pneumatic fittings for leaks per Section 5.4.12.1 (or Section 5.4.12.2 for detailed check if any leaking is suspected). CRITICAL TUBING, PRESSURE, VENTING AND EXHAUST REQUIREMENTS The requirements presented in this section apply to all pneumatic connection instructions. All other connection instructions are provided with their respective instrument configurations in Sections 2.3.2.2 through 2.3.2.4. Tubing: 34 • PTFE material • Outer diameter (OD) minimum ¼” • Min/max length 2 meters to 10 meters Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Pressure: • All Sample gas pressure must be at ambient atmospheric pressure, no greater than 1.0 psig. Venting (to prevent back diffusion and pressure effects): • Run tubing outside the enclosure or at least away from immediate area surrounding the instrument. Exhaust Outlet: • Run tubing outside the enclosure. BASIC CONNECTIONS FROM CALIBRATOR VENT here if input Removed during calibration at HIGH Span Concentration Calibrated NOX is pressurized Enclosure Wall Source of SAMPLE GAS MODEL T700 Gas Dilution Calibrator SAMPLE MODEL 701 Zero Gas Generator EXHAUST Chassis Vent here if output of calibrator is not already vented. PUMP Figure 2-13. Gas Line Connections from Calibrator – Basic Configuration 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 35 VENT here if input Removed during calibration at Span Concentration MODEL 701 Zero Gas Generator 3-way Valve SAMPLE Manual Control Valve EXHAUST Chassis VENT Calibrated NOX is pressurized Enclosure Wall Source of SAMPLE GAS PUMP Figure 2-14. Gas Line Connections from Bottled Span Gas – Basic Configuration For the analyzer’s basic configuration, in addition to tubing, pressure, venting, and exhaust requirements set out in Section 2.3.2.1, attach the following pneumatic lines: SAMPLE GAS SOURCE Connect a sample gas line to the SAMPLE inlet. CALIBRATION GAS SOURCES CAL GAS & ZERO AIR SOURCES: The source of calibration gas is attached to the SAMPLE inlet, but only when a calibration operation is actually being performed. VENTING Vent the output of the calibrator if calibrator not already vented. 36 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CONNECTIONS W/AMBIENT ZERO/AMBIENT SPAN VALVES (OPT 50A) This valve package includes: • two solenoid valves located inside the analyzer that allow the user to switch either zero, span or sample gas to the instrument’s sensor • two additional gas inlet ports (ZERO AIR and SPAN1) Figure 2-15. Rear Panel Layout with Z/S Valve Options (OPT 50A) 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 37 VENT here if input Source of SAMPLE Gas is pressurized MODEL 700 Gas Dilution Calibrator SAMPLE PUMP EXHAUST SPAN1 MODEL 701 Zero Gas Generator ZERO AIR VENT at HIGH Span Concentration Calibrated NOx Enclosure Wall VENT if Calibrator not already vented. Figure 2-16. Gas Line Connections with Z/S Valves Option (OPT 50A) In addition to tubing, pressure, venting, and exhaust requirements set out in Section 2.3.2.1, attach the following pneumatic lines: SAMPLE GAS SOURCE Attach a sample inlet line to the SAMPLE inlet fitting. • In applications where the sample gas is received from a pressurized manifold, vent the sample gas line. CALIBRATION GAS SOURCES SPAN GAS Attach a gas line from the source of calibration gas (e.g. a Teledyne API's T700 Dynamic Dilution Calibrator) to the SPAN1 inlet. ZERO AIR Zero air is supplied by the zero air generator such as a Teledyne API's M701. Attach a gas line from the source of zero air to the ZERO AIR inlet. VENTING Vent both the span gas and zero air supply lines. 38 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CONNECTIONS FOR CALIBRATION WITH O2 SENSOR OPTION VENT here if input Removed during calibration at High Span Concentration Manual Control Valve SAMPLE EXHAUST Chassis VENT at 20.8% Span Concentration 3-way Valve Calibrated O2 Calibrated N2 is pressurized Enclosure Wall Source of SAMPLE GAS PUMP Figure 2-17. Gas Line Connections for Calibration when O2 Sensor Option Installed O2 SENSOR ZERO GAS: Teledyne API’ recommends using pure N2 when calibrating the zero point of your O2 sensor option. O2 SENSOR SPAN GAS: Teledyne API’ recommends using 21% O2 in N2 when calibrating the span point of your O2 sensor option. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 39 PNEUMATIC FLOW DIAGRAMS This section shows the basic pneumatic flow diagram for the T200H and for the T200M, followed by their respective flow diagrams with the zero/span valves option, and then with the O2 sensor option. PNEUMATIC FLOW FOR BASIC CONFIGURATION FLOW PRESSURE SENSOR PCA SAMPLE GAS INLET NO/NOX VALVE NO COM NC VACUUM PRESS URE SENSO R EX HA UST GAS OUTLET SAMPL E PRESS URE SENSO R COM Orifice Dia. 0.007" AUTOZERO VALVE O3 NC GENERATOR EXHAUST MANIFOLD NO NOX Exhaust Scrubber Orifice Dia. 0.003" Orifice Dia. 0.007" O3 Destruct REACTION CELL Orifice Dia. 0.004" O3 FLOW SENSO R NO2 Converter PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 2-18. T200H Pneumatics, Basic Configuration 40 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 NO2 Converter FLOW PRESSURE SENSOR PCA NO/NOX VALVE NO COM VACUUM PRESS URE SENSO R NC SAMPL E PRESS URE SENSO R EX HA UST GAS OUTLET COM AUTOZERO VALVE O3 NC GENERATOR EXHAUST MANIFOLD NOX Exhaust Scrubber NO Orifice Dia. 0.007" Orifice Dia. 0.007" REACTION CELL Orifice Dia. 0.004" O3 FLOW SENSO R SAMPLE GAS INLET O3 Destruct PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 2-19. T200M Pneumatics, Basic Configuration 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 41 PNEUMATIC FLOW FOR AMBIENT ZERO/AMBIENT SPAN VALVES OPTION SAMPLE/ CAL VALVE Zero/Span Valve Option COM NO NC NO/NOX VALVE NO2 Converter SPA N GA S INLET ZERO GAS INLET COM COM NC VACUUM PRESS URE SENSO R SAMPL E PRESS URE SENSO R ZERO/SPAN VALVE COM AUTOZERO VALVE NC O3 NO Orifice Dia. 0.007" GENERATOR Orifice Dia. 0.007" Orifice Dia. 0.003" EXHAUST MANIFOLD NOX Exhaust Scrubber NO NC NO EX HA UST GAS OUTLET O3 Destruct REACTION CELL Orifice Dia. 0.004" PMT Filter PUMP FLOW PRESSURE SENSOR PCA O3 FLOW SENSO R SAMPLE GAS INLET OZONE DRYER INSTRUMENT CHASSIS Figure 2-20. T200H Pneumatics with Zero/Span Valves Option 42 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 COM NO NC NO2 Converter SAMPLE/ CAL VALVE NO/NOX VALVE COM NO NC FLOW PRESSURE SENSOR PCA SPA N GA S INLET Zero/Span Valve Option NC ZERO GAS INLET NO VACUUM PRESS URE SENSO R SAMPL E PRESS URE SENSO R COM O3 FLOW SENSO R SAMPLE GAS INLET ZERO/SPAN VALVE EX HA UST GAS OUTLET COM AUTOZERO VALVE O3 NC GENERATOR NO NOX Exhaust Scrubber EXHAUST MANIFOLD Orifice Dia. 0.007" Orifice Dia. 0.007" REACTION CELL Orifice Dia. 0.004" O3 Destruct PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 2-21. T200M Pneumatics with Zero/Span Valves Option Table 2-6. Zero/Span Valves Option’s Operating States MODE SAMPLE ZERO CAL SPAN CAL 083730210A DCN8164 VALVE CONDITION Sample/Cal Open to SAMPLE gas inlet Zero/Span Open to ZERO AIR inlet Sample/Cal Open to ZERO/SPAN inlet (activated) Zero/Span Open to ZERO AIR inlet Sample/Cal Open to ZERO/SPAN inlet (activated) Zero/Span Open to SPAN inlet / IZS gas (activated) Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 43 PNEUMATIC FLOW FOR O2 SENSOR OPTION NO/NOX VALVE FLOW PRESSURE SENSOR PCA NO COM NC VACUUM PRESS URE SENSO R SAMPL E PRESS URE SENSO R O2 SENSOR OPTION EX HA UST GAS OUTLET COM EXHAUST MANIFOLD NOX Exhaust Scrubber AUTOZERO VALVE O3 NC O2 Sensor GENERATOR NO Orifice Dia. 0.004" O3 FLOW SENSO R NO2 Converter SAMPLE GAS INLET Orifice Dia. 0.007" Orifice Dia. 0.007" REACTION CELL Orifice Dia. 0.004" O3 Destruct PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 2-22. T200H Pneumatics with O2 Sensor Option 44 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 NO/NOX VALVE FLOW PRESSURE SENSOR PCA NO COM NC VACUUM PRESS URE SENSO R SAMPL E PRESS URE SENSO R O2 SENSOR OPTION EX HA UST GAS OUTLET COM EXHAUST MANIFOLD NOX Exhaust Scrubber AUTOZERO VALVE O3 NC O2 Sensor GENERATOR NO Orifice Dia. 0.004" O3 FLOW SENSO R NO2 Converter SAMPLE GAS INLET Orifice Dia. 0.007" Orifice Dia. 0.007" REACTION CELL Orifice Dia. 0.004" O3 Destruct PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 2-23. T200M Pneumatics with O2 Sensor Option If this sensor option is installed, the analyzer should be calibrated as STARTUP, FUNCTIONAL CHECKS AND CALIBRATION We recommend reading Section 6 to become familiar with the principles of operation. When the instrument is first started (Section 2.3.4.1), check its functionality (Section 2.3.4.3) and run an initial calibration (Section 2.3.4.4). Section 2.4 introduces the menu system, and Section 2.5 provides setup/customization instructions. CAUTION! If the presence of ozone is detected at any time, power down the instrument and contact Teledyne API Technical Support as soon as possible: +1 800-324-5190 or email: [email protected] 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 45 STARTUP Upon initial startup, a sequence of status screens (Figure 2-24) appear prior to the Home page (Figure 2-25). Figure 2-24. Status Screens at Startup Upon any startup, this instrument should warm up for approximately one hour before reliable measurements can be taken. Figure 2-25. Home Page Example 46 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ALERTS: WARNINGS AND OTHER MESSAGES Because internal temperatures and other conditions may be outside the specified limits during the warm-up period, the software will suppress most Alerts for 30 minutes after power up. The Alerts page (Figure 2-26) shows the status of any active warning conditions or user-configured Events. (Section 2.4.3 provides more detailed information about Alerts, and Section 2.5.2 addresses Events). Alerts can be viewed and cleared via either the Alerts menu or the Alerts shortcut (Caution symbol, bottom right corner of the screen). Although these alerts can be cleared from the Active Alerts page, a history of all alerts remains in the Utilities>Alerts Log page. Figure 2-26. Viewing Active Alerts Page If Alerts about warning conditions persist after the warm up period or after being cleared, investigate their cause using the troubleshooting guidelines in Section 5.7. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 47 FUNCTIONAL CHECKS After warm-up, verify that the software properly supports any hardware options that are installed (Setup>Instrument menu), and that the instrument is functioning within allowable operating parameters. Check the Dashboard page against the instrument’s Final Test and Validation Data sheet, which lists these values as they appeared before the instrument left the factory. (If any functional parameters are not displayed, configure the Dashboard through the Setup>Dashboard menu to add them; see Section 2.4.2). These functions are also useful tools for diagnosing problems (information provided in Section 5.7.2). Figure 2-27. Sample Dashboard Page CALIBRATION Before operation begins, the analyzer requires zero and span calibrations, and possibly HVPS adjustment, followed by calibration of the converter efficiency (CE) points. Also, any time an analyzer is moved or its configuration changed, it must be calibrated. The method for performing a calibration differs slightly depending on whether or not any of the available internal zero air or valve options are installed. Follow the appropriate calibration instructions presented in Section 4. 48 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MENU OVERVIEW Table 2-7 describes the main menus and provides cross-references to the respective sections with configuration details. Table 2-7. Menu Overview MENU DESCRIPTION LOCATION Home View and plot concentration readings and other selectable parameter values (Figure 2-29). Dashboard View user-selected parameters and their values, some of which can be displayed in a live-plot graph (Figure 2-30). Alerts View and clear active Alerts that were triggered by factory-defined Events Section 2.4.3 as well as user-defined Events. (Active and past Alerts are recorded in the Utilities>Alerts Log). Calibration Run calibrations on the NO and NOx channels and calibrate converter efficiency points. Sections 2.4.4 and 4 Utilities View logs, download data and firmware updates, copy configurations between instruments, and run diagnostics. Section 2.4.5 Setup Configure a variety of features and functions through these submenus for Section 2.5 customized operation. Track and record concentration and calibration data and selectable diagnostic parameters, the reports for which can be viewed in the Utilities>Datalog View menu (Section 2.4.5) Datalogging and downloaded to a flash drive via the Utilities>USB Utilities menu (Section 2.4.5). Also, select configured Events (Section 2.5.2) and create customized triggers for data logging functions. Select parameters and define the conditions by which they are to be flagged and recorded in the Alerts log (Section Events 2.4.3) when they are triggered. Once configured, Events can be used to trigger Datalogs. (Section 2.5.1). Note that some Events are predefined and are not editable. Monitor instrument functionality (Figure 2-27) via selectable Dashboard parameters. Auto Cal When zero/span valve options installed, configure (with valve options) sequences for automatic calibration functions. Manually adjust several software variables that define specific operational parameters. Homescreen Select up to three parameters to be displayed in the meters (Figure 2-28). Map the rear-panel digital outputs to a variety of signals Digital present in the instrument to monitor the status of operating Outputs conditions or custom Events. Send user-selected parameter readings in the form of userAnalog defined voltage or current loop signals as outputs to a strip Outputs chart recorder and/or the data logger. View product and system information, including list of options, if any; view network settings; view/adjust Date and Time settings*; and check for firmware updates when Instrument connected to a network that is connected to the Internet. *Time Zone change requires special procedures (Section 5.5). Comm View and configure network and serial communications. Vars 083730210A DCN8164 Section 2.4.1 Section 2.4.2 Section 2.5.1 Section 2.5.2 Section 2.5.3 Section 4.3 Section 2.5.5 Section 2.5.6 Section 2.5.7 Section 2.5.8 Section 2.5.9 Section 2.5.10 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 49 HOME PAGE Figure 2-28 presents an orientation to the main display screen; Figure 2-29 shows that pressing the gas name or its concentration value or a meter below displays a live plot of their respective readings. Section 2.5.6 provides configuration instructions. Figure 2-28. User Interface Orientation 50 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 2-29. Concentration and Stability Graph (top) and Meter Graph (bottom) 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 51 DASHBOARD The Dashboard displays an array of user-selectable parameters and their values (Section 2.5.3 provides configuration instructions). If there is a graphing icon in the upper right corner of a parameter, pressing that parameter displays a live plot of its readings as in Figure 2-30. Figure 2-30. Dashboard Page 52 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ALERTS Alerts are notifications triggered by specific criteria having been met by either factorydefined conditions (standard and not editable) or user-defined Events (Section 2.5.2). The Active Alerts page shows the status of any active warning conditions or Events that have been triggered. When Alerts are triggered, a caution symbol appears in both the Alerts menu tab and in the bottom right corner of the software interface, which serves as a shortcut to the Alerts page from any other page. View a list of currently active Alerts by pressing either the Alerts menu on the Home screen or by pressing the Alerts shortcut (Figure 2-31). While Alerts can be cleared from the Active Alerts page, they remain recorded in the Utilities>Alerts Log menu. Figure 2-31. Navigating to the Active Alerts Page Alerts can be configured as either latching (appears in Active Alerts screen when Event is triggered and must be cleared by the user) or non-latching (Active Alerts screen continuously updates based on the Event criteria, clearing on its own). See Section 2.5.2. To clear Alerts from the Active Alerts page, either check individual boxes to choose specific Alerts, or check the Select All box to choose all Alerts, then press the Clear Selected button. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 53 When all Alerts are cleared, the Alerts menu tab no longer shows the caution symbol, and a green LED replaces the caution symbol in the bottom right corner of the interface (Figure 2-32). However, Alerts can reappear if the conditions causing them are not resolved. For troubleshooting guidance, refer to Section 5.7. Figure 2-32. Active Alerts Cleared Alerts and Events remain recorded in the Utilities>Alerts Log (Figure 2-33). Figure 2-33. Utilities>Alerts Log of Active and Past Alerts and Events CALIBRATION The Calibration menu is used for zero/span/multipoint calibrations and for external calibration with valve options installed. Calibration procedures are presented in Section 4. 54 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 UTILITIES The Utilities menu has a variety of functions as described next in Table 2-8. Table 2-8. Utilities Submenu Descriptions UTILITIES MENU DESCRIPTION Datalog View Displays the data logs that were configured via the Setup>Data Logging menu. From this list a log can be selected and filters applied to view the desired data. (For details on setting up and running the Data Logger, see Section 2.5.1). Alerts Log Displays a history of alerts that are triggered by factory-defined and user-defined Events, such as warnings and alarms (See Section 2.5.2 for Events configuration). USB Utilities Serves multiple purposes using a flash drive connected to the instrument’s front panel USB port: • download data from the instrument’s Data Acquisition System (DAS), the Data Logger, to a flash drive (Section 2.5.1.3) • update firmware (Section 5.3) • transfer instrument configuration from/to other same-model instruments (Section 2.6) • download a basic operation functionality report (Section 5.3). Provides access to various pages that facilitate troubleshooting. Diagnostics Analog Outputs Show the voltage signals for the functions selected and configured in the Setup>Analog Outputs menu (Section 2.5.8). Rear panel connections were presented in Section 2.3.1.2. Digital Inputs Show whether specific available features are turned ON or OFF; for example, whether or not Maintenance Mode input or Language selection can be controlled through the front panel, or whether a zero or span calibration can be activated remotely when an external source is connected to the rear panel Control In connector (Section 2.3.1.5). Digital Outputs Show the function of user-specified parameters configured in the Setup>Digital Outputs menu (Section 2.5.7). Flow Cal Used to calibrate the sample gas flow reading with actual flow measured by an external device. (See Section 5.6.9.3). OE Test Used to run either an electrical test (ETest) or an optics test (OTest) (Section 5.7.9.11). O3 Gen Override Used to override the Ozone Generator state when needed, such as for service (Section 5.7.9.15). SETUP The Setup menu is used to configure the instrument’s various features, functions, and data log. Section 2.5 provides details for the menus under Setup. SETUP MENU: FEATURES/FUNCTIONS CONFIGURATION Use the Setup menu to configure the instrument’s software features, to gather information on the instrument’s performance, and to configure and access data from the Datalogger, the instrument’s internal data acquisition system (DAS). Once the setups are complete, the saved configurations can be downloaded to a USB drive through the Utilities>USB Utilities menu and uploaded to other instruments of the same model (Section 2.6). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 55 SETUP>DATA LOGGING (DATA ACQUISITION SYSTEM, DAS) The Datalogger can be configured to capture and store user-defined data, which then can be viewed in the Alerts page, if elected, as well as downloaded from the instrument to a USB flash drive or using NumaView™ Remote software for examination and analysis. Figure 2-34 shows a new log; Figure 2-35 shows a sample existing log, which can be edited or deleted, and Figure 2-36 provides illustrated instructions for setting up a new log, with Sections 2.5.1.1 and 2.5.1.2 providing additional details. To transfer captured instrument data to a flash drive see Section 2.5.1.3. Figure 2-34. Datalog Configuration, New Log Page Figure 2-35. Datalog Configuration, Existing Log 56 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 2-36. Creating a New Data Log The parameters available in the list of Log Tags include the names of Events configured in the Events page (Section 2.5.2). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 57 CONFIGURING TRIGGER TYPES: PERIODIC The Periodic trigger is a timer-based trigger that is used to log data at a specific time interval. Periodic Trigger requires an interval that is set to number of minutes and a start time that is set to date and clock time. Figure 2-37. Datalog Periodic Trigger Configuration 58 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CONFIGURING TRIGGER TYPES: CONDITIONAL Conditional Trigger tracks/records data for user-selected parameters that meet specified conditions. Figure 2-38. Datalog - Conditional Trigger Configuration DOWNLOADING DAS (DATA ACQUISITION SYSTEM) DATA To download DAS data collected by the Datalogger from the instrument to a flash drive, navigate to the Utilities>USB Utilities>DAS Download menu. 1. Insert a flash drive into a front panel USB port and wait for the Status field to indicate that the drive has been detected; available buttons will be enabled. Figure 2-39. DAS Download Page 2. Select all or define a period from which to download the collected data. 3. Press the Download button, and when complete, as indicated in the Status field, press the Done button (changed from “Cancel”) and remove the flash drive. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 59 SETUP>EVENTS Events are occurrences that relate to any operating function, and are used to define the conditions that can be set to trigger Alerts (Section 2.4.3). Events can provide diagnostic information about the instrument, typically referred to as “Warnings”, or they can provide other information on instrument functionality, such as concentration alarms. Some Events are standard and not editable while others are user-configurable, described here. Existing Events are listed in the Events page (Figure 2-40) under the Setup menu. Figure 2-40. Events List Access the Events Configuration page either from the Active Alerts page (Alerts Menu) by pressing the configuration button, or through the Home>Setup>Events menu (Figure 2-40). Press ADD to create a new Event (refer to Figure 2-41 for details), or select an existing Event to either Edit or Delete it (Figure 2-43). 60 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 2-41. Event Configuration • allows the choice of whether to track and record the Event (uncheck this box to “turn off” or deactivate the Event without deleting it). An Event must be enabled in order to use the Visible and the Latching options. • allows the choice of whether or not to display the Event in the Alerts page when it is triggered (it will still be recorded and can be viewed in the Utilities>Alerts Log).To use this option, the Event must be enabled. • allows the choice of whether or not to keep an Event visible even if the conditions that triggered it were to correct themselves. (Latching requires that the user interact with the Active Alerts screen to manually clear the Alert and internal Event state. Non-latching allows the entry in the Active Alerts screen and the internal Event state to continuously update based on the Event criteria, requiring no user interaction to clear the Alert or Event state). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 61 Figure 2-42. Configured Event Sample EDITING OR DELETING EVENTS Select an Event from the list (Figure 2-40) and press the Edit button to view or edit the details (Figure 2-42), or press the Delete button to delete the Event. Figure 2-43. Edit or Delete an Event 62 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 USING EVENTS AS TRIGGERS FOR DATA LOGGING Events can also be used to create customized triggers for data logging functions. The name entered in the Name field of the Events Configuration page will appear in the list of Log Tags of the Datalog Configuration page. The Data Logger is presented in Section 2.5.1. SETUP>DASHBOARD Figure 2-44. Dashboard Display and Configuration 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 63 SETUP>AUTOCAL (WITH VALVE OPTION) Auto Cal is available with installed valve options (see Section 4.3). SETUP>VARS Vars are software variables that define operational parameters automatically set by the instrument’s firmware, and are user-adjustable through this menu. Access the menu to see the list of variables; select a variable to view its description; touch the Edit button to change its setting(s). Table 2-9. List of Variables with Descriptions VARIABLE DESCRIPTION NOTE: This list includes several of the most common Vars; selecting any Var in the NumaView™ software interface will display its description in the information field to its right. Depending on configuration, some, all, or more of these variables appear in your instrument’s Vars menu. Conc Precision (or PRIGAS/SECGAS Precision) Daylight Savings Enable Dilution Factor Option Dynamic Span Enable Dynamic Zero Enable Instrument ID Legacy Comm ID 64 Sets the number of significant digits to the right of the decimal point display of concentration and stability values. (“PRIGAS” = primary gas with two or more other gases; “SECGAS” = secondary gas) Enable or disable Daylight Savings Time (also see Setup>Instrument>Date/Time Settings) Sets the instrument to compensate for diluted sample gas, such as in continuous emission monitoring (CEM) where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas. Once the degree of dilution is known, this feature allows the user to add an appropriate scaling factor to the analyzer’s NO, NO2 and NOx concentration calculations so that the undiluted values for measurement range and concentration are shown on the instrument’s front panel display and reported via the instrument’s various outputs. 1. Set the appropriate units of measure (Setup>Vars>User Units). 2. Select the reporting range mode (Setup>Vars>Range Mode) and set the reporting range upper limit (Setup>Analog Output). Ensure that the upper span limit entered for the reporting range is the maximum expected concentration of the undiluted gas. 3. Set the dilution factor as a gain, e.g., a value of 20 means 20 parts diluent and 1 part sample gas (Setup>Vars>Dilution Factor). 4. Calibrate the analyzer; ensure that the calibration span gas is either supplied through the same dilution system as the sample gas or has an appropriately lower actual concentration. Dynamic span automatically adjusts the offsets and slopes of the NO and NOx response when performing a span point calibration during an AutoCal (Section 4.3). Dynamic zero automatically adjusts offset and slope of the NO and NOX response when performing a zero point calibration during an AutoCal (Section 4.3). Set unique identifier number for the instrument when it is connected with other instruments in multidrop configuration or on the same Ethernet LAN, or when applying MODBUS protocols. (Setup>Vars>Instrument ID) Set unique identifier number for the instrument when applying TAPI or Hessen protocols. (Setup>Vars>Instrument ID) Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 VARIABLE Maint Mode Max Concentration Range Measure Mode Range Mode System Hours TPC Enable User Units DESCRIPTION Software maintenance mode sets instrument to continue sampling, while ignoring calibration, diagnostic, and reset instrument commands. This feature is of particular use for instruments connected to Multidrop (2.3.1.7) or Hessen protocol networks. Set the highest concentration expected, as this is used by the CPU to adjust Preamp physical ranges. (Section 4.1.5 provides more information). Selects the gas measurement mode in which the instrument is to operate: NOx only, NO only, or NOx and NO simultaneously. Controls range mode, single (SNGL) or dual (DUAL). (When set to DUAL, ensure that Max Concentration Range has been set). Total system runtime hours Enables or disables the Temperature and Pressure Compensation (TPC) feature (For information on TPC, see Section 6.10.2). Change the concentration units of measure. SETUP>HOMESCREEN To select a parameter (“tag”) for display in each of the three meters at the bottom of the Home page, navigate to the Homescreen configuration page through either the Setup>Homescreen menu or from Home page using the configuration icon (Figure 2-45). Figure 2-45. Homescreen Configuration An orientation to the Homescreen was presented in Section 2.4.1, including Figure 2-28 and Figure 2-29. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 65 SETUP>DIGITAL OUTPUTS Specify the function of each digital output (connected through the rear panel STATUS connector) by mapping the output to a selection of “Signals” present in the instrument. Create custom “Signals” in the Setup>Events menu (Section 2.5.2). (If the Motherboard Relay Option was installed, the four additional relays can also be mapped). To map Digital Outputs to Signals, select a pin in the Outputs list, then make a selection from the Signals list and press the Map button; if/as needed, change the polarity by pressing the Polarity button. Save any changes by pressing the Apply button, or discard the changes by pressing the Home or the back button (a pop-up provides a warning that the changes will be lost, and will prompt for confirmation to apply changes or not). Go to the Utilities>Diagnostics>Digital Outputs menu to change the state (ON/OFF) of individual digital outputs. Figure 2-46. Digital Outputs Setup 66 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 SETUP>ANALOG OUTPUTS Map the four user-configurable Analog Outputs to any of a wide variety of “Signals” present in the instrument and customize their respective configurations. Figure 2-47. Analog Output Configuration Example Refer to Figure 2-47 for the following: • Signal Out: select a Signal for the output. • Min/Max: edit minimum and maximum values associated with the selected Signal. • Calibration Type: • AUTO for group calibration (Figure 2-48) of the analog outputs (cannot be selected when Current is selected for the Range) • MANUAL for individual calibration (Figure 2-49) of analog outputs where manual adjustments can be made (the only calibration type allowed when Current is selected for the Range). See Sections 2.5.8.1 and 2.5.8.2 . • Range: assign a voltage or select Current (refer to Table 2-10). • Recorder Offset: add a zero offset for recording slightly negative readings from noise around the zero point. • Allow Overrange: check to allow a ± 5% over-range; uncheck to disable over-range if the recording device is sensitive to excess voltage or current. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 67 Figure 2-48. Analog Outputs Group Calibration Screen Figure 2-49. Analog Outputs Manual Calibration Screen (AOUT2 Example) Table 2-10. Analog Output Voltage/Current Range RANGE1 RANGE SPAN MINIMUM OUTPUT MAXIMUM OUTPUT 100mV 0-100 mVDC -5 mVDC 105 mVDC 1V 0-1 VDC -0.05 VDC 1.05 VDC 5V 0-5 VDC -0.25 VDC 5.25 VDC 10V 0-10 VDC -0.5 VDC 10.5 VDC Current2 0-20 mA 0 mA 20 mA 1 Each range is usable from -5% to +5% of the rated span. 2 While these are the physical limits of the current loop modules, typical applications use 2-20 mA or 4-20 mA for the lower and upper limits. For manual calibration adjustments, see Section 2.5.8.1 for voltage and Section 2.5.8.2 for current. 68 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MANUAL CALIBRATION OF VOLTAGE RANGE ANALOG OUTPUTS It is possible to manually calibrate the voltages by using a voltmeter connected across the output terminals (Figure 2-50) and changing the output signal level in the Manual Adjust field of the Analog Outputs Calibration screen (Figure 2-49). Refer to Table 2-11 for voltage tolerances. +DC Gnd V Volt Meter V OUT + V IN + V OUT - V IN - ANALYZER Recording Device Figure 2-50. Setup for Checking / Calibrating DCV Analog Output Signal Levels Table 2-11. Voltage Tolerances SPAN VOLTAGE SPAN TOLERANCE MINIMUM ADJUSTMENT (1 count) ±0.0005V 90 mV ±0.001V 0.02 mV ±0.001V 900 mV ±0.001V 0.24 mV 5 VDC ±0.002V 4500 mV ±0.003V 1.22 mV 10 VDC ±0.004V 4500 mV ±0.006V 2.44 mV FULL SCALE ZERO TOLERANCE 0.1 VDC 1 VDC 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 69 MANUAL ADJUSTMENT OF CURRENT RANGE ANALOG OUTPUTS These instructions assume that the Current Loop Option is installed (Section 2.3.1.3). This option places circuitry in series with the output of the D-to-A converter on the motherboard that changes the normal DC voltage output to a 0-20 milliamp signal. Adjusting the signal zero and span levels of the current loop output is done by raising or lowering the voltage output of the D-to-A converter circuitry on the analyzer’s motherboard. This raises or lowers the signal level produced by the current loop option circuitry. The software allows this adjustment to be made in 100, 10 or 1 count increments. Since the exact amount by which the current signal is changed per D-to-A count varies from output-to-output and instrument–to–instrument, you will need to measure the change in the signal levels with a separate, current meter placed in series with the output circuit. See Figure 2-4 for pin assignments and diagram of the analog output connector. CAUTION! Do not exceed 60 V peak voltage between current loop outputs and instrument ground. mADC IN OUT Current Meter I OUT + I IN + I OUT - I IN - ANALYZER Recording Device Figure 2-51. Setup for Checking / Calibration Current Output Signal Levels An alternate method for measuring the output of the Current Loop converter is to connect a 250 ohm ±1% resistor across the current loop output in lieu of the current meter (see Figure 2-4 for pin assignments and diagram of the analog output connector). This allows the use of a voltmeter connected across the resistor to measure converter output as VDC or mVDC. 70 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 V +DC Gnd Volt Meter V OUT + V IN + 250 Ω V OUT - V IN - ANALYZER Recording Device Figure 2-52. Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels In this case, follow the procedure above but adjust the output for the following values: Table 2-12. Current Loop Output Check % FS Voltage across Resistor for 2-20 mA Voltage across Resistor for 4-20 mA 0 500 mVDC 1000 mVDC 100 5000 mVDC 5000 mVDC SETUP>INSTRUMENT As presented in Table 2-13, view product and system information and network settings, edit network settings, and perform certain maintenance tasks. Table 2-13. Setup>Instrument Menu MENU DESCRIPTION Product Info View Model, Part, and Serial Numbers and Package and Driver Versions, and options information. System Info View Windows and RAM information. Network Settings View the network settings (configurable through the Setup>Comm>Network Settings menu). Date/Time Settings Adjust date, hour, and minutes, select a time zone*, and set the system clock to automatically adjust for Daylight Savings Time or not. (Also see Setup>Vars>Daylight Savings Enable). *Time Zone change requires a special procedure; see Maintenance Section 5.5. NTP Time Settings Configure Network Time Protocol settings for clock synchronization. Language Select an available language. Remote Update When an instrument is connected to a network that is connected to the Internet, follow the instructions on this Remote Update page to check for and activate software/firmware updates. (Also refer to Section 5.3). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 71 SETUP>COMM (COMMUNICATIONS) This menu is for specifying the various communications configurations. COM1/COM2 Configure the instrument’s COM1 or COM2 ports to operate in modes listed in Table 2-14. Table 2-14. COM1/COM2 Configuration MODE 72 DESCRIPTION Baud Rate Set the baud rate for the COM1 or COM2 port being configured. Command Prompt Display Enable/disable a command prompt to be displayed when in terminal mode. Data Bits Set the data bits to 7 or 8 (typically set in conjunction with Parity and Stop bits). Echo and Line Editing Enable/disable character echoing and line editing. Handshaking Mode Choose SOFTWARE handshaking for data flow control (do NOT use SOFTWARE handshaking mode when using MODBUS RTU for Protocol mode; select only HARDWARE or OFF for MODBUS RTU), or HARDWARE for CTS/RTS style hardwired transmission handshaking. (This style of data transmission handshaking is commonly used with modems or terminal emulation protocols). Or choose to turn OFF handshaking. Hardware Error Checking Enable/disable hardware error checking. Hardware FIFO Enable/disable the hardware First In – First Out (FIFO) for improving data transfer rate for that COM port. Modem Connection Select either a modem connection or a direct cable connection. Modem Init String Input an initialization string to enable the modem to communicate. Multidrop Enable/disable multidrop mode for multi-instrument configuration on a single communications channel. Multidrop requires a unique ID for each instrument in the chain (Setup>Vars>Instrument ID). Parity Select odd, or even, or no parity (typically set in conjunction with Data Bits and Stop Bits). Protocol Select among the communications protocols: TAPI, Hessen, MODBUS RTU, or MODBUS ASCII (MODBUS: Section 3.4.1; Hessen: Section 3.4.2). Quiet Mode Enable/disable Quiet mode, which suppresses any feedback from the analyzer (such as warning messages) to the remote device and is typically used when the port is communicating with a computer program where such intermittent messages might cause communication problems. Such feedback is still available, but a command must be issued to receive them. RS-485 Enable/disable the rear panel COM2 Port for RS-485 communication. RS-485 mode has precedence over Multidrop mode if both are enabled. Also, RS-485 configuration disables the rear panel USB port. Security Enable/disable the requirement for a password for this serial port to respond. The only command that is active is the request-for-help command (? CR). Stop bits Select either 0 or 1 stop bit (typically set in conjunction with Parity and Data bits). Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 TCP PORT1 TCP Port1 allows choosing whether or not to display the command prompt, editing the Port 1 number for defining the terminal control port by which terminal emulation software addresses the instrument, such as Internet or NumaView™ Remote software, and enabling or disabling security on this port. TCP PORT2 TCP Port2 is configured with the port number for MODBUS. TCP PORT3 TCP Port3 is configured with the port number for Hessen. NETWORK SETTINGS The Setup>Comm>Network Settings menu is for Ethernet configuration. The address settings default to automatic configuration by Dynamic Host Configuration Protocol (DHCP). Most users will want to configure the instrument with a static IP address: click the Static radio button to manually assign a static IP address (consult your network administrator, and see Table 2-15 for information). Figure 2-53. Communications Configuration, Network Settings 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 73 Table 2-15. LAN/Ethernet Configuration Properties PROPERTY 74 DESCRIPTION IP address A string of four packets of 1 to 3 numbers each (e.g. 192.168.76.55.) is the internet protocol address of the instrument itself. Subnet Mask A string of four packets of 1 to 3 numbers each (e.g. 255.255.252.0) number that masks an IP address, and divides the IP address into network address and host address and identifies the LAN to which the device is connected. All addressable devices and computers on a LAN must have the same subnet mask. Any transmissions sent to devices with different subnets are assumed to be outside of the LAN and are routed through the gateway computer onto the Internet. Default Gateway A string of numbers very similar to the Instrument IP address (e.g. 192.168.76.1.) that is the address of the computer used by your LAN and serves as a router to access the Internet or another network. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 TRANSFERRING CONFIGURATION TO OTHER INSTRUMENTS Once an instrument is configured, the same configuration can be copied to other instruments of the same Model. This encompasses essentially anything the user can configure and does not apply to instrument-specific settings such as those that are configured at the factory for calibration. Figure 2-54. Configuration Transfer 1. In the source instrument, go to the Home>Utilities>USB Utilities>General page. 2. Insert a flash drive into either of the two front panel USB ports. 3. When the Status field indicates that the USB drive has been detected, press the “Download Configuration from Instrument” Start button. 4. When the Status field indicates that the download is complete, remove the flash drive. 5. In the target instrument, go to the Home>Utilities>USB Utilities>General page. 6. Insert a flash drive into either of the two front panel USB ports. 7. When the Status field indicates that the USB drive has been detected, press the “Upload Configuration to Instrument” Start button. 8. When the Status field indicates that the upload is complete, remove the flash drive. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 75 3. COMMUNICATIONS AND REMOTE OPERATION This instrument’s rear panel connections include an Ethernet port, a USB port (option) and two serial communications ports labeled RS232, which is the COM1 port in the software menu, and COM2 (refer to Figure 2-2). These ports allow the ability to communicate with, issue commands to, and receive data from the analyzer through an external computer system or terminal. Connection instructions were provided in Section 2.3.1.7. Configuration information was provided in Section 2.5.10. This section provides pertinent information regarding communication equipment, the communications ports, and communications protocol. Data acquisition is set up through the Datalogger (Section 2.5.1). DATA TERMINAL/COMMUNICATION EQUIPMENT (DTE DCE) RS-232 was developed for allowing communications between data terminal equipment (DTE) and data communication equipment (DCE). Basic terminals always fall into the DTE category whereas modems are always considered DCE devices. The difference between the two is the pin assignment of the Data Receive and Data Transmit functions. • DTE devices receive data on pin 2 and transmit data on pin 3. • DCE devices receive data on pin 3 and transmit data on pin 2. To allow the analyzer to be used with terminals (DTE), modems (DCE) and computers (which can be either), a switch mounted below the serial ports on the rear panel, labeled DCE DTE (Figure 2-2), allows the user to set the RS-232 configuration for one of these two data devices. This switch exchanges the Receive and Transmit lines on RS-232 emulating a cross-over or null-modem cable. The switch has no effect on COM2. MODES, BAUD RATE AND SERIAL COMMUNICATION Referring to Table 2-14, use the SETUP>COMM menu to configure COM1 (labeled RS232 on instrument rear panel) and/or COM2 (labeled COM2 on instrument rear panel) for communication modes, baud rate and serial communications. If using a USB option communication connection, setup requires that the instrument’s baud rate and personal computer baud rate match. 76 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 SERIAL COMMUNICATION: RS-232 The RS232 and COM2 communications ports operate on the RS-232 protocol (default configuration). Configurations possible for these two ports are: • RS232 port can also be configured to operate in single or RS-232 Multidrop mode (Option 62); refer to Section 2.3.1.7. • COM2 port can be left in its default configuration for standard RS-232 operation including multidrop, or it can be reconfigured for half-duplex RS-485 operation (please contact the factory for this configuration). When the rear panel COM2 port is in use, except for multidrop communication, the rear panel USB port cannot be used. (Alternatively, when the USB port is enabled, COM2 port cannot be used except for multidrop). Note A code-activated switch (CAS), can also be used on either port to connect typically between 2 and 16 send/receive instruments (host computer(s) printers, data loggers, analyzers, monitors, calibrators, etc.) into one communications hub. Contact Teledyne API Sales (front cover, this manual) for more information on CAS systems. SERIAL COMMUNICATION: RS-485 (OPTION) The COM2 port of the instrument’s rear panel is set up for RS-232 communication but can be reconfigured for RS-485 communication. Contact Technical Support for reconfiguration unless this option was elected at the time of purchase, then the rear panel was preconfigured at the factory. ETHERNET When using the Ethernet interface, the analyzer can be connected to any standard 10BaseT or 100BaseT Ethernet network via low-cost network hubs, switches or routers. The interface operates as a standard TCP/IP device on port 3000. This allows a remote computer to connect through the network to the analyzer using NumaView™ Remote, terminal emulators or other programs. The Ethernet connector has two LEDs that are on the connector itself, indicating its current operating status. Table 3-1. Ethernet Status Indicators LED FUNCTION amber (link) On when connection to the LAN is valid. green (activity Flickers during any activity on the LAN. The analyzer is shipped with DHCP enabled by default. This allows the instrument to be connected to a network or router with a DHCP server; however, it should be configured with a Static IP address as soon as practical. See Section 2.5.10.5 for configuration details. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 77 COMMUNICATIONS PROTOCOLS MODBUS (Section 3.4.1) and Hessen (Section 3.4.2) are available with the analyzer. MODBUS registers are provided in Appendix A. MODBUS These instructions assume that the user is familiar with MODBUS communications, and provide minimal information to get started. Please refer to the Teledyne API MODBUS manual, PN 06276, and to www.modbus.org for MODBUS communication protocols. Minimum Requirements: • Instrument firmware with MODBUS capabilities installed • MODBUS-compatible software (TAPI uses MODBUS Poll for testing; see www.modbustools.com) • Personal computer with communications cable (Ethernet or USB or RS232), and possibly a null modem adapter or cable MODBUS COM PORT CONFIGURATION MODBUS communications can be configured for transmission over Ethernet or serial COM port through the Setup>Comm menu. Make the appropriate cable connections (Ethernet or COM port) between the instrument and a PC. Check the instrument’s Modbus Units selection in the Setup>Vars menu and edit if needed. Ethernet: MODBUS is available on TCP port 502. By default, port 502 is assigned to the instrument’s TCP Port 2. (Setup>Comm> TCP Port2, Figure 3-1). Figure 3-1. MODBUS via Ethernet 78 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Serial COM: Both COM1 (labeled “RS232” on the instrument’s rear panel) and COM2 are configurable for RS-232 or RS-485 communication with either MODBUS RTU or MODBUS ASCII transmission modes. In the Setup>Comm COM1[COM2] menu, edit the Protocol parameter to select a MODBUS transmission mode; edit Baud Rate, Parity, Data Bits, etc., if necessary (see descriptions in Table 2-14). Important When using MODBUS RTU, ensure that the COM1[COM2] Handshaking Mode is set to either Hardware or OFF. Do NOT set it to Software. Press the Accept button to apply the settings. (Figure 3-2 shows an example for MODBUS RTU). Figure 3-2. MODBUS via Serial Communication (example) Important When more than one analyzer is connected to the network, create a unique identification number for each in the Setup>Vars>Instrument ID menu. Next, for the settings to take effect, power off the analyzer, wait 5 seconds, and power it on again. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 79 HESSEN Hessen is a multidrop protocol, in which several remote instruments (slaves) are connected via a common communications channel to a host computer. Slaves respond only to commands sent by the host using their unique identification. Important Create a unique identification number for each instrument in the multidrop chain via the Setup>Vars>Instrument ID menu. The Hessen protocol is not strictly defined; therefore, while Teledyne API’s application is completely compatible with the protocol itself, it may be different from implementations by other companies. HESSEN COM PORT CONFIGURATION Configure the COM1/COM2 port for Hessen protocol through the Setup>Comm>COM1[COM2] menu: select COM1[COM2] Protocol and press Edit to select HESSEN, then press Accept. Ensure that the communication parameters of the host computer are also properly set. Figure 3-3. Serial Communication, Setting Hessen Protocol 80 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 The instrument software has a 200 ms latency period before it responds to commands issued by the host computer. This latency should present no problems, but be mindful of issuing commands to the instrument too frequently. Note HESSEN SETTINGS CONFIGURATION Hessen configuration includes settings for alarms, version, response mode, status flags and gas list. Locate the alarms in the Hessen Settings list (Setup>Comm>Hessen>Hessen Settings) and edit as desired. HESSEN VARIATION For the Hessen Variation setting, there are two versions. • TYPE 1 is the original implementation. • TYPE 2 has more flexibility when operating with instruments that can measure more than one type of gas. For more specific information about the difference between the two versions, download the Manual Addendum for Hessen Protocol from the Teledyne API's web site: http://www.teledyne-api.com/manuals/. HESSEN PROTOCOL RESPONSE MODE Set the response mode under Hessen Response Mode, referring to Table 3-2 for descriptions. Table 3-2. Teledyne API's Hessen Protocol Response Modes MODE ID CMD MODE DESCRIPTION This is the default setting. Reponses from the instrument are encoded as the traditional command format. Style and format of responses depend on exact coding of the initiating command. BCC Responses from the instrument are always delimited with <STX> (at the beginning of the response, <ETX> (at the end of the response followed by a 2 digit Block Check Code (checksum), regardless of the command encoding. TEXT Responses from the instrument are always delimited with <CR> at the beginning and the end of the string, regardless of the command encoding. HESSEN STATUS FLAGS Locate the various status flags in the Hessen Settings list and edit as needed. They are listed by status flag name with their default bit assignments. (Those with unassigned flags are listed as “0x0000”). • The status bits are included in the instrument’s responses to inform the host computer of its condition. Each bit can be assigned to one operational and warning message flag. • It is possible to assign more than one flag to the same Hessen status bit. This allows the grouping of similar flags, such as all temperature warnings, under the same status bit. • Assigning conflicting flags to the same bit will cause each status bit to be triggered if any of the assigned flags is active. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 81 Table 3-3. Hessen Status Flags and Default Bit Assignments STATUS FLAG NAME3 DEFAULT BIT ASSIGNMENT (USER EDITABLE; ALSO SEE NOTE3) WARNING FLAGS SAMPLE FLOW WARNING 0001 OZONE FLOW WARNING 0002 RCEL PRESS WARNING 0004 BOX TEMP WARNING 0008 RCELL TEMP WARNING 0010 IZS TEMP WARNING1 0020 PMT TEMP WARN 0040 CONV TEMP WARNING 0080 INVALID CONC 8000 OPERATIONAL FLAGS In MANUAL Calibration Mode 0200 In ZERO Calibration Mode 0400 In SPAN Calibration Mode 0800 In WARMUP Mode 1000 UNITS OF MEASURE FLAGS UGM 0000 MGM 2000 PPB 4000 PPM 6000 SPARE/UNUSED BITS 0100 UNASSIGNED FLAGS (0000) MANIFOLD TEMPERATURE2 HVPS WARNING OZONE GEN OFF FRONT PANEL WARN SYSTEM RESET ANALOG CAL WARNING RELAY BOARD WARNING CANNOT DYN ZERO REAR BOARD NOT DETECTED CANNOT DYN SPAN AUTOZERO WARNING Instrument is in MP CAL mode 1 Only applicable if the optional internal span gas generator is installed. 2 Only applicable if the analyzer is equipped with an oxygenator option. 3 It is possible to assign more than one flag to the same Hessen status bit. This allows the grouping of similar flags, such as all temperature warnings, under the same status bit. Be careful not to assign conflicting flags to the same bit as each status bit will be triggered if any of the assigned flags is active. 82 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 HESSEN GAS LIST CONFIGURATION Configure the Hessen Gas List in the Setup>Comm>Hessen>Hessen Gas List page. Choose the Gas, the concentration Range, and enter the gas ID. Refer to and to the table below. Figure 3-4. Hessen Gas List Configuration Table 3-4. Hessen Gas List Definitions PARAMETER Gas DEFINITION type of gas to be reported Range concentration range to be reported (when Reported box is checked) 0 currently active range 1 only when range 1 or low range is active 2 only when range 2 or high range is active 3 Not Applicable Id specific gas identification 211 NOx 212 NO 213 NO2 Reported choice of whether to report when polled by the Hessen network 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 83 4. CALIBRATION This section is organized into subsections as follows: SECTION 4.1 – Important Precalibration Information : contains important information you should know before calibrating the instrument. SECTION 4.2 – Calibration Procedures: describes the procedure for manually checking calibration and performing actual calibration of the instrument. SECTION 4.3 – Automatic Zero/Span Cal/Check (Auto Cal): describes the procedure for using the AutoCal feature to check calibration or to calibrate the instrument. (The AutoCal feature requires that either the zero/span valve option or the internal span gas generator option be installed and operating). SECTION 4.4 – Calibration Quality Analysis: describes how to evaluate quality of each calibration. SECTION 4.5 – Conversion Efficiency (CE) C: provides information on monitoring and calibrating the efficiency of the converter. IMPORTANT PRECALIBRATION INFORMATION Note A start-up period of 4-5 hours is recommended prior to calibrating the analyzer. CALIBRATION REQUIREMENTS The following equipment, supplies, and expendables are required for calibration: • Zero-air source • Span gas source • Gas lines - all gas line materials should be stainless steel or Teflon-type (PTFE or FEP). • High-concentration NO gas transported over long distances may require stainless steel lines to avoid oxidation of NO due to the possibility of O2 diffusing into the tubing. Optional equipment: A recording device such as a strip-chart recorder and/or data logger. For electronic documentation, the internal data acquisition system (DAS) can be used by configuring the Datalogger through the Setup>Data Logging menu; Section 2.5.1). The method for performing an initial calibration for the analyzer differs between the standard instrument and those with options. 84 • See Section 4.2.1 for instructions for initial calibration of the analyzer in its base configuration. • See Section 4.2.2 for information regarding setup and calibration of the analyzer with Z/S Valve options. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Zero air and span gases must be supplied at twice the instrument’s specified gas flow rate. Therefore, the zero and span gases should be supplied to their respective inlets in excess of 1000 cc/min (500 cc/min x 2). Note ZERO AIR Zero air or zero calibration gas is similar in chemical composition to the measured medium but without the gas to be measured by the analyzer. For the T200H/M, this means zero air should be devoid of NO, NO2, CO2, NH3 or H2O vapor. Moderate amounts of NH3 and H2O can be removed from the sample gas stream by installing the optional sample gas dryer/scrubber (Call Sales). Note • If your application is not a measurement in ambient air, the zero calibration gas should be matched to the composition of the gas being measured. • Pure nitrogen (N2) could be used as a zero gas for applications where NOX is measured in nitrogen. • If your analyzer is equipped with an external zero air scrubber option, it is capable of creating zero air from ambient air. • For analyzers without the external zero air scrubber, a zero air generator such as the Teledyne API's Model T701 can be used. Please visit the company website for more information. CALIBRATION (SPAN) GAS Calibration gas is specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired reporting range. To measure NOX with the analyzer, it is recommended that you use a span gas with an NO concentration equal to 80% of the measurement range for your application. EXAMPLE: • If the application is to measure NOX in ambient air between 0 ppb and 500 ppb, an appropriate span gas would be 400 ppb. • If the application is to measure NOX in ambient air between 0 ppb and 1000 ppb, an appropriate span gas would be 800 ppb. SPAN GAS FOR MULTIPOINT CALIBRATION Some applications, such as EPA monitoring, require a multipoint calibration where span gases of different concentrations are needed. We recommend using an NO gas of higher concentration combined with a gas dilution calibrator such as the Teledyne API T700/T700U Models. Calibrators mix high concentration gas with zero air to accurately produce span gas of the desired concentration. Linearity profiles can be automated with these models and run unattended overnight. If a dynamic dilution system is used to dilute high concentration gas standards to low, ambient concentrations, ensure that the NO concentration of the reference gas matches the 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 85 dilution range of the calibrator. (Section 2.5.5 contains information about the dilution option). Choose the NO gas concentration so that the dynamic dilution system operates in its midrange and not at the extremes of its dilution capabilities. EXAMPLE: • A dilution calibrator with 10-10000 dilution ratio will not be able to accurately dilute a 5000 ppm NO gas to a final concentration of 500 ppb, as this would operate at the very extreme dilution setting. • A 100 ppm NO gas in nitrogen is much more suitable to calibrate the analyzer (dilution ratio of 222, in the mid-range of the system’s capabilities). PHYSICAL RANGE MEASUREMENTS The measurement physical ranges for NOx, NO and NO2 concentrations are 0-50 ppb (low range) or 0-20,000 ppb (high range). Electronically the analyzer converts the 0-5 volt analog signal output from the PMT to a digital signal with 4096 counts of resolution. Since its measurement range is 0 ppb to 20,000 ppb, this only allows about 3 ppb per count. While this might be acceptable for high concentration measurements made in parts per million units (ppm), it is not useful enough for lower level NOx measurements. To overcome this limitation the analyzer is designed with two physical measurement ranges: • LOW range to measure concentrations from 0 ppb to 50 ppb • HIGH range to measure the full 20,000 ppb range of the analyzer The analyzer’s CPU chooses the appropriate physical range, by adjusting the hardware gain on the preamp PCA, based on the configuration of the Max Concentration Range variable in the Setup>Vars menu (see Table 2-9). INTERFERENTS The chemiluminescence method for detecting NOX is subject to interference from a number of sources including water vapor (H2O), sulfur dioxide (SO2), and carbon dioxide (CO2); however, the analyzer has been designed to reject most of these interferents. • • Ammonia is the most common interferent, which is converted to NO and creates a NOx signal artifact. • If the analyzer is installed in an environment with high ammonia, steps should be taken to remove it from the sample gas before it enters the reaction cell. • Teledyne API offers a sample gas conditioning option (call Sales) to remove ammonia and water vapor. Carbon dioxide (CO2) diminishes the NOX signal when present in high concentrations. • If the analyzer is used in an application with excess CO2, contact Teledyne API's Technical Support Department (see Section 5.9) for possible solutions. For more detailed information regarding interferents for NOx, NO and NO2 measurement, see Section 6.1.5. 86 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 DATA RECORDING DEVICES A strip chart recorder, data acquisition system or digital data acquisition system should be used to record data from either the Ethernet, serial or analog outputs. • If analog readings are used, the response of the recording system should be checked against a NIST traceable voltage source or meter. • Data recording devices should be capable of bi-polar operation so that negative readings can be recorded. For electronic data recording, the analyzers provide an internal data logger, which is configured through the Setup>Data Logger menu (Section 2.5.1). NumaView™ Remote is a remote control program, which is also available as a convenient and powerful tool for data viewing and handling, download, storage, quick check and plotting. NO2 CONVERSION EFFICIENCY (CE) The efficiency at which the NO2-to-NO converter changes NO2 into NO directly affects the accuracy of the instrument’s NOx, NO and NO2 measurements. The firmware includes a Converter Efficiency (CE) gain factor that is multiplied by the NO2 and NOX measurements to calculate the final concentrations for each. This gain factor is stored in the analyzer’s memory. The default setting for the NO2 converter efficiency is 1.0000. Over time, the molybdenum in the converter oxidizes and it becomes less efficient at converting NO2 into NO. To ensure accurate performance of the analyzer, it is important to check the NO2 conversion efficiency (CE) periodically as presented in Section 4.5. CALIBRATION PROCEDURES Check that the pneumatic connections for the specific instrument configuration are as instructed in Section 2.3.2. Calibration procedures include setting the expected span gas concentration (see Note below). Verify/change (if needed) the settings in the Setup>Vars menu as follows: • User Units (unit of Measure): PPB • Max Concentration Range (highest concentration expected to measure) • Range Mode: SNGL Then perform the calibration: • Perform a Zero calibration using zero air. • Perform a span calibration on both the NO & NOx channels using a known concentration of NO span gas. • Perform the two-point Converter Efficiency (CEA and CEB) calibration using a known concentration of NO2 span gas. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 87 Note Tips for Setting the Expected Span Gas Concentration: • The expected concentrations for both NO and NOx are usually set to the same value. • When setting expected concentration values, consider impurities in your span gas source (e.g. NO often contains 13% NO2 and vice versa). • The NO and NOx span gas concentrations should be 80% to 90% of range of concentration values likely to be encountered in your application. To calibrate or to perform a calibration check for basic configuration instruments, see Section 4.2.1. To calibrate or to perform a calibration check for instruments with valve options, see Section 4.2.2. To perform a calibration check for instruments with the internal span gas generator, see Section 4.3. To calibrate Conversion Efficiency, see Section 4.5. CALIBRATION AND CHECK PROCEDURES FOR BASIC CONFIGURATION Although this section uses the Calibration menu for both check and actual calibration, a check does not require the Calibration menu. Instead, while in Home page, simply flow the zero air or the span gas through the Sample port, and check the reading after the Stability falls below 1.0 PPB (either in the gas graph or in the Dashboard). Otherwise, follow the steps presented in Sections 4.2.1.1 and 4.2.1.2. Figure 4-1. Multi-Point Calibration Page 88 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ZERO CALIBRATION CHECK AND ACTUAL CALIBRATION Navigate to the Calibration>M-P menu. Input Zero air through the Sample port and press the Start button. Either check or calibrate as follows: CHECK ONLY: a. Wait for reading to stabilize. b. Press Stop and check the reading. ACTUAL CALIBRATION: a. Press the Zero button. b. Press Stop and check the reading. SPAN CALIBRATION CHECK AND ACTUAL CALIBRATION 1. While still in the Calibration>M-P menu, input NO Span gas through the Sample port and press the Start button. 2. Either check or calibrate as follows: CHECK ONLY: a. Wait to reach stability, then press Stop. b. Record the reading(s). ACTUAL CALIBRATION: a. Press the Set Span Target button and enter the NO and NOx concentrations. b. Verify the concentration reading is the same as the NO concentration being supplied. c. If correct, wait to reach stability, then press the Span button. d. In the Cal Result window, press OK. 3. Press the Stop button and return to Home screen. 4. In the Dashboard, check and record the Slope(s) and the Offset(s). (See Table 4-4 in Section 4.4, Calibration Quality Analysis, for expected/acceptable values). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 89 CALIBRATION AND CHECK PROCEDURES WITH VALVE OPTIONS INSTALLED Figure 4-2. Zero and Span Calibration Screens Follow the instructions in Section 4.2.1, except instead of the M-P menu, go to the Calibration>Zero menu for Zero cal and to the Calibration>Span menu for NO Span cal. 90 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 USE OF ZERO/SPAN VALVE WITH REMOTE CONTACT CLOSURE Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN connector. Instructions for setup and use of these contacts are in Section 2.3.1.5. When the contacts are closed for at least 5 seconds, the instrument switches into zero, low span or high span mode and the internal zero/span valves will be automatically switched to the appropriate configuration. • The remote calibration contact closures may be activated in any order. • It is recommended that contact closures remain closed for at least 10 minutes to establish a reliable reading. • The instrument will stay in the selected mode for as long as the contacts remain closed. If contact closures are being used in conjunction with the analyzer’s AutoCal (see Section 4.3) feature and the AutoCal attribute “Calibrate” is enabled (selection box is checked), the analyzer will not recalibrate the analyzer UNTIL the contact is opened. At this point, the new calibration values will be recorded before the instrument returns to SAMPLE mode. If the AutoCal attribute “Calibrate” is disabled (selection box is unchecked), the instrument will return to SAMPLE mode, leaving the instrument’s internal calibration variables unchanged. CALIBRATION AND CHECK PROCEDURES WITH O2 SENSOR OPTION INSTALLED Connections for calibration are illustrated in Figure 2-17. Figure 4-3. O2 Sensor Calibration Screens See Figure 2-17 in Section 2.3.2.4 for connections setup. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 91 O2 ZERO CALIBRATION To check or calibrate the zero point of the O2 sensor option: 1. While in the Calibration>O2 menu, input Zero gas (pure N2) through the Sample port, then press the Start button. 2. Either check or calibrate as follows: CHECK ONLY: a. Wait to reach stability (below 0.1%), then press Stop. b. Record the reading(s). ACTUAL CALIBRATION: a. Press the Zero button. b. A window will pop-up with a message that the Zero function is complete. c. Press OK. 3. Press the Stop button and either return to Home screen or continue with O2 Span Calibration next. O2 SPAN CALIBRATION 1. While in the Calibration>O2 menu, input Span gas (21% O2 in N2) through the Sample port, then press the Start button. 2. Either check or calibrate as follows: CHECK ONLY: c. Wait to reach stability, then press Stop. d. Record the reading(s). d. e. f. g. ACTUAL CALIBRATION: Press the Set Span Target button and enter the O2 concentration (default is 21%). Verify the concentration reading is the same as the O2 concentration being supplied. If correct, wait to reach stability (below 0.1%), then press the Span button. In the Cal Result window, press OK. 3. Press the Stop button and return to Home screen. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTO CAL) The Auto Cal feature allows unattended periodic operation of the ZERO/SPAN valve options by using the instrument’s internal time of day clock. Auto Cal operates by executing preprogrammed calibrations or calibration checks set up by the user to initiate the various calibration states of the analyzer and to open and close valves appropriately. It is possible to set up and run up to three separate preprogrammed calibrations or calibration checks (labeled # 1, 2 and 3). Each calibration or check can operate in one of three modes (Zero, Low or High), or be disabled. Table 4-1 and Table 4-2 show how to set up the operating states of each calibration or check, and Table 4-3 shows how to program the execution of each. 92 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 4-4. Auto Cal Page Table 4-1. AUTO CAL States MODE NAME Enabled Calibrate ACTION enables the sequence; disables the sequence. enables an actual calibration when the Enabled box is also allows a calibration check when the Enabled box is also . . causes the sequence to perform a Zero calibration when both the Calibrate and Enabled boxes are also . Zero causes a Zero check when the Enabled box is also Calibrate box is unchecked ( and the ). disables Zero calibration and check causes the sequence to perform a Low Span calibration when both the Calibrate and Enabled boxes are also . Low causes a Low Span check when the Enabled box is also the Calibrate box is unchecked ( and ). disables Low Span calibration and check High causes the sequence to perform a High Span concentration calibration when both the Calibrate and Enabled boxes are also . causes a High Span check when the Enabled box is also the Calibrate box is unchecked ( and ). disables the High Span calibration and check. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 93 Table 4-2 shows how the selection boxes would be enabled/disabled for calibration checks and calibrations. Table 4-2. Auto Cal Setup Combinations MODE ACTION STATE Enabled Zero Low High Zero Low High Calibrate Zero Low High Check Calibrate Check Calibrate Check Calibrate Check Calibrate For each sequence, there are four parameters that control operational details: Date, Time (both in the Start field), Interval, and Duration, as presented in Table 4-3. Table 4-3. Auto Cal Programming Sequence Execution ATTRIBUTE 94 ACTION Start When the Enabled box is “on” , the Sequence (identified by its number) begins on the date and time shown in the configurable Start field. (Click the field for the pop-up window and toggle between the Time (Hour/Minutes) and the Date (Year/Month/Day) attributes to edit as needed). Interval Number of minutes to skip between each Sequence execution. (Click the field to input the number of minutes in the pop-up window). Duration Number of minutes that each Sequence execution is to run. (Click the field to input the number of minutes in the pop-up window). Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Important IMPACT ON READINGS OR DATA • The programmed STARTING_TIME must be a minimum of 5 minutes later than the real time clock for setting real time clock (Setup>Instrument, Section 2.5.9). • Avoid setting two or more sequences at the same time of the day. • Any new sequence that is initiated whether from a timer, the COM ports or the contact closure inputs will override any sequence that is in progress. • It is recommended that calibrations be performed using external sources of Zero Air and Span Gas whose accuracy is traceable to EPA standards. CALIBRATION QUALITY ANALYSIS It is important to evaluate the analyzer’s calibration SLOPE and OFFSET parameters. These values describe the linear response curve of the analyzer, separately for NO and NOX. The values for these terms, both individually and relative to each other, indicate the quality of the calibration. Set up the Data Logger with a Periodic trigger to record the values of the following parameters (see Section 2.5.1). NO Norm Offset NO Slope NOx Norm Offset NOx Slope Ensure that these parameters are within the limits listed in Table 4-4 and frequently compare them to those values on the Final Test and Validation Data Sheet that came with your instrument, which should not be significantly different. Otherwise, refer to the troubleshooting Section 5.7.7. Table 4-4. Calibration Data Quality Evaluation FUNCTION MINIMUM VALUE OPTIMUM VALUE MAXIMUM VALUE NO SLOPE 0.700 1.000 1.300 NOx SLOPE 0.700 1.000 1.300 NO Norm Offset -20.0 mV 0.0 mV 150.0 mV NOx Norm Offset -20.0 mV 0.0 mV 150.0 mV 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 95 CONVERSION EFFICIENCY (CE) CHECK This section describes how to determine the NO2 à NO converter’s efficiency using a GPT method where the actual concentration of ozone is not a factor in the accuracy of the calculation. • This procedure is based on the Code of Federal Regulations, Title 40, Chapter I, subchapter C, Part 50, Appendix F. • In the following example a reference point of 450 ppb NO gas will be used. This is only an example. Any other reference points within measurement range of the instrument may be used. • For this procedure use a calibrated O3 generator, such as a Teledyne API's T700. Note There must be a minimum of 10% more NO than O3 produced. Example, if the O3 concentration used is 400 ppb, then the NO concentration used must be 440 ppb or more. PART 1: PREPARATION 1. Leak check machine to ensure that there are no leaks in the analyzer. 2. Calibrate the instrument at the same NO span gas value as being used in this method. • For this example we use 450 ppb NO span gas PART 2: DETERMINE THE AMOUNT OF NO OUTGASSED BY THE NO2 à NO CONVERTER. 3. Bypass the NO2 à NO converter by placing a short piece of tubing in the gas stream in place of the converter. 4. Perform a straight dilution with 450 ppb NO gas & air as a diluent gas. 5. Input the NO gas into the analyzer. 6. Allow the machine to stabilize & write down the NOx value on line 2 of GPT data sheet (Section 4.5.1.1). 7. Remove the converter bypass so that the NO gas is flowing through the NO2 à NO converter 8. Allow the machine to stabilize. 9. Write down your NOx value on your data sheet on lines 3 AND line 5 of the GPT data sheet. 10. Subtract line 2 from line 3 & write that number down on line 4. Also write the NO value on line 8 of the data sheet. • The specification shown on the data sheet is the value that is used by Teledyne API when performing the procedure on new NO2 à NO converters. • Older NO2 à NO converters might outgas a bit more NO, therefore a slightly wider specification might be in order. • If this value is a constant or changes only slightly over time, this is not a problem the machine will calibrate this out. PART 3: PERFORM THE SIMPLIFIED GPT CALCULATION. 11. Generate the same 450 ppb NO gas & input 400 ppb of O3 (or generate 450 ppb NO & 400 ppb NO2, if that’s what your calibrator says). 12. Allow the instrument to stabilize for 10 minutes. 96 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 13. Write down the NOx value on line 6 & the NO value on line 9. 14. Subtract line 6 from line 5 & put that onto line 7. 15. Subtract line 8 from line 7 & put that onto line 10. 16. Write the number from line 7 into the blank next to letter A on line 11 & put the number from line 10 into the blank next to letter B on line 11. 17. Divide A by B & multiply it by 100. 18. Write this value it into the blank next to letter C on lines 11 and 12. 19. Subtract that value from 100 & write it in the blank next to the letter D on line 12. 20. This is the converter efficiency. • This value should be >96%. SIMPLIFIED GPT DATA SHEET Line # TEST RESULT 1 LEAK-CHECK (WHEN HOT) YES / NO 2 NOx RESPONSE (MOLY BYPASSED) __________ 3 NOx RESPONSE (MOLY IN-LINE) __________ 4 OUT-GASSING (NO – NOX) __________ (>-5 ppb, <5 ppb) 5 (NOx ORIG) (NOx mode, O3 off) __________ ppb 6 (NOx REM) (NOx mode, O3 on) __________ ppb 7 NOx LOSS 8 (NO ORIG) (NO mode, O3 off) __________ ppb 9 (NO REM) (NO mode, O3 on) __________ ppb __________ (A) (<4% of NOx ORIG:for 450PP 4% is 18 ppb) __________ (B) (>300ppb) 10 NO2 11 Efficiency LOSS [ ( A / B ) x 100 ] = [ ( ____A / ____B ) x 100 ] = 12 Total Conv Eff [ 100% – C 083730210A DCN8164 ____C% ] = 100% - ____C = _____D% ( > 96%) Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 97 5. MAINTENANCE AND SERVICE Section 5.1 includes a typical maintenance schedule for the instrument. Service and troubleshooting are covered in Section 5.7. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Avoid spraying anything directly onto any part of the analyzer. MAINTENANCE SCHEDULE The actual frequency of performing the maintenance procedures (Table 5-1) can vary depending on the operating environment. Additionally, in some cases, there are local regulations or standards that also need to be considered. In certain environments (e.g., dusty, very high ambient pollutant levels) some maintenance procedures may need to be performed more often than shown. WARNING – ELECTRICAL SHOCK HAZARD Disconnect power before performing any of the following operations that require entry into the interior of the analyzer. As a CE Mark safety requirement, always ensure that the front panel locking screw, located on the right side of the front panel, is securely in place before operating the analyzer. CAUTION – QUALIFIED PERSONNEL These maintenance procedures must be performed by qualified technicians only. Important IMPACT ON READINGS OR DATA A span and zero calibration check (see CAL CHECK column of Table 5-1) must be performed following some of the maintenance procedures listed herein. To perform a CHECK of the instrument’s Zero or Span Calibration, refer to Sections 4.2.1.1 and 4.2.1.2, respectively. DO NOT press the Zero or Span buttons at the end of each operation (actual calibration), as this will reset the stored values for OFFSET and SLOPE and alter the instrument’s calibration. Alternatively, use the Auto Cal feature described in Section 4.3 with the CALIBRATE attribute set to OFF (not enabled). 98 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Table 5-1. Maintenance Schedule ITEM ACTION Dashboard functions Particulate filter Review and evaluate Change Zero/span check Zero/span calibration Evaluate offset and slope Zero and span calibration External zero air scrubber option FREQ CAL CHECK REQ’D Weekly No Monthly or as necessary Weekly No Every 3 months Yes Exchange chemical Every 3 months No External dryer option Replace chemical When indicator color changes No Software/ Firmware Check for updates Every 6 months or whenever serviced Yes Ozone cleanser (T200H) Change chemical Annually Yes Reaction cell window Clean optics, change o-rings Annually or as necessary Yes Air Inlet Filter Of Permeation Dryer Change particle filter Annually (or as needed for highly polluted sample air) No Pneumatic subsystem Check for leaks in gas flow paths Annually or after repairs involving pneumatics All critical flow orifice O-rings & sintered filters Replace Annually Yes PMT Sensor Hardware Calibration Low-level hardware calibration When PMT/ preamp changes or if slope is outside of 1.0±0.3 Yes 1 Pump Rebuild head Annually Yes Inline Exhaust Scrubber Replace Annually No NO2 converter Replace converter & check efficiency Every 3 years or if conversion efficiency drops below 96% Yes Desiccant bags Replace Any time PMT housing is opened for maintenance n/a DATE PERFORMED No Yes if a leak is repaired 1 A pump rebuild kit is available from Teledyne API Technical Support including all instructions and required parts (the pump part number is on the label of the pump itself). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 99 PREDICTIVE DIAGNOSTICS Predictive diagnostic functions, including failure warnings and alarms built into the analyzer’s firmware, aid in determining whether and when repairs are necessary. Dashboard Functions can also be used to predict failures by looking at how their values change over time, compared to the values recorded on the printed record of the Final Test and Validation Data Sheet. The internal data logger is a convenient way to record and track these changes (set up through the Data Logger, Section 2.5.1). Use NumaView™ Remote to download and review this data from a remote location. The following table, checked weekly, can be used as a basis for taking action as these values change with time. Table 5-2. Predictive Uses for Dashboard Functions FUNCTION EXPECTED ACTUAL Rx Cell Press (pressure) Constant to within ± 0.5 inHg-A Fluctuating Sample Press (pressure) Constant within atmospheric changes O3 Flow Constant to within ± 15 Auto Zero Constant within ±20 of checkout value NO2 Conc (Concentration) Constant for constant concentrations NO2 Conc with IZS Option installed (Concentration) Constant response from day to day NO Conc (Concentration) Constant for constant concentration Slowly increasing Fluctuating INTERPRETATION & ACTION Developing leak in pneumatic system. Check for leaks. Pump performance is degrading. Rebuild pump when pressure is above 10 in-Hg-A. Developing leak in pneumatic system. Check for leaks. Slowly increasing Flow path is clogging up. Replace orifice filters. Slowly decreasing Developing leak in pneumatic system to vacuum (developing valve failure). Check for leaks. Slowly decreasing Flow path is clogging up. Replace orifice filters. Developing AUTO ZERO valve failure. Replace valve. Significantly increasing PMT cooler failure. Check cooler, circuit, and power supplies. Developing light leak. O3 air filter cartridge is exhausted. Change chemical. 100 Slowly decreasing signal for same concentration Converter efficiency may be degrading. Clean or replace converter components. Decreasing over time Change in instrument response. Low level (hardware): calibrate the sensor. Degradation of IZS permeation tube. Change permeation tube. Heavily fluctuating day to day Ambient changes in moisture are affecting the performance. Add a dryer to the zero air inlet.. Decreasing over time Drift of instrument response; clean RCEL window. Check for flow leaks or irregularities. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 OPERATIONAL HEALTH CHECKS Navigate to the Utilities>USB Utilities>Report menu (Figure 5-1) to download a report on the basic operations of the instrument. To download the report for your own viewing on a computer or to send to others, insert a flash drive into a front panel USB port and press the Download button, which is enabled when the instrument detects the flash drive. Figure 5-1: Report Generation Page The report can also be set to generate periodically and sent to a Web services “cloud” where it is available for viewing by Teledyne API technical support personnel. Set this function with two Vars: Setup>Vars>Upload Report to Cloud: set to True. Setup>Vars>Report Upload>Interval: edit the number of hours between report uploads. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 101 SOFTWARE/FIRMWARE UPDATES There are two ways to check for and acquire updates: either remotely or manually. REMOTE UPDATES The instrument must be connected to a network that is connected to the Internet. In the Setup>Instrument menu, select the Remote Update menu and press the Check for Updates button. If an update is available, it can be downloaded through this page. Figure 5-2. Remote Update Page MANUAL RELOAD/UPDATE PROCEDURES To reload or update firmware, first contact Technical Support to obtain the applicable file(s): [email protected] /+1 800-324-5190. 1. Follow Technical Support’s instructions for copying the firmware files to a flash drive. 2. Go to the Utilities>USB Utilities>General menu. Figure 5-3. Manual Update Page (and other utilities) 3. Insert a flash drive into a front panel USB port and wait for the Status field to indicate that the drive has been detected. 102 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 4. In the Update Firmware field, press the Check button for the instrument to determine whether the firmware on the flash drive is more recent than what is currently installed. Once it’s been determined that the firmware is new, the Install button will be enabled; if the firmware version on the flash drive is the same as or older than the current firmware of the instrument, the Install button will not be enabled. 5. Press the Install button, and note the messages in the Status field at the bottom of the page. Use the Cancel button if necessary. 6. When complete, as indicated in the Status field, press the Done button, which replaces the Cancel button, and remove the flash drive. 7. Power off and restart the instrument to complete the new firmware installation. INSTRUMENT DISPLAY CALIBRATION (FOR EARLIER INSTRUMENTS) This section applies to instruments shipped before January 2017. Although unlikely, if ever the touchscreen appears unresponsive or responds incorrectly, the screen can be calibrated via the Setup>Instrument>Display Settings menu. Figure 5-4. Touchscreen Calibration Page 1. Connect a mouse to either of the front panel USB ports. 2. Navigate with the pointer to Setup>Instrument>Display Settings. 3. Click on “Calibrate Touch” and a crosshair appears in the center of the display screen. 4. Note that a timer function is enabled, allowing only 15 seconds to start the calibration process. If the timer expires, the instrument will exit the calibration screen and return to normal operation. 5. Click the very center of the crosshair. 6. When a new crosshair appears in the upper left corner of the screen, carefully and accurately click and hold the very center of that crosshair until it finishes shrinking, then release. 7. Repeat Step 6 for each of the corners. 8. Once the process is completed, a CANCEL and an ACCEPT button appear in the lower left corner: Test the accuracy of the calibration by touching parts of the screen and see that the mouse pointer follows your touches. 9. If you press the CANCEL button, the calibration won’t be altered. Otherwise, press the ACCEPT button. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 103 TIME ZONE CHANGES There is an option to change between 12-hour and 24-hour format in the Setup>Vars menu (System Time Format). Effectively changing the Time Zone requires a specific procedure as follows: 1. In Setup>Instrument>Date/Time Settings select the applicable Time Zone. 2. Allow adequate time for the selected Time Zone to be properly accepted. 3. Verify: return to Home page then back to the Date/Time Settings page, and check that the selected Time Zone is now highlighted. 4. Without making any other changes, power OFF the instrument and power ON again. 5. Once restarted, return to the Date/Time Settings page where the newly selected Time Zone should be highlighted. (If not, it means that not enough time had passed for the instrument to accept the change before the power was cycled OFF). 6. After the Time Zone is implemented first (Steps 1 through 5), then other changes to the date and/or time can be made, and recycling the power is not necessary. Figure 5-5. Time Zone Change Requirements 104 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 HARDWARE MAINTENANCE PROCEDURES Perform the following procedures as standard maintenance per Table 5-1. REPLACING THE SAMPLE PARTICULATE FILTER Inspect the particulate filter often for signs of plugging or contamination. To avoid contamination of the sample filter assembly use only gloves or PTFE-coated tweezers (or similar protective items) to handle any part of the housing, filter element, PTFE retaining ring, glass cover and the o-ring – do not use bare hands. To change the filter: 1. Turn OFF the analyzer to prevent drawing debris into the instrument. 2. To open the hinged front panel, remove the CE Mark locking screw located on the right side of the front panel (this must be secured back in place before operating the analyzer). 3. Unscrew the retaining ring on the filter assembly. RETAINING RING PTFE O-RING HOLDER Figure 5-6. Replacing the Particulate Filter 4. Carefully remove the retaining ring, PTFE o-ring, glass window and filter element. 5. Replace the filter, being careful that the element is fully seated and centered in the bottom of the holder. 6. Reinstall the PTFE o-ring with the notches up; the glass window, then screw on the retaining ring and hand tighten. Inspect the seal between the edge of filter and the o-ring to assure a proper gas tightness. 7. Close the panel, reinstall the locking screw on the right side of the front panel (a requirement to fulfill CE Mark safety compliance) and restart the analyzer. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 105 CHANGING THE O3 DRYER PARTICULATE FILTER The air for the O3 generator passes through a dryer equipped with a small particulate filter at its inlet, which prevents dust from entering the ozone dryer and degrading the dryer’s performance over time. Change the filter as follows: 1. Before starting the procedure, check and record the average Rx Cell Press and the O3 Flow values in the Dashboard. (If not visible, see Section 2.5.3 to configure). 2. Turn off the analyzer, unplug the power cord and remove the cover. 3. Unscrew the nut around the port of the filter using two 5/8” wrenches. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Ensure to use proper wrenches. Hold the main dryer fitting with a 5/8” wrench to ensure that it does not turn against the dryer. Performing this procedure improperly or with incorrect tools creates the risk of causing a significant leak. 4. Take off the old filter element and replace it with a suitable equivalent (Teledyne API P/N FL-3). Figure 5-7. Particle Filter on O3 Supply Air Dryer 5. Hold the main dryer fitting steady with a 5/8” wrench and tighten the nut with your hands. 6. If necessary use a second wrench but do not over-tighten the nut. 7. Replace the cover, plug in the power cord and restart the analyzer. 8. Check the O3 flow (O3 Flow) rate; it should be around 80 cc/min ± 15. 9. Check the Rx Cell Press; it should be the same value as before. 10. Refer to Section 5.6.9 to perform a leak check after installing the new DFU particle filter. 106 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MAINTAINING THE EXTERNAL SAMPLE PUMP (PUMP PACK) REBUILDING THE PUMP The sample pump head periodically wears out and must be replaced when the reaction cell pressure (Rx Cell Press) exceeds 10 in-Hg-A (at sea level; adjust this value accordingly for elevated locations). • A pump rebuild kit is available from the factory. Refer to the label on the pump for the part number. Instructions and diagrams are included in the kit. • A flow and leak check after rebuilding the sample pump is recommended. • A span check and re-calibration after this procedure is necessary as the response of the analyzer changes with the Rx Cell Press. REPLACING THE INLINE EXHAUST SCRUBBER CAUTION! Do NOT attempt to change the contents of the inline exhaust scrubber cartridge; change the entire cartridge. Through the Utilities>Diagnostics menu turn OFF the O3 Gen Override. Wait 10 minutes to allow pump to pull room air through scrubber before proceeding to the next step. Disconnect exhaust line from analyzer. Turn off (unplug) analyzer sample pump. Disconnect tubing from (NOx or charcoal) scrubber cartridge. Remove scrubber from system. Dispose of according to local laws. Install new scrubber into system. Reconnect tubing to scrubber and analyzer. Turn on pump. Through the Utilities>Diagnostics menu (per Step 1 above) turn ON the O3 Gen Override. Note 083730210A DCN8164 The inline exhaust scrubber is strictly intended for Nitric Acid and NO2 only. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 107 CHANGING THE EXTERNAL ZERO AIR SCRUBBER OPTION (T200H) The external zero air scrubber that is included with the T200H’s optional ambient zero/pressurized span calibration valve contains two chemicals: • Pink Purafil© (P/N CH 9) that converts NO in the ambient air to NO2, and; • Black, charcoal (P/N CH 1) that absorbs the NO2 thereby creating zero air. These chemicals need to be replaced periodically (see Table 5-1) or as needed. CAUTION! The following procedures apply only to the External Zero Air Scrubber and NOT to the inline exhaust scrubber cartridge that is part of the pump pack assembly. Important IMPACT ON READINGS OR DATA This procedure can be carried out while the instrument is running, however ensure that the analyzer is not in ZERO calibration mode. 1. Locate the scrubber on the outside rear panel; Figure 5-8 shows the exploded assembly. 2. Remove the old scrubber by disconnecting the 1/4” plastic tubing from the DFU particle filter using 9/16” and 1/2" wrenches. 3. Remove the DFU particle filter from the cartridge using 9/16” wrenches. 4. Unscrew the top of the scrubber canister and discard the Purafil© and charcoal contents. • Ensure to abide by local laws about discarding these chemicals. • The rebuild kit comes with a Material and Safety Data Sheet, which contains more information on these chemicals. 5. It is not necessary to remove the insert from the barrel, but if removed, perform the following procedure: • Coat the threads of the insert with epoxy (Teledyne API P/N CH32). • Hand tighten the insert to the barrel. 6. It is not necessary to remove the nylon tube fitting from the insert, but if removed, apply Teflon tape (Teledyne API P/N HW36) to the threads of the nylon tube fitting before installing on the insert. 7. Refill the scrubber with charcoal at the bottom and the Purafil© chemical at the top. • Use three, white retainer pads to separate the chemicals as shown in Figure 5-8. 8. Replace the screw-top cap and tighten the cap; hand-tighten only. 108 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 9. If necessary, replace the filter (DFU, Figure 5-8) with a new unit and discard the old. (The bottom retainer pad should catch most of the dust; the filter should not be visibly dirty on the inside). • Disconnect the tube and fitting from one end and remove the filter from the scrubber canister. • Insert a new filter, ensuring that the small arrow embedded on the filter points in flow direction, i.e., to analyzer. 10. Replace the scrubber assembly into its clips on the rear panel. 11. Reconnect the plastic tubing to the fitting of the DFU particle filter. 12. Adjust the scrubber cartridge such that it does not protrude above or below the analyzer in case the instrument is mounted in a rack. • If necessary, squeeze the clips for a tighter grip on the cartridge. Figure 5-8. Zero Air Scrubber Assembly 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 109 CHANGING OR CLEANING THE NO2 CONVERTER The NO2 converter is located in the center of the instrument, see Figure 2-3 for the location and Figure 5-9 for the assembly. The converter is designed for replacement of the cartridge only; the heater with built-in thermocouple is to be reused. CAUTION! PERSONAL SAFETY HAZARD Wear gloves prior to changing the NO2 Converter to ensure that the fiberglass insulation does not come into contact with your skin. Power OFF the instrument. Remove the instrument cover and allow the converter to cool. Remove the converter assembly cover as well as the Moly insulation (top layer and corner cut out layers) until the Moly converter assembly can be seen. CAUTION! HOT SURFACE HAZARD The converter operates at 315º C. Severe burns can result if the assembly is not allowed to cool. Do not handle the assembly until it is at room temperature. This may take several hours. Remove the tube fittings from the Moly converter assembly. Disconnect the power and the thermocouple from the Moly converter assembly. Unscrew the steel cable clamp (for the power leads) from the converter housing with a Phillips-head screw driver. Remove the Moly converter assembly (converter cartridge and band heater) from the converter housing. • Make a note of the orientation of the tubes relative to the heater cartridge. Unscrew the band heater and loosen it. Remove the old converter cartridge. 110 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 5-9. NO2 Converter Assembly Wrap the band heater around the new replacement converter cartridge and tighten the screws using a high-temperature anti-seize agent (Teledyne API P/N CH42) such as copper paste. o Ensure to use proper alignment of the heater with respect to the converter tubes. Replace the Moly converter assembly by routing the cables through the holes in the converter housing and reconnecting them properly. Reconnect the steel cable clamp around the power leads for safe operation. Reattach the tube fittings to the converter and replace the Moly insulation (top layer and corner cut out layers). Reinstall the converter assembly cover. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 111 Reinstall the instrument cover and power up the analyzer. Allow the converter to burn-in for 24 hours, and then recalibrate the instrument. CLEANING THE REACTION CELL A dirty reaction cell will cause excessive noise, drifting zero or span values, low response or a combination of all. To clean the reaction cell, it is necessary to remove it from the sensor housing. Refer to Figure 5-10 for the following procedure. 1. Turn off the instrument power and vacuum pump. 2. Disconnect the black 1/4" exhaust tube and the 1/8” sample and ozone air tubes from the reaction cell. Disconnect the heater/thermistor cable. 3. Remove two screws (Teledyne API P/N SN144) and two washers holding the reaction cell to the PMT housing and lift the cell and manifold out. 112 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 5-10. Reaction Cell Assembly 4. Remove two screws (Teledyne API P/N SN150) and two washers. 5. The reaction cell will separate into two halves, the stainless steel manifold assembly and the black plastic reaction cell with window gasket, stainless steel reaction cell sleeve, optical filter and O-rings. 6. The reaction cell (both plastic part and stainless steel sleeve) and optical filter should be cleaned with Distilled Water (DI - Water) and an appropriate optical wipe and then dried. 7. Usually it is not necessary to clean the sample and ozone flow orifices since they are protected by sintered filters. • 083730210A DCN8164 If tests show that cleaning is necessary, refer to Section 5.6.7 on how to clean the critical flow orifice. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 113 8. Do not remove the sample and ozone nozzles. They are Teflon threaded and require a special tool for reassembly. If necessary, the manifold with nozzles attached can be cleaned in an ultrasonic bath. 9. Reassemble in proper order and re-attach the reaction cell to the sensor housing. Reconnect pneumatics and heater connections, then re-attach the pneumatic sensor assembly and the cleaning procedure is complete. 10. After cleaning, the analyzer span response may drop 10 - 15% in the first 10 days as the reaction cell window conditions. This is normal and does not require another cleaning. SERVICING CRITICAL FLOW ORIFICES There are several critical flow orifices installed in the analyzer (see Figure 6-7 for a pneumatic location of each orifice). Despite the fact that these flow restrictors are protected by sintered stainless steel filters, they can, on occasion, clog up, particularly if the instrument is operated without sample filter or in an environment with very fine, submicron particle-size dust. Figure 5-11. Critical Flow Orifice Assembly 114 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 To clean or replace a critical flow orifice: 1. Turn off power to the instrument and vacuum pump. 2. Remove the analyzer cover and locate the reaction cell assembly (refer to Figure 2-3 and Figure 5-10). 3. Unscrew the 1/8” sample and ozone air tubes from the reaction cell. For orifices on the reaction cell: 4. Unscrew the orifice holder with a 9/16” wrench. • This part holds all components of the critical flow assembly as shown in Figure 5-11. For orifices in the vacuum manifold: the assembly is similar to the one shown in Figure 5-11, except: • Without the orifice holder, P/N 04090, and bottom O-ring, P/N OR34 and; • With an NPT fitting in place of the FT 10 fitting. 5. After taking off the connecting tube, unscrew the NPT fitting. 6. Take out the components of the assembly: Note • spring • sintered filter • two O-rings • the orifice For the vacuum manifold only, you may need to use a scribe or pressure from the vacuum port to get the parts out of the manifold. 7. Discard the two O-rings and the sintered filter and install new ones. 8. Reassemble the parts as shown in Figure 5-11. 9. Reinstall the critical flow orifice assembly into the reaction cell manifold or the vacuum manifold. 10. Reconnect all tubing, power up the analyzer and pump. After a warm-up period of 30 minutes, carry out a leak test as described in Section 5.6.9. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 115 CHECKING FOR LIGHT LEAKS When re-assembled or operated improperly, the PMT assembly can develop small gaps, which let stray light from the analyzer surrounding into the PMT housing. To find such light leaks, follow the procedures below. CAUTION – QUALIFIED PERSONNEL ONLY This procedure is carried out with the analyzer running and its cover removed. 1. In the Dashboard view the PMT Signal (if not visible, configure the Dashboard to add; see Section 2.5.3). 2. Supply zero gas to the analyzer. 3. With the instrument still running, carefully remove the analyzer cover. WARNING – ELECTRICAL SHOCK HAZARD Do NOT touch any of the inside wiring with the metal cover or with your body. Do NOT drop screws or tools into a running analyzer. 4. Shine a powerful flashlight or portable incandescent light at the inlet and outlet fitting and at all of the joints of the reaction cell as well as around the PMT housing. • The PMT value should not respond to the light, the PMT signal should remain steady within its usual noise floor. 5. If there is a PMT response to the external light, symmetrically tighten the reaction cell mounting screws or replace the 1/4” vacuum tubing with new, black PTFE tubing (this tubing will fade with time and become transparent). Note Often, light leaks are also caused by O-rings being left out of the assembly. 6. If, during this procedure, the black PMT housing end plate for the Sensor Assembly is removed, ensure to replace the 5 desiccant bags inside the housing. 7. Carefully replace the analyzer cover. If tubing was changed, carry out a pneumatic leak check (Section 5.6.9). 116 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CHECKING FOR PNEUMATIC LEAKS This section covers a simple leak check and a detailed leak check. CAUTION - TECHNICAL INFORMATION Do not exceed 15 psi when pressurizing the system during either Simple or Detailed checks. SIMPLE VACUUM LEAK AND PUMP CHECK Leaks are the most common cause of analyzer malfunction. This section presents a simple leak check, whereas the next section details a more thorough procedure. The method described here is easy, fast and detects, but does not locate, most leaks. It also verifies the sample pump condition. 1. Turn the analyzer ON, and allow at least 30 minutes for flows to stabilize. 2. Cap the sample inlet port (cap must be wrench-tight). 3. After several minutes, when the pressures have stabilized, note the Sample Press (sample pressure) and the Rx Cell Press (vacuum pressure) readings. • If both readings are equal to within 10% and less than 10 in-Hg-A, the instrument is free of large leaks. • It is still possible that the instrument has minor leaks. • If both readings are < 10 in-Hg-A, the pump is in good condition. • A new pump will create a pressure reading of about 4 in-Hg-A (at sea level). 4. When done switch off the pump and open the cap to the sample inlet port slowly to minimize inrush flow. DETAILED PRESSURE LEAK CHECK If a leak cannot be located by the above procedure, obtain a leak checker that contains a small pump, shut-off valve, and pressure gauge to create both over-pressure and vacuum. Alternatively, a tank of pressurized gas, with the two-stage regulator adjusted to ≤ 15 psi, a shutoff valve and a pressure gauge may be used. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Once tube fittings have been wetted with soap solution under a pressurized system, do not apply or reapply vacuum as this will cause soap solution to be sucked into the instrument, contaminating inside surfaces. 1. Turn OFF power to the instrument and remove the instrument cover. 2. Install a leak checker or a tank of gas (compressed, oil-free air or nitrogen) as described above on the sample inlet at the rear panel. 3. Disconnect the pump tubing on the outside rear panel and cap the pump port. 083730210A DCN8164 • If IZS or zero/span valves are installed, disconnect the tubing from the zero and span gas ports and plug the ports. • Cap the DFU particle filter on the dryer. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 117 4. Pressurize the instrument with the leak checker or tank gas, allowing enough time to fully pressurize the instrument through the critical flow orifice. • Check each tube connection (fittings, hose clamps) with soap bubble solution, looking for fine bubbles. • Once the fittings have been wetted with soap solution, do not reapply vacuum as it will draw soap solution into the instrument and contaminate it. • Do not exceed 15 psi pressure. 5. If the instrument has the zero and span valve option, the normally closed ports on each valve should also be separately checked. • Connect the leak checker to the normally closed ports and check with soap bubble solution. 6. If the analyzer is equipped with an IZS Option, connect the leak checker to the Dry Air inlet and check with soap bubble solution. 7. Once the leak has been located and repaired, the leak-down rate of the indicated pressure should be less than 1 in-Hg-A (0.4 psi) in 5 minutes after the pressure is turned off. 8. Clean surfaces from soap solution, reconnect the sample and pump lines and replace the instrument cover. 9. Restart the analyzer. PERFORMING FLOW CHECKS/CALIBRATIONS Important IMPACT ON READINGS OR DATA Use a separate, calibrated flow meter capable of measuring the flow specifications for the instrument being checked/calibrated in order to get accurate measurements. Do not use the built in flow measurement viewable in the Dashboard. This value is only calculated, not measured. The rates of sample gas flow and O3 flow through the analyzer are a key part of the NOx, NO and NO2 concentration readings, but the readings are only calculated values derived by the CPU. The Flow Cal and Ozone Flow Cal features under the Utilities>Diagnostics menu are used to check and to calibrate/adjust these calculations. Such checks are useful for monitoring the actual flow of the instrument, using an external volumetric flow meter. A decreasing, actual sample flow may point to slowly clogging pneumatic paths, most likely critical flow orifices or sintered filters (Section 5.6.7). 118 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 FLOW CHECK Low flows indicate blockage somewhere in the pneumatic pathway. To check the Sample flow with the external flow meter: 1. Disconnect the sample inlet tubing from the rear panel SAMPLE port. 2. Attach the outlet port of a suitable flow meter to the rear panel SAMPLE port. • Ensure that the inlet to the flow meter is at atmospheric pressure. 3. The sample flow measured with the external flow meter should be within ± 10% of the analyzer’s Flow specification (Table 1-1). • If a combined sample/ozone air dryer is installed (optional equipment), the flow will be an additional 80 cc/min for the ozone generator supply air and 60 cc/min for the purge flow). To check the Ozone flow with the external flow meter: 1. Open the analyzer to gain access to the reaction cell. 2. Disconnect the tube going to the reaction cell’s 4 mil fitting. 3. Connect the flow meter to the reaction cell’s 4 mil fitting. 4. The ozone flow measured with the external flow meter should be 80 cc/min. FLOW CALIBRATION To calibrate the Sample flow (Flow Cal) or the O3 flow (Ozone Flow Cal): 1. In the Utilities>Diagnostics>Flow Cal or Ozone Flow Cal menu (Figure 5-12), edit the Actual Flow value by inputting the reading from the external flow meter obtained in the corresponding check of the flow to be calibrated. 2. Press the Calibrate button. Figure 5-12. Flow Calibration Menu 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 119 SERVICE AND TROUBLESHOOTING This section contains methods to identify the source of performance problems with the analyzer and procedures to service the instrument. Section 6, Principles of Operation, provides information about how the instrument works, to support your understanding of the technical details of maintenance. Note CAUTION The operations outlined in this section must be performed by qualified maintenance personnel only. WARNING – RISK OF ELECTRICAL SHOCK Some operations need to be carried out with the analyzer open and running. Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to the analyzer. Do not drop tools into the analyzer or leave them after your procedures. Do not short or touch electric connections with metallic tools while operating inside the analyzer. Use common sense when operating inside a running analyzer. The analyzer has been designed so that problems can be rapidly detected, evaluated and repaired. During operation, it continuously performs diagnostic tests and provides the ability to evaluate its key operating parameters without disturbing monitoring operations. A systematic approach to troubleshooting will generally consist of the following five steps: 1. Note any Alerts and take corrective action as necessary (see Table 5-3). 2. Examine the values of all basic functions in the Dashboard and compare them to factory values. Note any major deviations from the factory values and take corrective action. 3. Use the internal electronic status LEDs to determine whether the electronic communication channels are operating properly. 120 • Verify that the DC power supplies are operating properly by checking the voltage test points on the relay PCA. • Note that the analyzer’s DC power wiring is color-coded and these colors match the color of the corresponding test points on the relay PCA. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 4. Suspect a leak first! • Customer service data indicate that the majority of all problems are eventually traced to leaks in the internal pneumatics of the analyzer or the diluent gas and source gases delivery systems. • Check for gas flow problems such as clogged or blocked internal/external gas lines, damaged seals, punctured gas lines, damaged / malfunctioning pumps, etc. 5. Follow the procedures defined in Section 2.3.4.3 to confirm that the analyzer’s vital functions are working (power supplies, CPU, relay PCA, touchscreen, PMT cooler, etc.). FAULT DIAGNOSIS WITH ALERTS Table 5-3 lists brief descriptions of warning Alerts that may occur during start up and describes their possible causes for diagnosis and troubleshooting.. It should be noted that if more than two or three warning Alerts occur at the same time, it is often an indication that some fundamental sub-system (power supply, relay PCA, motherboard) has failed rather than an indication of the specific failures referenced by the warnings. Table 5-3. Warning Alerts, Fault Conditions and Possible Causes WARNING FAULT CONDITION AUTO ZERO WARN XXX.X MV BOX TEMP WARNING CANNOT DYN SPAN 2 AutoZero reading too high. (Auto-zero reading above 200 mV). Value shown in message indicates auto-zero reading at time warning was displayed. Temperature of chassis is outside specified limits. (typically < 7°C or > 48°C) Dynamic Span operation failed. (Contact closure span calibration failed while DYN_SPAN was set to ON). POSSIBLE CAUSES AUTO ZERO valve not working Valve control driver failed Bad Relay PCA Failed +12 VDC power supply Gas leak across AUTO ZERO Valve ports Dirty Reaction Cell O3 flow problem to RCELL Box Temperature typically runs ~7°C warmer than ambient temperature Poor/blocked ventilation to the analyzer Stopped Exhaust-Fan Ambient Temperature outside of specified range Measured concentration value is too high or low Concentration Slope value to high or too low CANNOT DYN ZERO 3 Dynamic Zero operation failed. (Contact closure zero calibration failed while DYN_ZERO was set to ON). Measured concentration value is too high Concentration Offset value to high CONFIG INITIALIZED Configuration and Calibration data reset to original Factory state or erased. Failed Disk on Module User erased data 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 121 WARNING FAULT CONDITION CONV TEMP WARNING NO2 to NO converter temperature too high or too low to efficiently convert NO2 to NO. (NO2 to NO converter temperature < 305°C or > 325°C). Heater configured for wrong voltage type Failed converter Temperature Sensor Relay controlling the Heater is not working Failed Relay Board DATA INITIALIZED Data Storage in DAS was erased before the last power up occurred. Failed Disk-on-Module User cleared data. HVPS WARNING High voltage power supply output is too high or too low for proper operation of the PMT. (Outside of warning limits). OZONE FLOW WARNING Ozone gas flow is too high or too low for accurate NOx, NO and NO2 readings. (O3 flow rate < 50 cc/min or > 150 cc/min). No +15 VDC power supply to Preamplifier PCA Drive voltage not adjusted properly Failed PMT Preamplifier PCA Dirty reaction cell Bad pneumatic flow Failed Sample Pump Blocked O3 dryer Blocked inlet/outlet to O3 purifier Dirty O3 dryer DFU Leak downstream of RCELL Failed O3 Flow Sensor Ozone generator is off. This is the only warning message that automatically clears itself. It clears itself when the ozone generator is turned on. Upon power up the Ozone generator will remain off for 30 minutes, which allows the ozone dryer to reach its working dew point. O3 generator override is turned ON. Electrical connection between motherboard and generator is faulty. Bad +15VDC power supply 5 IZS temperature is too high or too low for efficient O3 production. (Permeation tube oven temperature is < 45°C or > 55°C). Heater configured for wrong voltage type Failed permeation tube Temperature Sensor Relay controlling the Heater is not working Failed Relay Board PMT TEMP WARNING PMT temperature outside of warning limits. (Sample temperature is < 5°C or > 12°C). RCELL PRESS WARN Reaction cell pressure is too high or too low for accurate NOx, NO and NO2 readings. (RCELL pressure is < 0.5 in-Hg or >15 in-Hg). Nominal range 4-7 in-Hg. OZONE GEN OFF 4 IZS TEMP WARNING RCELL TEMP WARN 122 POSSIBLE CAUSES Reaction cell temperature is too high or too low for accurate NOx, NO and NO2 readings. (RCELL temperature is < 45°C or > 55°C). PMT fan not operating Failed PMT Temperature Sensor TEC not functioning Failed PMT Preamp PCA Pump may not be functioning properly, Or if Reaction Cell Pressure is < 0.5 in-Hg: • Blocked Particulate Filter • Blocked Sample Inlet/Gas Line • Failed Pressure Sensor/circuitry If Sample Pressure is > 15 in-Hg: • Blocked vacuum manifold • Broken Ozone Dryer Heater configured for wrong voltage type Failed RCELL Temperature Sensor Relay controlling the heater is not working Failed Relay Board I2C Bus Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 WARNING FAULT CONDITION REAR BOARD NOT DET Motherboard not detected on power up. (CPU unable to communicate with motherboard). RELAY BOARD WARN The CPU unable to communicate with the Relay PCA. SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits. (Sample flow rate is < 350 cc/min or > 600 cc/min). SAMPLE PRESS WARN Sample pressure is too high or too low for accurate NOx, NO, NO2 readings. (Sample Pressure is <15 in-Hg or > 35 in-Hg). Normally 29.92 in-Hg at sea level decreasing at 1 in-Hg per 1000 ft of altitude (with no flow – pump disconnected). SYSTEM RESET 1 2 3 4 5 The computer has rebooted. POSSIBLE CAUSES This warning only appears on Serial I/O COM Port(s). Front panel display will be frozen, blank or will not respond. Failure of motherboard I2C Bus failure Failed Relay Board Loose connectors/wiring Failed Sample Pump Blocked Sample Inlet/Gas Line Dirty Particulate Filter Leak downstream of RCELL Critical Flow Orifice Failed Sample Pressure Sensor Failed Vacuum Pressure Sensor If Sample Pressure is < 15 in-Hg: • Blocked Particulate Filter • Blocked Sample Inlet/Gas Line • Failed Pressure Sensor/circuitry If Sample Pressure is > 35 in-Hg: • Bad Pressure Sensor/circuitry • Pressure too high at Sample Inlet. This message occurs at power on. If it is confirmed that power has not been interrupted: Failed +5 VDC power Fatal Error caused software to restart Loose connector/wiring Clears 45 minutes after power up. Clears the next time successful zero calibration is performed. Clears the next time successful span calibration is performed. Clears 30 minutes after power up. Only appears if the IZS option is installed. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 123 FAULT DIAGNOSIS WITH DASHBOARD FUNCTIONS In addition to being useful as predictive diagnostic tools, the functions viewable in the Dashboard can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzer’s principles of operation (see Section 6). The acceptable ranges for these functions are listed in the “Nominal Range” column of the analyzer Final Test and Validation Data Sheet shipped with the instrument. Values outside these acceptable ranges indicate a failure of one or more of the analyzer’s subsystems. Functions whose values are still within acceptable ranges but have significantly changed from the measurement recorded on the factory data sheet may also indicate a failure. Make note of these values for reference in troubleshooting. 124 Note If no value displays for any of these Dashboard functions, it indicates an OUT OF RANGE reading. Note Sample Pressure measurements are represented in terms of “Absolute Atmospheric Pressure” because this is the least ambiguous method for reporting gas pressure. Absolute atmospheric pressure is about 29.92 in-Hg-A at sea level. It decreases about 1 in-Hg per 1000 ft gain in altitude. A variety of factors such as air conditioning systems, passing storms, and air temperature, can also cause changes in the absolute atmospheric pressure. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Table 5-4. Dashboard Functions - Indicated Failures DASHBOARD FUNCTION INDICATED FAILURE(S) Stability Unstable concentrations; leaks Sample Flow Leaks; clogged critical flow orifice O3 Flow Leaks; clogged critical flow orifice PMT Calibration off; HVPS problem; no flow (leaks) Norm PMT Auto Zero too high Auto Zero Leaks; malfunctioning NO, NOx or Auto Zero valve; O3 air filter cartridge exhausted HVPS Calibration off; preamp board circuit problems Rx Cell Temp Malfunctioning heater; relay board communication (I2C bus); relay burnt out Box Temp Environment out of temperature operating range; broken thermistor PMT Temp TEC cooling circuit broken; relay board communication (I2C bus); 12 V power supply IZS Temp (option) Malfunctioning heater; relay board communication (I2C bus); relay burnt out Moly Temp Malfunctioning heater; disconnected or broken thermocouple; relay board communication (I2C bus); relay burnt out; incorrect AC voltage configuration Rx Cell Press Leak; malfunctioning valve; malfunctioning pump; clogged flow orifices Sample Pressure Leak; malfunctioning valve; malfunctioning pump; clogged flow orifices; sample inlet overpressure NOx Slope HVPS out of range; low-level (hardware) calibration needs adjustment; span gas concentration incorrect; leaks NOx Norm Offset Incorrect span gas concentration; low-level calibration off NO Slope HVPS out of range; low-level calibration off; span gas concentration incorrect; leaks NO Norm Offset Incorrect span gas concentration; low-level calibration off USING THE DIAGNOSTIC SIGNAL I/O FUNCTIONS The signal I/O functions in the Utilities>Diagnostics menu allows access to the digital and analog I/O in the analyzer. Some of the digital signals can be controlled through the Setup menu. These signals, combined with a thorough understanding of the instrument’s principles of operation (Section 6), are useful for troubleshooting in three ways: • The technician can view the raw, unprocessed signal level of the analyzer’s critical inputs and outputs. • Many of the components and functions that are normally under algorithmic control of the CPU can be manually exercised. • The technician can directly control the signal level Analog and Digital Output signals. This allows the technician to observe systematically the effect of directly controlling these signals on the operation of the analyzer. Use the Utilities>Diagnostics menu to view the raw voltage of an input signal or the Setup menu to control the state of an output voltage or control signal. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 125 USING THE ANALOG OUTPUT CHANNELS Signals available for output over the analyzer’s analog output channel (configured in the Setup>Analog Outputs menu; see Section 2.5.8) can also be used as diagnostic tools through the Utilities>Diagnostics menu. Some of the outputs and their descriptions and causes are presented in Table 5-5. Table 5-5. Analog Outputs as Diagnostic Tools TEST CHANNEL DESCRIPTION PMT The output of the PMT detector converted to a 0 to 5 VDC scale. O3 Flow The flow rate of O3 through the analyzer as measured by the O3 flow sensor Sample Flow The calculated flow rate for sample gas through the analyzer. Sample Press Rx Cell Press Rx Cell Temp IZS Temp (with IZS option) The pressure of the sample gas measured upstream of the Auto Zero Valve The pressure of gas inside the reaction cell of the sensor module The temperature of gas inside the reaction cell of the sensor module The temperature of the permeation tube oven of the optional internal span gas generator. ZERO FULL SCALE Failed PMT PMT Temperature too High/Low Bad PMT Preamp PCA Failed HVPS Misadjusted HVPS drive Voltage Light Leak in reaction cell 0 mV 5000 mV 0 cm3/min 1000 cm3/min Check for Gas Flow problems in the O3 gas lines. 0 cm3/min 1000 cm3/min Check for Gas Flow problems in the sample gas lines. 0 In-Hg-A 40 In-Hg-A 0 In-Hg-A 40 In-Hg-A 0 °C 70 °C 0 °C 70 °C PMT Temp The temperature inside PMT 0 °C 50 °C Box Temp The temperature inside the analyzer’s chassis 0 °C 70 °C 126 CAUSES OF EXTREMELY HIGH / LOW READINGS Check for Gas Flow problems in the sample gas lines. Check for Gas Flow problems in all gas lines. Heater configured for wrong voltage type Failed RCELL Temperature Sensor Relay controlling the heater is not working Failed Relay Board I2C Bus Heater configured for wrong voltage type Failed permeation tube Temperature Sensor Relay controlling the Heater is not working Failed Relay Board PMT fan not operating Failed PMT Temperature Sensor TEC not functioning Failed PMT Preamp PCA Box Temperature typically runs ~7°C warmer than ambient temperature Poor/blocked ventilation to the analyzer Stopped Exhaust-Fan Ambient Temperature outside of specified range Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 USING THE INTERNAL ELECTRONIC STATUS LEDS Several LEDs are located inside the instrument to assist in determining if the analyzer’s CPU, I2C bus and Relay PCA are functioning properly. CPU STATUS INDICATOR DS5, a red LED located on the motherboard (Figure 5-13), flashes when the CPU is running the main program loop. After power-up, approximately 30 – 60 seconds, DS5 should flash on and off. If the front panel displays properly but DS5 does not flash, then the program files have become corrupted, contact Teledyne API's Technical Support Department (see Section 5.9) because it may be possible to recover operation of the analyzer. If after 30 – 60 seconds, neither DS5 is flashing nor does the front panel display properly then the CPU is bad and must be replaced. Motherboard CPU Status LED Figure 5-13. CPU Status Indicator RELAY PCA WATCHDOG AND STATUS LEDS There are sixteen LEDs located on the Relay PCA (some are not used on this model). The most important of the LEDs is D1 (see Figure 5-14), which indicates the health of the I2C bus. LEDs that remain continuously on or off (not blinking) indicate a default state for their respective components as described in Table 5-6. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 127 D10 (green) – NO/NOx Valve D9 (green) – AutoZero Valve D8 (green) – Optional Sample/Cal Valve D7 (green) – Optional Zero/Span Valve D4 (yellow) Manifold Heater D3 (yellow) NO2 à NO Converter Heater D2 (yellow) Reaction Cell Heater D6 (yellow) – O2 Sensor Option Heater D5 (yellow) and D11 – 16 (green) – Spares D1 (RED) Watchdog Indicator Figure 5-14. Relay PCA Status LEDS Used for Troubleshooting Table 5-6. Relay PCA Watchdog and Status LED Failure Indications LED COLOR FUNCTION INDICATED FAILURE(S) Failed/Halted CPU D1 Faulty Motherboard, Touchscreen, or Relay PCA Faulty Connectors/Wiring between Motherboard and Touchscreen or Relay PCA Failed/Faulty +5 VDC Power Supply (PS1) Red Watchdog Circuit: I2C bus health D2 Yellow Reaction Cell heater Heater broken, thermistor broken D3 Yellow NO2 converter heater Heater broken, thermocouple broken D4 Yellow Manifold heater D7 Green Zero/Span valve option status Valve broken or stuck, valve driver chip broken D8 Green Sample/Cal valve option status Valve broken or stuck, valve driver chip broken D9 Green Auto-zero valve status Valve broken or stuck, valve driver chip broken D10 Green NO/NOx valve status Valve broken or stuck, valve driver chip broken Yellow O2 sensor option heater LED ROW 1 Heater broken, thermistor broken LED ROW 2 D6 D5, D11-D16 Heater broken, thermistor broken Spare FLOW PROBLEMS The analyzer has two main flow paths, the sample flow and the flow of the ozone supply air. With the zero/span valve option installed, there is a third (zero air) and a fourth (span 128 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 gas) flow path, but either one of those is only controlled by critical flow orifices and not displayed on the front panel or stored to the DAS. In the two main flow paths, flow problems occur in the following three ways: • Flow is zero (no flow) • Flow is too high • Flow is greater than zero, but is too low, and/or unstable When troubleshooting flow problems, it is essential to confirm the actual flow rate without relying on the analyzer’s flow display. The use of an independent, external flow meter to perform a flow check as described in Section 5.6.9.3 is essential. Refer to the pneumatic flow diagrams (Section 2.3.3) as needed for reference. SAMPLE FLOW IS ZERO OR LOW The analyzer does not actually measure the sample flow but rather calculates it from a differential pressure between sample and vacuum manifold. On flow failure, the unit will display a SAMPLE FLOW WARNING in the Active Alerts page and the respective function reports nothing instead of a numerical value. This message applies to both a flow rate of zero as well as a flow that is outside the standard range (350-600 cc/min). If the analyzer displays nothing for the sample flow, confirm that the external sample pump is operating and configured for the proper AC voltage. • Whereas the analyzer can be internally configured for two different power regimes (100-120 V and 220-240 V, either 50 or 60 Hz), the external pump is physically different for each of three power regimes (100 V / 50 Hz, 115 V / 60 Hz and 230 V / 50 Hz). • If the pump is not running, use an AC Voltmeter to ensure that the pump is supplied with the proper AC power. If AC power is supplied properly, but the pump is not running, replace the pump. Sample and vacuum pressures mentioned in this chapter refer to operation of the analyzer at sea level. Pressure values need to be adjusted for elevated locations, as the ambient pressure decreases by about 1 in-Hg per 300 m / 1000 ft. Note If the pump is operating but the unit is not reporting gas flow value(s), take the following three steps: 1. Check for actual sample flow. 083730210A DCN8164 • To check the actual sample flow, disconnect the sample tube from the sample inlet on the rear panel of the instrument. • Ensure that the unit is in basic SAMPLE mode. • Place a finger over the inlet and feel for suction by the vacuum or, more properly, use a flow meter to measure the actual flow. • If there is proper flow of around 450-550 cc/min, contact Technical Support. • If there is no flow or low flow, continue with the next step. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 129 2. Check pressures. • Check that the sample pressure is at or around 28 in-Hg-A at sea level (adjust as necessary when in elevated location, the pressure should be about 1” below ambient atmospheric pressure) and that the Rx Cell pressure is below 10 in-Hg-A. • The analyzer will calculate a sample flow up to about 14 in-Hg-A RCEL pressure but a good pump should always provide less than 10 in-Hg-A. • If both pressures are the same and around atmospheric pressure, the pump does not operate properly or is not connected properly. The instrument does not get any vacuum. • If both pressures are about the same and low (probably under 10 in-Hg-A, or ~20” on sample and 15” on vacuum), there is a cross-leak between sample flow path and vacuum, most likely through the dryer flow paths. Check for leaks (Section 5.6.9). • If the sample and vacuum pressures are around their nominal values (28 and <10 in-Hg-A, respectively) and the flow still displays no numerical value, carry out a leak check as described in Section 5.6.9. • If gas flows through the instrument during the above tests but goes to zero or is low when it is connected to zero air or span gas, the flow problem is not internal to the analyzer but likely caused by the gas source such as calibrators/generators, empty gas tanks, clogged valves, regulators and gas lines. • If a Zero/Span valve option is installed in the instrument, press Start in the Calibration>Zero and Span menus. If the sample flow increases, suspect a bad Sample/Cal valve. 3. If none of these suggestions help, carry out a detailed leak check of the analyzer as described in Section 5.6.9.2. OZONE FLOW IS ZERO OR LOW If there is zero or a low (< 200 cc/min) ozone flow, the unit displays an OZONE FLOW WARNING message in the Alerts page and a value between 0.0 and 200 cc/min for the actual ozone flow as measured by the internal mass flow meter. In this case, carry out the following steps: 130 • Check the actual flow rate through the ozone dryer by using an external volumetric flow meter to the inlet port of the dryer. • This inlet port is inside the analyzer at the end of the plastic particle filter (Section 5.6.2 for illustration). • If there is nominal flow (refer to Table 6-3), consult Technical Support as there is a problem with the firmware or electronics. • If the actual flow is low or zero, check if the pump operates properly. The RCEL pressure should be below 10 in-Hg-A at sea level. • If it is above 10 in-Hg-A, rebuild the pump (Section 5.6.3.1). Check the spare parts list in Appendix B on how to order pump rebuild kits. • Check if the particle filter is clogged. • Briefly remove the particle filter to see if this improves the flow. • Be very cautious when handling the dryer fittings (see Section 5.6.2 on proper handling instructions). Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 • • • If the filter is clogged, replace it with a new unit. If taking off this filter does not solve the problem, continue to the next step. Do not leave the dryer without filter for more than a few seconds, as you may draw in dust, which will reduce the performance of the dryer. • A leak between the flow meter and the reaction cell (where the flow-determining critical orifice is located) may cause a low flow (the system draws in ambient air through a leak after the flow meter). • Check for leaks as described in Section 5.6.9. • Repair the leaking fitting, line or valve and re-check. • The most likely cause for zero or low ozone flow is a clogged critical flow orifice or sintered filter within the orifice assembly. The orifice that sets the ozone flow is located on the reaction cell. • Check the actual ozone flow by disconnecting the tube from the reaction cell and measuring the flow going into the cell. • If this flow is correct (check Table 6-3 for flow rates), the orifice works properly. • If this flow is low, replace or clean the orifice. • The orifice holder assembly allows a quick and easy replacement of the filter (Section 5.6.7). Order a spare part kit with a complete orifice assembly that allows a quick replacement with minimum instrument down-time. The clogged orifice can then be cleaned while the instrument is running with the replacement. HIGH FLOW Flow readings that are significantly higher than the allowed operating range (typically ±1011% of the nominal flow) should not occur in the analyzer unless a pressurized sample, zero or span gas is supplied to the inlet ports. • Ensure to vent excess pressure and flow just before the analyzer inlet ports. • When supplying sample, zero or span gas at ambient pressure, a high flow could indicate a broken critical flow orifice (very unlikely case), allowing more than nominal flow, or were replaced with an orifice of wrong specifications. • If the flows are within 15% above normal, we recommend measuring and recalibrating the flow electronically (Section 5.6.9.3), followed by a regular review of these flows over time to see if the new setting is retained properly. • Also, check the flow assembly o-rings and replace as needed. SAMPLE FLOW IS ZERO OR LOW BUT ANALYZER REPORTS CORRECT FLOW The analyzer can report a correct flow rate even if there is no or a low actual sample flow through the reaction cell. • The sample flow is only calculated from the sample pressure and critical flow condition is verified from the difference between sample pressure and vacuum pressure. • If the critical flow orifice assembly is partially or completely clogged, both the sample and vacuum pressures are still within their nominal ranges (the pump keeps pumping, the sample port is open to the atmosphere), but there is no flow possible through the reaction cell. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 131 Although measuring the actual flow is the best method, in most cases, this fault can also be diagnosed by evaluating the two pressure values. • Since there is no longer any flow, the sample pressure should be equal to ambient pressure, which is about 1 in-Hg-A higher than the sample pressure under normal operation. • The reaction cell pressure, on the other hand, is significantly lower than under normal operation, because the pump no longer has to remove 500 cc/min of sample gas and evacuates the reaction cell much better. • Those two indicators, taken together with a zero or low actual flow, indicate a clogged sample orifice. The analyzer features a new orifice holder, which makes switching sample and ozone flow orifices very easy; refer to Section 5.6.7 on how to change the sample orifices. Again, monitoring the pressures and flows regularly will reveal such problems, because the pressures would slowly or suddenly change from their nominal, mean values. Teledyne API recommends reviewing all test data once per week and to do an exhaustive data analysis for test and concentration values once per month, paying particular attention to sudden or gradual changes in all parameters that are supposed to remain constant, such as the flow rates. CALIBRATION PROBLEMS This section describes possible causes of calibration problems. NEGATIVE CONCENTRATIONS Negative concentration values can be caused for several reasons: • • 132 A slight, negative signal is normal when the analyzer is operating under zero gas and the signal is drifting around the zero calibration point. • This is caused by the analyzer’s zero noise and may cause reported concentrations to be negative for a few seconds at a time down to -0.2 ppm, but should randomly alternate with similarly high, positive values. • The analyzer has a built-in Auto Zero function, which should take care of most of these deviations from zero, but may yield a small, residual, negative value. • If larger, negative values persist continuously, check if the Auto Zero feature is functioning. If not, the sensitivity of the analyzer may be drifting negative. A corruption of the Auto Zero filter may also cause negative concentrations. • If a short, high noise value was detected during the Auto Zero cycle, that higher reading will alter the Auto Zero filter value. • As the value of the Auto Zero filter is subtracted from the current PMT response, it will produce a negative concentration reading. • High Auto Zero readings can be caused by: • a leaking or stuck Auto Zero valve (replace the valve), • an electronic fault in the preamplifier causing it to have a voltage on the PMT output pin during the Auto Zero cycle (replace the preamplifier), Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 • • • a reaction cell contamination causing high background (>40 mV) PMT readings (clean the reaction cell per Section 5.6.6), • a broken PMT temperature control circuit, allowing high zero offset (repair the faulty PMT cooler). After fixing the cause of a high Auto Zero filter reading, allow 15 minutes for the filter to clear itself. Calibration error is the most likely explanation for negative concentration values. • If the zero air contained some NO or NO2 gas (contaminated zero air or a worn-out zero air scrubber) and the analyzer was calibrated to that concentration as “zero”, the analyzer may report negative values when measuring air that contains little or no NOx. • The same problem occurs, if the analyzer was zero-calibrated using zero gas that is contaminated with ambient air or span gas (cross-port leaks or leaks in supply tubing or user not waiting long enough to flush pneumatic systems). If the response offset test functions for NO (NO OFFS) or NOX (NOX OFFS) are greater than 150 mV, a reaction cell contamination is indicated. • Clean the reaction cell as described in Section 5.6.6. ABSENCE OF ANALYZER RESPONSE TO SAMPLE GAS If the instrument shows no response (display value is near zero) even though sample gas is supplied properly and the instrument seems to perform correctly: 1. Carry out an electrical test with the ELECTRICAL TEST procedure (Run ETest) in the Utilities>Diagnostics>OE Test menu. See Electrical Test (ETest) in Section 5.7.9.11. • If this test produces a concentration reading, the analyzer’s electronic signal path is correct. 2. Carry out an optical test using the OPTIC TEST procedure (Run OTest) in the Utilities>Diagnostics>OE Test menu. See Optic Test (OTest) in Section 5.7.9.11. • If this test results in a concentration signal, then the PMT sensor and the electronic signal path are operating properly. • If the analyzer passes both ETest and OTest, it is capable of detecting light and processing the signal to produce a reading. • Therefore, the problem must be in the pneumatics or the ozone generator. 3. Check if the ozone generator is turned on. 083730210A DCN8164 • Usually, the analyzer issues a warning whenever the ozone generator is turned off. • Go to Utilities>Diagnostics>O3 Gen Override and see if it shows ON. • If it shows OFF, turn it ON and check the O3 Flow reading in the Dashboard menu. • If this is done and the ozone flow is correct, the analyzer should be properly supplied with ozone unless the generator itself is broken. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 133 4. Confirm the lack of response by supplying NO or NO2 span gas of about 80% of the range value to the analyzer. 5. Check the sample flow and ozone flow rates for proper values. 6. Check for disconnected cables to the sensor module. 7. If the NO2 signal is zero while NO signal is correct, check the NO/NOx valve and the NO2 converter for proper operation. UNSTABLE ZERO AND SPAN Leaks in the external gas supply and vacuum systems are the most common source of unstable and non-repeatable concentration readings. 1. Check for leaks in the pneumatic systems as described in Section 5.6.9. 2. Consider pneumatic components in the gas delivery system outside the analyzer such as a change in zero air source (ambient air leaking into zero air line or a wornout zero air scrubber) or a change in the span gas concentration due to zero air or ambient air leaking into the span gas line. 3. Once the instrument passes a leak check, do a flow check (this chapter) to ensure that the instrument is supplied with adequate sample and ozone air. 4. Confirm the sample pressure, sample temperature, and sample flow readings are correct and steady. 5. Verify that the sample filter element is clean and does not need to be replaced. INABILITY TO SPAN - DEACTIVATED SPAN BUTTON In general, the analyzer will deactivate certain buttons whenever the actual value of a parameter is outside of the expected range for that parameter. If the Span is grayed out, the actual concentration must be outside of the range of the expected span gas concentration, which can have several causes. 1. Verify that the expected concentration is set properly to the actual span gas concentration in the CONC sub-menu. 2. Confirm that the NOx span gas source is accurate. • This can be done by comparing the source with another calibrated analyzer, or by having the NOx source verified by an independent traceable photometer. 3. Check for leaks in the pneumatic systems as described in Section 5.6.9. • Leaks can dilute the span gas and, hence, the concentration that the analyzer measures may fall short of the expected concentration defined in the CONC submenu. 4. If the low-level, hardware calibration has drifted (changed PMT response) or was accidentally altered by the user, a low-level calibration may be necessary to get the analyzer back into its proper range of expected values. • 134 One possible indicator of this scenario is a slope or offset value that is outside of its allowed range (0.7-1.3 for slope, -20 mV to 150 mV for offsets). See Section 5.7.10.4 on how to carry out a low-level hardware calibration. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 INABILITY TO ZERO - DEACTIVATED ZERO BUTTON In general, the analyzer will deactivate certain buttons whenever the actual value of a parameter is outside of the expected range for that parameter. If the Zero button is grayed out, the actual gas concentration must be significantly different from the actual zero point (as per last calibration), which may be for any of several reasons. 1. Confirm that there is a good source of zero air. If the IZS option is installed, compare the zero reading from the IZS zero air source to a zero air source using NOX-free air. Check any zero air scrubber for performance. It may need to be replaced (Section 5.6.3.2). 2. Check to ensure that there is no ambient air leaking into zero air line. Check for leaks in the pneumatic systems as described in Section 5.6.9. NON-LINEAR RESPONSE The analyzer was factory calibrated to a high level of NO and should be linear to within 1% of full scale. Common causes for non-linearity are: • • • Leaks in the pneumatic system: • Leaks can add ambient air, zero air or span gas to the current sample gas stream, which may be changing in concentrations as the linearity test is performed. • Check for leaks as described in Section 5.6.9. The calibration device is in error: • Check flow rates and concentrations, particularly when using low concentrations. • If a mass flow calibrator is used and the flow is less than 10% of the full scale flow on either flow controller, you may need to purchase lower concentration standards. The standard gases may be mislabeled as to type or concentration. • • Labeled concentrations may be outside the certified tolerance. The sample delivery system may be contaminated. • Check for dirt in the sample lines or reaction cell. • Calibration gas source may be contaminated (NO2 in NO gas is common). • Dilution air contains sample or span gas. • Ozone concentration too low because of wet air in the generator. • • Generator system needs to be cleaned and dried with dry supply air. • Check the dryer for leaks. • This mostly affects linearity at the low end. Sample inlet may be contaminated with NOx exhaust from this or other analyzers. • • Verify proper venting of the pump exhaust. Span gas overflow is not properly vented and creates a back-pressure on the sample inlet port. • Also, if the span gas is not vented at all and does not supply enough sample gas, the analyzer may be evacuating the sample line. • Ensure to create and properly vent excess span gas. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 135 • Diffusion of oxygen into Teflon-type tubing over long distances. • PTFE or related materials can act as permeation devices. In fact, the permeable membrane of NO2 permeation tubes is made of PTFE. • When using very long supply lines (> 1 m) between high concentration span gases and the dilution system, oxygen from ambient air can diffuse into the line and react with NO to form NO2. • This reaction is dependent on NO concentration and accelerates with increasing NO concentration, hence, affects linearity only at high NO levels. • Using stainless steel for long span gas supply lines avoids this problem. DISCREPANCY BETWEEN ANALOG OUTPUT AND DISPLAY If the concentration reported through the analog outputs does not agree with the value reported on the front panel, you may need to recalibrate the analog outputs. • This becomes more likely when using a low concentration or low analog output range. • Analog outputs running at 0.1 V full scale should always be calibrated manually. • See Section 2.5.8.1 for a detailed description of this procedure. DISCREPANCY BETWEEN NO AND NOX SLOPES If the slopes for NO and NOX are significantly different after software calibration (more than 1%), consider the following three problems: • • NO2 impurities in the NO calibration gas. NO gases often exhibit NO2 on the order of 1-2% of the NO value. • This will cause differences in the calibration slopes. If the NO2 impurity in NO is known, it can easily be accounted for by setting the expected values for NO and NO2 accordingly to different values, e.g., 448 ppb NO and 450 ppb NOX. • This problem is worse if NO gas is stored in a cylinder with balance air instead of balance gas nitrogen or large amounts of nitrous oxide (N2O), because the oxygen in the air slowly reacts with NO to yield NO2, increasing over time. The expected concentrations for NO and NOX in the calibration menu are set to different values. • If a gas with 100% pure NO is used, this would cause a bias. • See Section 4.2 on how to set expected concentration values. OTHER PERFORMANCE PROBLEMS Dynamic problems (i.e., problems that only manifest themselves when the analyzer is monitoring sample gas) can be the most difficult and time consuming to isolate and resolve. The following section provides an itemized list of the most common dynamic problems with recommended troubleshooting checks and corrective actions. EXCESSIVE NOISE Excessive noise levels under normal operation usually indicate leaks in the sample supply or the analyzer itself. 136 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 • Ensure that the sample or span gas supply is leak-free and carry out a detailed leak check as described earlier in this chapter. Another possibility of excessive signal noise may be the preamplifier board, the high voltage power supply and/or the PMT detector itself. • Contact the factory for troubleshooting these components. SLOW RESPONSE If the analyzer starts responding too slow to any changes in sample, zero or span gas, check for the following: • Dirty or plugged sample filter or sample lines. • Sample inlet line is too long. • Leaking NO/NOX valve. Carry out a leak check. • Dirty or plugged critical flow orifices. Check flows, pressures and, if necessary, change orifices (Section 5.6.7). • Wrong materials in contact with sample - use glass, stainless steel or Teflon materials only. Porous materials, in particular, will cause memory effects and slow changes in response. • Dirty reaction cell. Clean the reaction cell. • Insufficient time allowed for purging of lines upstream of the analyzer. Wait until stability is low. • Insufficient time allowed for NO or NO2 calibration gas source to become stable. Wait until stability is low. • Moly temperature is too low. Check for proper temperature. AUTO ZERO WARNINGS Auto Zero warnings occur if the signal measured during an Auto Zero cycle is outside the range of -20 mV to 200 mV. Note • • The Auto-Zero warning displays the value of the Auto Zero reading when the warning occurs. If this value is higher than 150 mV, check that the Auto Zero valve is operating properly. • To do so, use the Utilities>Diagnostics>Digital Outputs menu to toggle the valve on and off. • Listen if the valve is switching, see if the respective LED on the relay board is indicating functionality. Alternatively, navigate to the Dashboard and observe the PMT value change between the two valve states. • 083730210A DCN8164 If the valve is operating properly, you should be able to hear it switch (once a minute under normal operation or when manually activated from the Utilities>Diagnostics>Digital Outputs menu): Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 137 Note • the PMT value should drop from its nominal reading for span gas level measurements to less than 150 mV, and the LED on the relay board should light up when the valve is activated. • If the PMT value drops significantly but not to less than 150 mV, the valve is probably leaking across its ports. In this case, replace the valve. • If the PMT value does not change at all, the valve is probably not switching at all. Check the power supply to the valve (12 V to the valve should turn on and off when measured with a voltmeter). It takes only a small leak across the ports of the valve to show excessive Auto Zero values when supplying high concentrations of span gas. Another reason for high (although not necessarily out-of-range) values for Auto Zero could be the ozone air filter cartridge, if its contents have been exhausted and must be replaced. • This filter cartridge chemicals that can cause chemiluminescence and, if saturated, these chemicals can break through to the reaction cell, causing an erroneously high Auto Zero value (background noise). A dirty reaction cell can cause high Auto Zero values. • Clean the reaction cell according to Section 5.6.6. Finally, a high HVPS voltage value may cause excess background noise and a high Auto Zero value. • The HVPS value changes from analyzer to analyzer and could show nominal values between 450 and 800 V. • Check the low-level hardware calibration of the preamplifier board and, if necessary, recalibrate exactly as described in Section 5.7.10.4 in order to minimize the HVPS. SUBSYSTEM CHECK FOR TROUBLESHOOTING The preceding sections of this manual discussed a variety of methods for identifying possible sources of failures or performance problems within the analyzer. In most cases this included a list of possible causes and, in some cases, quick solutions or at least a pointer to the appropriate sections describing them. This section describes how to determine if a certain component or subsystem is actually the cause of the problem being investigated. 138 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 AC MAIN POWER The analyzer’s electronic systems will operate with any of the specified power regimes. As long as system is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display. • Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. • • If they do not, check the circuit breaker built into the ON/OFF switch on the instrument’s front panel. If the configuration plug is set for 115 or 100 VAC and the unit is plugged into a 230 VAC circuit, the circuit breaker built into the ON/OFF Switch on the front panel will trip to the OFF position immediately after power is switched on. WARNING – ELECTRICAL SHOCK HAZARD Should the AC power circuit breaker trip, investigate and correct the condition causing this situation before turning the analyzer back on. DC POWER SUPPLY If the analyzer’s AC mains power is working, check the DC output with a voltmeter at the test points described in Table 5-7 and shown in Figure 5-15. Refer to Table 5-8 for acceptable values. Check for excessive noise (> 100 mV p-p), using an oscilloscope in AC mode with band limiting turned on. Table 5-7. DC Power Test Point and Wiring Color Codes NAME 083730210A DCN8164 TEST POINT# 1 COLOR DEFINITION DGND Black Digital ground +5V 2 Red AGND 3 Green +15V 4 Blue -15V 5 Yellow +12R 6 Purple +12V 7 Orange Analog ground 12 V return (ground) line Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 139 TP1 TP2 TP3 TP4 TP5 TP6 TP7 DGND +5V AGND +15V -15V +12R 12V Figure 5-15. Location of DC Power Test Points on Relay PCA Table 5-8. DC Power Supply Acceptable Levels VOLTAGE POWER SUPPLY CHECK RELAY BOARD TEST POINTS FROM TO Test Point MIN V MAX V Test Point NAME # NAME # +5 2 +4.80 +5.25 PS1 +5 DGND 1 PS1 +15 AGND 3 +15 4 +13.5 +16.0 PS1 -15 AGND 3 -15V 5 -14.0 -16.0 PS1 AGND AGND 3 DGND 1 -0.05 +0.05 PS1 Chassis DGND 1 Chassis N/A -0.05 +0.05 PS2 +12 +12V Ret 6 +12V 7 +11.8 +12.5 PS2 DGND +12V Ret 6 DGND 1 -0.05 +0.05 I2C BUS Verify operation of the I2C bus by checking whether the LEDs are flashing at the Relay PCA’s D1 and the Valve Driver PCA’s D2. If both are solid lit or are steady off, and the DC power supplies are operating properly, there is a problem with the I2C bus. 140 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 LCD/DISPLAY MODULE AND TOUCHSCREEN Assuming that there are no wiring problems and that the DC power supplies are operating properly, the display screen should light and show the splash screen and other indications of its state as the CPU goes through its initialization process. If pressing a touch-screen control button gets no response on the display, either the touch-screen controller or the internal USB bus is malfunctioning. Verify the failure by logging on with NumaView™ software Remote: if the analyzer responds to remote commands and the display changes accordingly, the touch-screen interface may be faulty. RELAY PCA The Relay PCA can be most easily checked by observing the condition of its status LEDs (see Section 5.7.5.2), and using the Utilities>Diagnostics>Digital Outputs menu (see Section 5.7.3) to toggle each LED ON or OFF. If D1 on the Relay PCA is flashing and the status indicator for the output in question (Heater power, Valve Drive, etc.) toggles properly using the Signal I/O function, then the associated control device on the Relay PCA is bad. Several of the control devices are in sockets and can be easily replaced. The following table lists the control device associated with a particular function: Table 5-9. Relay PCA Control Devices FUNCTION CONTROL DEVICE SOCKETED All valves U5 Yes All Heaters K1-K5 Yes MOTHERBOARD A/D FUNCTIONS The simplest method to check the operation of the A-to-D converter on the motherboard is to navigate to the Dashboard and check the two A/D reference voltages and input signals that can be easily measured with a voltmeter (configure the Dashboard to show the necessary parameters). 1. Navigate to the Dashboard to view the value of Ref 4096mV and Ref Ground. • If both are within 3 mV of nominal (4096 and 0), and are stable (±0.2 mV) then the basic A/D is functioning properly. If not then the motherboard is bad. 2. Choose a parameter in the Dashboard function list such as O3FLOW. 083730210A DCN8164 • Compare the voltage at its origin (see the interconnect drawing in Appendix B) with the voltage displayed through the signal I/O function. • If the wiring is intact but there is a large difference between the measured and displayed voltage (±10 mV) then the motherboard is bad. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 141 STATUS OUTPUTS V +DC 1 2 SYSTEM_OK 3 4 5 Gnd 6 7 8 D + 1000 Ω Figure 5-16. Typical Set Up of Status Output Test To test the status output electronics: 1. Connect a jumper between the “D" pin and the “” pin on the status output connector. 2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested. 3. Connect a voltmeter between the “D” pin and the pin of the output being tested. 4. In the Utilities>Diagnostics>Digital Outputs menu (see Section 5.7.3), scroll through the outputs until you get to the output in question. 5. Alternatively, turn on and off the output noting the voltage on the voltmeter. • It should vary between 0 volts for ON and 5 volts for OFF. CONTROL INPUTS The control input bits can be tested by applying a trigger voltage to an input and watching changes in the status of the associated function in the Utilities>Diagnostics menu: EXAMPLE: to test the “A” and “B” control inputs: 1. Under the Utilities> Diagnostics>Digital Inputs menu, scroll through the signals to find EXTERNAL_ZERO_CAL. 2. Connect a jumper from the “+” pin on the appropriate connector to the “U” on the same connector. 3. Connect a second jumper from the “” pin on the connector to the “A” pin. 4. The status of EXTERNAL_ZERO_CAL should change to read “ON”. 5. Connect a second jumper from the “” pin on the connector to the “B” pin. 6. The status of EXTERNAL_HIGHSPAN_CAL should change to read “ON.” Table 5-10. Control Input Pin Assignments and Corresponding Signal I/O Functions INPUT 142 CORRESPONDING I/O SIGNAL A EXT_ZERO_CAL B EXT_HIGHSPAN_CAL C, D, E& F NOT USED Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PRESSURE / FLOW SENSOR ASSEMBLY The flow and pressure sensors are located on a PCA just behind the PMT sensor (see Figure 2-3) can be checked with a voltmeter. Measure the voltage across TP1 and TP2, it should be 10.0 ± 0.25 V. If not, the board is faulty. Measure the voltage across the leads of capacitor C2. It should be 5.0 ± 0.25 V, if not, the board may be faulty. Figure 5-17. Pressure / Flow Sensor Assembly REACTION CELL PRESSURE CHECK Measure the voltage across test points TP1 and TP5. With the sample pump disconnected or turned off, the voltage should be 4500 ± 250 mV. With the pump running, it should be 800-1700 mV depending on the performance of the vacuum pump. The lower the reaction cell pressure, the lower the resulting voltage is. If this voltage is significantly different, the pressure transducer S1 or the board may be faulty. If this voltage is between 2 and 5 V, the pump may not be performing well, check that the reaction cell pressure is less than 10 in-Hg-A (at sea level). Ensure that the tubing is connected to the upper port, which is closer to the sensor’s contacts; the lower port does not measure pressure. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 143 SAMPLE PRESSURE SENSOR CHECK Measure the voltage across test points TP1 and TP4. With the sample pump disconnected or turned off, this voltage should be 4500 ± 250 mV. With the pump running, it should be about 0.2 V less as the sample pressure drops by about 1 in-Hg-A below ambient pressure. If this voltage is significantly different, the pressure transducer S2 or the board may be faulty. A leak in the sample system to vacuum may also cause this voltage to be between about 0.6 and 4.5. Make sure that the front panel reading of the sample pressure is at about 1 in-Hg-A less than ambient pressure. Ensure that the tubing is connected to the upper port, which is closer to the sensor’s contacts; the lower port does not measure pressure. O3 FLOW SENSOR CHECK Measure the voltage across TP1 and TP3. With proper ozone flow (250 cm3/min), this should be approximately 3.0 ± 0.3 V (this voltage will vary with altitude). With flow stopped (pump turned off), the voltage should be approximately 0 V. If the voltage is incorrect, the flow sensor or the board may be faulty. A cross-leak to vacuum inside the ozone dryer may also cause this flow to increase significantly, and the voltage will increase accordingly. Also, make sure that the gas flows from P1 to P2 as labeled on the flow sensor (“high” pressure P1 to “low” pressure P2 or “Port” 1 to “Port” 2). CPU There are two major types of CPU board failures, a complete failure and a failure associated with the Disk on Module (DOM). If either of these failures (described next) occurs, contact the factory. For a complete failure, assuming that the power supplies are operating properly and the wiring is intact, the CPU is faulty if on power-on, the watchdog LED on the motherboard is not flashing. • In some rare circumstances, this failure may be caused by a bad IC on the motherboard, specifically U57, the large 44 pin device on the lower right hand side of the board. If this is true, removing U57 from its socket will allow the instrument to start up but the measurements will be invalid. • For a failure associated with the DOM, the analyzer could stop during initialization (the front panel display shows a fault or warning message), a likely indicator that the DOM, the firmware or the configuration and data files have been corrupted. RS-232 COMMUNICATIONS GENERAL RS-232 TROUBLESHOOTING Teledyne API's analyzers use the RS-232 communications protocol to allow the instrument to be connected to a variety of computer-based equipment. Problems with RS-232 connections usually center around five general areas: 144 • Incorrect cabling and connectors. See Section 2.3.1.7 under RS-232 Connection for connector and pin-out information. • The BAUD rate and protocol are incorrectly configured. See Section 2.3.1.7 under RS-232 Connection. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 • If a modem is being used, additional configuration and wiring rules must be observed. See Sections 3.1 and 3.2. • Incorrect setting of the DTE – DCE Switch. See Section 3.1 to set correctly. • Possible improper/incomplete seating of the cable (P/N 03596) that connects the serial COM ports of the CPU to J12 of the motherboard. TROUBLESHOOTING ANALYZER/MODEM OR TERMINAL OPERATION These are the general steps for troubleshooting problems with a modem connected to a Teledyne API's analyzer. 1. Check cables for proper connection to the modem, terminal or computer. 2. Check to ensure that the DTE-DCE is in the correct position as described in Section 3.1. 3. Check to ensure that the set up command is correct. 4. Verify that the Ready to Send (RTS) signal is at logic high. The analyzer sets pin 7 (RTS) to greater than 3 volts to enable modem transmission. 5. Ensure that the BAUD rate, word length, and stop bit settings between modem and analyzer match. 6. Use the RS-232 test function to send “w” characters to the modem, terminal or computer. 7. Get your terminal, modem or computer to transmit data to the analyzer (holding down the space bar is one way); the green LED should flicker as the instrument is receiving data. 8. Ensure that the communications software or terminal emulation software is functioning properly. NO2 à NO CONVERTER Provided that oxygen was present in the Sample stream during operation for the NO2 converter to function properly, the NO2 converter assembly can fail in two ways: • An electrical failure of the band heater and/or the thermocouple control circuit and; • A performance failure of the converter itself. NO2 à NO CONVERTER ELECTRICAL FAILURE NO2 converter heater failures can be divided into two possible categories: • 083730210A DCN8164 Temperature is reported properly but heater does not heat to full temperature. In this case, the heater is either disconnected or broken or the power relay is broken. • Disconnect the heater cable coming from the relay board and measure the resistance between any two of the three heater leads with a multi-meter. • The resistance between A and B should be about 1000 Ω. • The resistance between A and C should be the same as between B and C, about 500 Ω each. • If any of these resistances is near zero or without continuity, the heater is broken. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 145 • • Temperature reports zero or overload (near 500° C). This indicates a disconnected or failing thermocouple or a failure of the thermocouple circuit. • Check that the thermocouple is connected properly and the wire does not show signs of a broken or kinked pathway. • If it appears to be properly connected, disconnect the yellow thermocouple plug (marked K) from the relay board and measure the voltage (not resistance) between the two leads with a multi-meter capable of measuring in the low mV range. • The voltage should be about 12 mV (ignore the sign) at 315° C and about 0 mV at room temperature. Measure the continuity with an Ohm-meter. • It should read close to zero Ω. If the thermo-couple does not have continuity, it is broken. • If it reads zero voltage at elevated temperatures, it is broken. • To test the thermocouple at room temperature, heat up the converter can (e.g., with a heat gun) and see if the voltage across the thermocouple leads changes. • If the thermocouple is working properly, the electronic circuit is broken. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY If the thermocouple is broken, do NOT replace the thermocouple without first consulting the factory; using the wrong Type could cause permanent damage to the instrument. The Type K thermocouple has a red and a yellow wire. If in doubt, consult the factory. NO2 à NO CONVERTER FAILURE The efficiency at which the NO2 à NO converter changes NO2 into NO directly affects the accuracy of the NOx, NO and NO2 measurements. The analyzer’s firmware includes a Converter Efficiency (CE) gain factor that is multiplied by the NO2 and NOX measurements to calculate the final concentrations for each. This gain factor is stored in the analyzer’s memory. The default setting for the NO2 converter efficiency is 1.0000. Over time, the molybdenum in the NO2 à NO converter oxidizes and it becomes less efficient at converting NO2 into NO. To ensure accurate operation of the analyzer, it is important to check the NO2 conversion efficiency (CE) periodically. See Section 4.5 for checking and calculating the CE. 146 • For the analyzer to function correctly, the converter efficiency must be greater than 0.9600 (96% conversion efficiency) as per US-EPA requirements. • If the converter’s efficiency is below this limit, the NO2 converter should be replaced. • The current converter efficiency level is also recorded along with the calibration data in the DAS for documentation and performance analysis (Section 2.5.1). Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PHOTOMULTIPLIER TUBE (PMT) SENSOR MODULE The PMT detects the light emitted by the reaction of NO with ozone. It has a gain of about 500,000 to 1,000,000. It is not possible to test the detector outside of the instrument in the field. The basic method to diagnose a PMT fault is to eliminate the other components using ETEST, OTEST and specific tests for other sub-assemblies. OPTIC TEST (OTEST) The optic test function tests the response of the PMT sensor by turning on an LED located in the cooling block of the PMT (see Figure 5-19). The analyzer uses the light emitted from the LED to test its photo-electronic subsystem, including the PMT and the current to voltage converter on the pre-amplifier board. • To ensure that the analyzer measures only the light coming from the LED, the analyzer should be supplied with zero air. • The optic test should produce a PMT signal of about 2000±1000 mV. To activate the optics test, go to the Utilities>Diagnostics>OE Test menu and press the Run OTest button. Note This is a coarse test for functionality and not an accurate calibration tool. The resulting PMT signal can vary significantly over time and also changes with low-level calibration. ELECTRICAL TEST (ETEST) The electrical test function creates a current, which is substituted for the PMT signal and feeds it into the preamplifier board. • This signal is generated by circuitry on the pre-amplifier board itself and tests the filtering and amplification functions of that assembly along with the A/D converter on the motherboard. • It does not test the PMT itself. • The electrical test should produce a PMT signal of about 2000 ±1000 mV. To activate the electrical test, go to the Utilities>Diagnostics>OETest menu and press the Run ETest button. PMT PREAMPLIFIER BOARD To check the correct operation of the preamplifier board, perform an optics test (Utilities>Diagnostics>OE Test>Run OTest) and an electrical test (Utilities>Diagnostics>OE Test>Run ETest) described in Section 5.7.9.11 above. • If the instrument passes the OTEST but fails the ETEST, the preamplifier board may be faulty or need a hardware calibration. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 147 HIGH VOLTAGE POWER SUPPLY (HVPS) The HVPS is located in the interior of the sensor module and is plugged into the PMT tube. It requires two voltage inputs. • The first is +15 V, which powers the supply. • The second is the programming voltage which is generated on the preamplifier board. • Adjustment of the HVPS is covered in the factory calibration procedure in Section 5.7.10.4. This power supply has 10 independent power supply steps, one to each pin of the PMT. The following test procedure below allows you to test each step. 1. Turn off the instrument. 2. Remove the cover and disconnect the two connectors at the front of the NOx sensor module. 3. Remove the end cap from the sensor (four screws). 4. Remove the HVPS/PMT assembly from the cold block inside the sensor (two plastic screws). 5. Disconnect the PMT from the HVPS. 6. Re-connect the 7-pin connector to the sensor end cap, and power-up the instrument. 7. Navigate to the HVPS parameter in the Dashboard (if not shown, configure the Dashboard to display HVPS, Section 2.5.3). 8. Divide the displayed HVPS voltage by 10 and test the pairs of connector points as shown in the example below. 9. Check the overall voltage (should be equal to the HVPS value displayed in the Dashboard and the voltages between each pair of pins of the supply). EXAMPLE: if the HVPS signal is 700 V the pin-to-pin voltages should be 70 V. 10. Turn off the instrument power, and reconnect the PMT, and then reassemble the sensor. • If any faults are found in the test, you must obtain a new HVPS as there are no user serviceable parts inside the supply. 148 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PMT TEMPERATURE CONTROL PCA The temperature control PCA is located on the sensor housing assembly, under the slanted shroud, next to the cooling fins and directly above the cooling fan. If the red LED located on the top edge of this assembly is not glowing the control circuit is not receiving power. Check the analyzer’s power supply, the relay board’s power distribution circuitry and the wiring connecting them to the PMT temperature control PCA. TEC CONTROL TEST POINTS Four test points are also located at the top of this assembly and they are numbered left to right, starting with the T1 point immediately to the right of the power status LED. These test points provide information regarding the functioning of the control circuit. • To determine the current running through the control circuit, measure the voltage between T1 and T2. Multiply that voltage by 10. • To determine the drive voltage being supplied by the control circuit to the TEC, measure the voltage between T2 and T3. • If this voltage is zero, the TEC circuitry is most likely open. or, • • • If the voltage between T2 and T3 = 0 VDC and the voltage measured between T1 and T2 is 0 VDC, there is most likely an open circuit or failed op amp on control PCA itself. If the voltage between T2 and T3 is 0 VDC and the voltage measured between T1 to T2 is some voltage other than 0 VDC, the TEC is most likely shorted. T4 is tied directly to ground. To determine the absolute voltage on any one of the other test points make a measurement between that test point and T4. O3 GENERATOR The ozone generator can fail in two ways, electronically (printed circuit board) and functionally (internal generator components). Assuming that air is supplied properly to the generator, the generator should automatically turn on 30 minutes after the instrument is powered up or if the instrument is still warm. See Section 6.2.3 for ozone generator functionality. Accurate performance of the generator can only be determined with an ozone analyzer connected to the outlet of the generator. However, if the generator appears to be working properly but the sensitivity or calibration of the instrument is reduced, suspect a leak in the ozone generator supply air. A leak in the dryer or between the dryer and the generator can reduce sensitivity and cause performance drift. Carry out a leak check (Section 5.6.9). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 149 O3 GENERATOR OVERRIDE This feature in the Utilities>Diagnostics menu is used to manually turn the ozone generator off and on. This should be done before disconnecting the generator, to prevent ozone from leaking out, or after a system restart if the user does not want to wait for 30 minutes during warm-up time. Note The ozone generator does not turn on if the ozone flow conditions are out of specification, e.g., if there is no flow through the system or the pump is broken. VALVE OPTIONS The zero/span valves option must be enabled in the software (contact the factory on how to do this). The semi-permeable PTFE membrane of the permeation tube is severely affected by humidity. Variations in humidity between day and night are usually enough to yield very variable output results. If the instrument is installed in an air-conditioned shelter, the air is usually dry enough to produce good results. If the instrument is installed in an environment with variable or high humidity, variations in the permeation tube output will be significant. In this case, a dryer for the supply air is recommended (dewpoint should be –20° C or less). The permeation tube of the internal span gas generator option is heated with a proportional heater circuit and the temperature is maintained at 50°C ±1°C. Check the IZS Temp in the Dashboard or the IZS Temp Raw signal in the Utilities>Diagnostics>Analog Inputs menu. At 50° C, the temperature signal from the IZS thermistor should be around 2500 mV. TEMPERATURE SENSOR BOX TEMPERATURE SENSOR The box temperature sensor (thermistor) is mounted on the motherboard below the bottom edge of the CPU board when looking at it from the front. It cannot be disconnected to check its resistance. 150 • Box temperature will vary with, but will usually read about 5° C higher than, ambient (room) temperature because of the internal heating zones from the NO2 converter, reaction cell and other devices. • To check the box temperature functionality, we recommend checking the Box Temp signal voltage in the Utilities>Diagnostics>Analog Inputs menu (Section 5.7.3). • At about 30° C, the signal should be around 1500 mV. • To check the accuracy of the sensor, use a calibrated external thermometer / temperature sensor to verify the accuracy of the box temperature by: • Placing it inside the chassis, next to the thermistor labeled XT1 (above connector J108) on the motherboard. • Compare its reading to the value of the PMT TEMP. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PMT TEMPERATURE SENSOR CONTROL The temperature of the PMT should be low and constant. It is more important that this temperature is maintained at a constant level than it is to be a specific temperature. The PMT cooler uses a Peltier, thermo-electric cooler element supplied with 12 V DC power from the switching power supply PS2. The temperature is controlled by a proportional temperature controller located on the preamplifier board. • Voltages applied to the cooler element vary from 0.1 to 12 VDC. • The temperature set point (hard-wired into the preamplifier board) will vary by ±2 ° C. • The actual temperature will be maintained to within 0.1° C around that set point. To check the operation of the PMT temperature control system: 1. Turn off the analyzer and let its internal components cool / heat to ambient temperature. 2. Turn on the analyzer. 3. Set the front panel to show the PMT TEMP test function (Setup>Dashboard). • The temperature should fall steadily to 6-10° C. • If the temperature fails to reach this point after 60 minutes, there is a problem in the cooler circuit. • If the control circuit on the preamplifier board is faulty, a temperature of –1° C will be reported. SERVICE PROCEDURES This section contains some procedures that may need to be performed when a major component of the analyzer requires repair or replacement. Note Regular maintenance procedures are discussed in Section 5.5 and are not listed here). Also, there may be more detailed service notes for some of the below procedures. Contact Teledyne API's Technical Support Department. WARNING – ELECTRICAL SHOCK HAZARD Unless the procedure being performed requires the instrument to be operating, turn it off and disconnect power before opening the analyzer and removing, adjusting or repairing any of its components or subsystems. CAUTION – QUALIFIED TECHNICIAN The operations outlined in this chapter are to be performed by qualified maintenance personnel only. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 151 DISK-ON-MODULE REPLACEMENT PROCEDURE ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Servicing of circuit components requires electrostatic discharge protection, i.e. ESD grounding straps, mats and containers. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. For information on preventing ESD damage, refer to the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.com under Help Center > Product Manuals in the Special Manuals section. Replacing the Disk-on-Module (DOM) will cause loss of all DAS data; it may also cause loss of some instrument configuration parameters unless the replacement DOM carries the exact same firmware version. Whenever changing the version of installed software, the memory must be reset. Failure to ensure that memory is reset can cause the analyzer to malfunction, and invalidate measurements. After the memory is reset, the A/D converter must be re-calibrated, and all information collected in Step 1 below must be re-entered before the instrument will function correctly. Also, zero and span calibration should be performed. 1. Document all analyzer parameters that may have been changed, such as range, auto-cal, analog output, serial port and other settings before replacing the DOM. 2. Turn off power to the instrument, fold down the rear panel by loosening the mounting screws. 3. While looking at the electronic circuits from the back of the analyzer, locate the Disk-onModule in the right-most socket of the CPU board. 4. The DOM should carry a label with firmware revision, date and initials of the programmer. 5. Remove the nylon standoff clip that mounts the DOM over the CPU board, and lift the DOM off the CPU. Do not bend the connector pins. 6. Install the new Disk-on-Module, making sure the notch at the end of the chip matches the notch in the socket. 7. It may be necessary to straighten the pins somewhat to fit them into the socket. Press the chip all the way in. 8. Close the rear panel and turn on power to the machine. 9. If the replacement DOM carries a firmware revision, re-enter all of the setup information. 152 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 O3 GENERATOR REPLACEMENT The ozone generator is a black, brick-shaped device with a printed circuit board attached to its rear and two tubes extending out the right side in the front of the analyzer (see Figure 2-3). The board has a red LED that, when lit, indicates ozone is being generated. To replace the ozone generator: 1. Turn off the analyzer power; remove the power cord and the analyzer cover. 2. Disconnect the 1/8” black tube from the ozone scrubber cartridge and the ¼” clear tube from the plastic extension tube at the brass fitting nearest to the ozone generator. 3. Unplug the electrical connection on the rear side of the brick. 4. Unscrew the two mounting screws that attach the ozone generator to the chassis and take out the entire assembly. 5. If you received a complete replacement generator with circuit board and mounting bracket attached, simply reverse the above steps to replace the current generator. Ensure to carry out a leak check (Section 5.6.9) and a recalibration after the analyzer has warmed up for about 60 minutes. Note SAMPLE AND OZONE DRYER REPLACEMENT The analyzer’s standard configuration is equipped with a dryer for the ozone supply air. An optional dryer is available for the sample stream, and a combined dryer for both gas streams can also be purchased. To change one or both of these dryers: 1. Turn off power to the analyzer and pump, and remove the power cord and the analyzer cover. 2. Locate the dryer(s), and gently disconnect all tubing that extends out of the dryer assembly. Note Do not twist any of the white plastic fittings on the dryer: they connect the inner drying tube to the outer purge tube and are delicate. See Section 5.6.2. 3. Make note of the dryer’s orientation on the bracket in order to correctly position the replacement dryer. 4. Cut the tie wraps that hold the dryer to the mounting bracket and take out the old dryer. • If necessary, unscrew the two mounting screws on the bracket and take out the entire assembly. 5. Attach the replacement dryer to the mounting bracket in the same orientation as the old dryer. 6. Fix the dryer to the bracket using new tie wraps. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 153 7. Cut off excess length of the wraps. 8. Put the assembly back into the chassis and tighten the mounting screws. 9. Use at least two wrenches to carefully re-attach the tubes to vacuum manifold, flow meter and/or NO/NOx valve using at least two wrenches. Note Avoid twisting the dryer’s white plastic fittings, as this will result in large leaks, which are difficult to trouble-shoot or fix. 10. Carry out a detailed leak check (see Section 5.6.9.2), 11. Close the analyzer and reconnect the power cord. 12. Power up pump and analyzer and re-calibrate the instrument after it stabilizes. PMT SENSOR HARDWARE CALIBRATION The sensor module hardware calibration is used in the factory to adjust the slope and offset of the PMT output and to optimize the signal output and HVPS. • If the instrument’s slope and offset values are outside the acceptable range and all other more obvious causes for this problem have been eliminated, the hardware calibration can be used to adjust the sensor as was done in the factory. • This procedure is also recommended after replacing the PMT or the preamplifier board. To calibrate the PMT preamplifier PCA: 1. Perform a full zero point calibration using zero air (see Section 4.2.1.1). 2. Display the NOX Stability value either on the NOX plot by clicking the NOX label or value in the display, or if configured in a Home page meter (Section 2.5.6) or in the Dashboard (Section 2.5.3). 3. Locate the preamplifier board (PMT Preamp PCA) (see Figure 2-3). 4. Locate the following components on the preamplifier board (Figure 5-18): • HVPS coarse adjustment switch (Range 0-9, then A-F). • HVPS fine adjustment switch (Range 0-9, then A-F). • Gain adjustment potentiometer (Full scale is 10 turns). 5. Turn the gain adjustment potentiometer 12 turns clockwise or to its maximum setting. 6. Feed NO gas into the analyzer. • 154 This should be 90% of the upper limit setting for the analyzer’s reporting range; for example, if the reporting range is set at 500 ppb, use 450 ppb NO. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 7. Wait until the Stability is below 0.5 ppb Figure 5-18. Pre-Amplifier Board Layout 8. Scroll to the NORM PMT test function on the analyzer’s front panel. 9. With the NO gas concentrations mentioned in Step 5 above, the NORM PMT value should be 900 mV. 10. Set the HVPS coarse adjustment to its minimum setting (0). 11. Set the HVPS fine adjustment switch to its maximum setting (F). • Set the HVPS coarse adjustment switch to the lowest setting that will give you just above the target value for NORM PMT signal. 12. Adjust the HVPS fine adjustment such that the NORM PMT value is close to the target value. • It may be necessary to go back and forth between coarse and fine adjustments if the proper value is at the threshold of the min/max coarse setting. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Do not overload the PMT by accidentally setting both adjustment switches to their maximum setting. Start at the lowest setting and increment slowly: no sooner than every 10 seconds between adjustments. Note During these adjustments, the NORM PMT value will fluctuate as the analyzer continues to switch between NO and NOx streams as well as between measure and Auto Zero modes. 13. Perform a span point calibration (Section 4.2.1.2) to normalize the sensor response to its new PMT sensitivity. 14. Review the slope and offset values: 083730210A DCN8164 • The slope values should be 1.000 ±0.300. • The offset values should be approximately 0.0 (-20 to +150 mV is allowed). Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 155 REPLACING THE PMT, HVPS OR TEC The photo multiplier tube (PMT) should last for the lifetime of the analyzer, however, the high voltage power supply (HVPS) or the thermo-electric cooler (TEC) components may fail. Replacing any of these components requires opening the sensor module. This is a delicate assembly and it is recommend that you ensure the PMT, HVPS or TEC modules are, indeed, faulty before unnecessarily opening of the module. CAUTION – QUALIFIED PERSONNEL While the PMT or HVPS can be removed through the front panel without un-mounting the entire sensor module, we recommend turning off the instrument, opening its top cover and removing the entire assembly so that further repairs can be carried out at an anti-ESD workstation. Follow the guidelines for preventing electrostatic damage to electronic components, defined in the manual, Fundamentals of ESD, PN 04786, which can be downloaded from our website at http://www.teledyne-api.com under Help Center > Product Manuals in the Special Manuals section.. 1. Turn OFF the analyzer and disconnect the power cord. 2. Remove the cover. 3. Disconnect all pneumatic and electrical connections from the sensor assembly. 4. Remove the sensor assembly. 5. If the TEC is to be replaced, remove the reaction cell assembly at this point by unscrewing two holding screws. • 156 This is necessary only if the repair being performed involves removing the PMT cold block. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PMT Housing End Plate This is the entry to the PMT Exchange PMT Output Connector PMT Preamp PCA PMT Power Supply & Aux. Signal Connector High voltage Power Supply (HVPS) PMT O-Test LED Sensor Housing PMT Cold Block Connector to PMT Pre Amp PCA 12V Power Connector Insulation Gasket Insertion point for reaction cell assembly PMT Temperature Sensor (thermistor) Light from Reaction Chamber shines through hole in side of Cold Block Thermo-Electric Cooler (TEC) PMT Heat Exchange Fins TEC Driver PCA Cooling Fan Housing Figure 5-19. Sensor Assembly 6. Remove the two connectors on the PMT housing end plate facing towards the front panel. 7. Remove the end plate itself (4 screws with plastic washers). Note Any time the black PMT housing end plate for the Sensor Assembly is removed, replace the five desiccant bags inside the housing. 8. Remove the desiccant bags from the PMT housing. 9. Unscrew the PMT assembly, which is held to the cold block by two plastic screws. 10. Discard the plastic screws and replace with new screws at the end of this procedure (the threads get stripped easily and it is recommended to use new screws). 11. Along with the plate, slide out the optic test (O-Test) LED and the thermistor that measures the PMT temperature. 083730210A DCN8164 • Thermistor will be coated with a white, thermal conducting paste. • Do not contaminate the inside of the housing with this grease, as it may contaminate the PMT glass tube on re-assembly. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 157 12. Carefully take out the assembly consisting of the HVPS, the insulation gasket and the PMT. 13. Change the PMT or the HVPS or both, clean the PMT glass tube with a clean, anti-static wipe and do not touch it after cleaning. 14. If the cold block or TEC is to be changed: • Disconnect the TEC driver board from the preamplifier board, remove the cooler fan duct (4 screws on its side) including the driver board. • Disconnect the driver board from the TEC and set the sub-assembly aside. 15. Remove the end plate with the cooling fins (4 screws) and slide out the PMT cold block assembly, which contains the TEC. 16. Unscrew the TEC from the cooling fins and the cold block and replace it with a new unit. 17. Reassemble this TEC subassembly in reverse order. • Ensure to use thermal grease between TEC and cooling fins as well as between TEC and cold block and that the side opening in the cold block will face the reaction cell when assembled. • Evenly tighten the long mounting screws for good thermal conductivity. CAUTION – QUALIFIED PERSONNEL The thermo-electric cooler needs to be mounted flat to the heat sink. If there is any significant gap, the TEC might burn out. Ensure to apply heat sink paste before mounting it and tighten the screws evenly and cross-wise. 18. Reinsert the TEC subassembly in reverse order. • Ensure that the O-ring is seated properly and the assembly is tightened evenly. 19. Insert the O-Test LED and thermistor into the cold block, insert new desiccant bags and carefully replace the end plate by making sure that the O-ring is properly in place. • Improperly placed O-rings will cause leaks, which – in turn – cause moisture to condense on the inside of the cooler and likely cause a short in the HVPS. 20. Reinsert the PMT/HVPS subassembly in reverse order. • Don’t forget the insulation gasket between HVPS and PMT. • Use new plastic screws to mount the PMT assembly on the PMT cold block. 21. Install new silica gel packets (desiccant bags). 22. Reconnect the cables and the reaction cell (evenly tighten these screws). 23. Replace the sensor assembly into the chassis and fasten with four screws and washers. 24. Reconnect all electrical and pneumatic connections. 158 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 25. Leak check the system (see Section 5.6.9). 26. Turn ON the analyzer. 27. Verify the basic operation of the analyzer using the ETEST and OTEST features (Section 5.7.9.11) or zero and span gases, then carry out a hardware calibration of the analyzer followed by a zero/span point calibration Section 4.2.1). REMOVING / REPLACING THE RELAY PCA FROM THE INSTRUMENT This is the most commonly used version of the Relay PCA. It includes a bank of solid state AC relays. This version is installed in analyzers where components such as AC powered heaters must be turned ON & OFF. A retainer plate is installed over the relay to keep them securely seated in their sockets. Figure 5-20. Relay PCA with AC Relay Retainer In Place The Relay retainer plate installed on the relay PCA covers the lower right mounting screw of the relay PCA. Therefore, when removing the relay PCA, the retainer plate must be removed first. Figure 5-21. Relay PCA Mounting Screw Locations 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 159 FREQUENTLY ASKED QUESTIONS The following list was compiled from the Teledyne API's Technical Support Department’s ten most commonly asked questions relating to the analyzer. QUESTION ANSWER Why does the ENTR button sometimes disappear on the front panel display? Sometimes the ENTR button will disappear if you select a setting that is invalid or out of the allowable range for that parameter, such as trying to set the 24-hour clock to 25:00:00 or a range to less than 1 or more than 20000 ppb. Once you adjust the setting to an allowable value, the ENTR button will re-appear. Why is the ZERO or SPAN button deactivated during calibration? This happens when the measured gas concentration differs significantly from the span or zero gas concentration value entered by the user. This prevents accidental recalibration of the analyzer to an out-of-range response curve. EXAMPLE: The span set point is 400 ppb but gas concentration being measured is only 50 ppb. How do I enter or change the value of my Span Gas? See Section 4.2.1.2. Can I automate the calibration of my analyzer? Any analyzer with zero/span valve or IZS option can be automatically calibrated using the instrument’s AutoCal feature (Section 4.3). Can I use the IZS option to calibrate the analyzer? Yes. However, the accuracy of the IZS option’s permeation tube is only ±5%. To achieve highest accuracy, it is recommended to use cylinders of calibrated span gases in combination with a zero air source. How do I measure the sample flow? For accurate measurement, attach a calibrated flow meter to the sample inlet port, and get a reading while the instrument is operating. The sample flow should be as specified in Table 1-1. (To calibrate, use the Utilities>Diagnostics menu; refer to Section 5.6.9.3). How often do I need to change the particulate filter? Refer to the Maintenance Schedule in Table 5-1. Keep in mind that highly polluted sample air may require more frequent changes. How long does the sample pump last? The sample pump should last one to two years and the pump head should be replaced when necessary. If the reaction cell pressure value goes above 10 in-Hg-A, on average, the pump head needs to be rebuilt. Why does my RS-232 serial connection not work? There are several possible reasons: • The wrong cable: please use the provided or a generic “straightthrough” cable (do not use a “null-modem” type cable) and ensure the pin assignments are correct (Section 2.3.1.7 under RS-232 Connection. • The DCE/DTE switch on the back of the analyzer is not set properly; ensure that both green and red lights are on (Section 3.1). • The baud rate of the analyzer’s COM port does not match that of the serial port of your computer/data logger (Table 2-14). This most commonly occurs when an independent metering device is used besides the data logger/recorder to determine gas concentration levels while calibrating the analyzer. These disagreements result from the analyzer, the metering device and the data logger having slightly different ground levels. Use the data logger itself as the metering device during calibration procedures. How do I make the instrument’s display and my data logger agree? 160 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 QUESTION ANSWER Do the critical flow orifices of my analyzer require regular replacement? No. The o-rings and the sintered filter associated with them require replacement once a year, but the critical flow orifices do not. See Section 5.6.7 for instructions. How do I set up and use the contact closures (Control Inputs) on the rear panel of the analyzer? See Section 2.3.1.5. TECHNICAL ASSISTANCE If this manual and its troubleshooting & service section do not solve your problems, technical assistance may be obtained from: Teledyne API Technical Support 9970 Carroll Canyon Road San Diego, California 92131-1106 USA Toll-free Phone: +1 800-324-5190 Phone: +1 858-657-9800 Fax: +1 858-657-9816 Email: Website: 083730210A DCN8164 [email protected] http://www.teledyne-api.com/ Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 161 6. PRINCIPLES OF OPERATION The T200H/M Nitrogen Oxides Analyzer is a microprocessor controlled instrument that determines the concentration of nitric oxide (NO), total nitrogen oxides (NOX, the sum of NO and NO2) and nitrogen dioxide (NO2) in a sample gas drawn through the instrument. • It requires that sample and calibration gases be supplied at ambient atmospheric pressure in order to establish a constant gas flow through the reaction cell where the sample gas is exposed to ozone (O3), initiating a chemical reaction that gives off light (hv). • The instrument measures the amount of chemiluminescence to determine the amount of NO in the sample gas. • A catalytic-reactive converter converts NO2 in the sample gas to NO which, along with the NO present in the sample is reported as NOX. NO2 is calculated as the difference between NOX and NO. Calibration of the instrument is performed in software and usually does not require physical adjustments to the instrument. During calibration, the microprocessor measures the sensor output signal when gases with known amounts of NO or NO2 are supplied and stores these results in memory. The microprocessor uses these calibration values along with the signal from the sample gas and data of the current temperature and pressure of the gas to calculate a final NOX concentration. The concentration values and the original information from which it was calculated are stored in the unit’s internal data acquisition system and are reported to the user through a vacuum fluorescence display or several output ports. MEASUREMENT PRINCIPLE CHEMILUMINESCENCE CREATION IN THE REACTION CELL The analyzer measures the amount of NO present in a gas by detecting the chemiluminescence which occurs when nitrogen oxide (NO) is exposed to ozone (O3). This reaction is a two-step process: • In the first step, one molecule of NO and one molecule of O3 collide and chemically react to produce one molecule of oxygen (O2) and one molecule of nitrogen dioxide (NO2). Some of the NO2 molecules created by this reaction retain excess energy from the collision and exist in an excited state, where one of the electrons of the NO2 molecule resides in a higher energy state than normal (denoted by an asterisk in the following equation). * 2 NO + O3 → NO + O2 162 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software Equation 6-1 083730210A DCN8164 • The second step occurs because the laws of thermodynamics require that systems seek the lowest stable energy state available, therefore the excited NO2 molecule quickly returns to its ground state, releasing the excess energy. This release takes the form of a quantum of light (hν). The distribution of wavelengths for these quanta range between 600 and 3000 nm, with a peak at about 1200 nm. Equation 6-2 NO2* → NO2 + hν 1200 nm • All things being constant (temperature, pressure, amount of ozone present, etc.), the relationship between the amount of NO present in the reaction cell and the amount of light emitted from the reaction is very linear. If more NO is present, more IR light is produced. By measuring the amount of IR light produced with a sensor sensitive in the near-infrared spectrum (see Figure 6-2) the amount of NO present can be determined. In addition, sometimes the excited NO2 collides with other gaseous molecules in the reaction cell chamber or even the molecules of the reaction cell walls and transfers its excess energy to this collision partner (represented by M in Equation 6-3 below) without emitting any light at all. In fact, by far the largest portion of the excited NO2 returns to the ground state this way, leaving only a few percent yield of usable chemiluminescence. Equation 6-3 NO2* + M → NO2 + M The probability of a collision between the NO2* molecule and a collision partner M increases proportionally with the reaction cell pressure. This non-radiating collision with the NO2* molecules is usually referred to as third body quenching, an unwanted process further described in Section 6.1.5.2. Even under the best conditions only about 20% of the NO2 that is formed by the reaction described in equation 12-1 is in the excited state. In order to maximize chemiluminescence, the reaction cell is maintained at reduced pressure (thereby reducing the amount of available collision partners) and is supplied with a large, constant excess of ozone (about 3000-5000 ppm) from the internal ozone generator. CHEMILUMINESCENCE DETECTION IN THE REACTION CELL The detection of chemiluminescence involves the use of a photo multiplier tube (PMT) and an optical filter working together with the reaction cell, as described in the next two subsections and illustrated in Figure 6-1. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 163 THE PHOTO MULTIPLIER TUBE (PMT) The analyzer uses a special kind of vacuum tube, called a photo-multiplier tube (PMT), to detect the amount of light created by the NO and O3 reaction in the reaction cell. Photons enter the PMT and strike a negatively charged photo cathode causing it to emit electrons. These electrons are accelerated by an applied high voltage and multiplied through a sequence of similar acceleration steps (dynodes) until a useable current signal is generated (see Section 6.6 for a more detailed description). The more light present (in this case photons given off by the chemiluminescent reaction described above), the more current is produced. Therefore the more NO present in the reaction cell the more current is produced by the PMT. The current produced by the PMT is converted to a voltage and amplified by the preamplifier board and then communicated to the analyzer’s CPU via the Aà D converter circuitry on the analyzer. OPTICAL FILTER A high pass optical filter, only transparent to wavelengths of light above 645nm, placed between the reaction cell and the PMT (see Figure 6-1) in conjunction with the response characteristics of the PMT creates a very narrow window of wavelengths of light to which the analyzer will respond. O3 NO Reaction Cell NO+O3 Optical Filter PMT PMT HOUSING Figure 6-1. Reaction Cell with PMT Tube and Optical Filter The narrowness of this band of sensitivity allows the analyzer to ignore extraneous light and radiation that might interfere with the analyzer’s measurement (more on interferents in Section 6.1.5). For instance, some oxides of sulfur can also be chemiluminescent emitters when in contact with O3 but give off light at much shorter wavelengths (usually around 260nm to 480nm). 164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 140 Visible Infrared àà Intensity (arbitrary units) 120 Spectrum 100 80 NO + O3 Emission Spectrum PMT Response 60 40 20 Optical Hi-Pass Filter Performance 0 0.5 0.7 0.9 1.1 1.3 1.7 1.5 1.9 Wavelength (micrometers) Area of Sensitivity Figure 6-2. Sensitivity Spectrum NOX AND NO2 DETERMINATION The only gas that is actually measured by the T200H/M is NO. NO2, and therefore NOx (which is defined here as the sum of NO and NO2 in the sample gas), contained in the gas is not detected because NO2 does not react with O3 to create chemiluminescence. In order to measure the concentration of NO2, and therefore the concentration of NOx, the analyzer periodically switches the sample gas stream so that the pump pulls it through a special converter cartridge filled with molybdenum (Mo, “moly”) chips that are heated to a temperature of 315°C. 3 NO/NOX VALVE 1 2 NO only AUTOZERO VALVE 2 NO2 + Mo NO + MoyOz at 315˚C MOLYBDENUM CONVERTER 1 To Exhaust Manifold & Pump NO only 3 O3 from O3 Generator NO+O3 To Exhaust Manifold & Pump NO2 + NO from Sample Gas Inlet PMT Figure 6-3. NO2à NO Conversion 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 165 The heated molybdenum reacts with NO2 in the sample gas and produces a NO gas and a variety of molybdenum. Equation 6-4 xNO2 + yMo → xNO + M y Oz (at 315° C ) Once the NO2 in the sample gas has been converted to NO, it is routed to the reaction cell where it undergoes the chemiluminescence reaction described in Equation 6-1 and Equation 6-2. By converting the NO2 in the sample gas into NO, the analyzer can measure the total NOX content of the sample gas (i.e. the NO present + the converted NO2 present). By switching the sample gas stream in and out of the “moly” converter every 6 - 10 seconds, the analyzer is able to quasi-continuously measure both the NO and the total NOX content. Finally, the NO2 concentration is not directly measured but calculated by subtracting the known NO content of the sample gas from the known NOX content. AUTO ZERO Inherent in the operation of any PMT is a certain amount of noise. This is due to a variety of factors such as black body infrared radiation given off by the metal components of the reaction cell, unit to unit variations in the PMT units and even the constant universal background radiation that surrounds us at all times. In order to reduce this amount of noise and offset, the PMT is kept at a constant 7° C (45° F) by a Thermo-Electric Cooler (TEC). While this intrinsic noise and offset is significantly reduced by cooling the PMT, it is not eradicated. To determine how much noise remains, once every minute for a short period the analyzer diverts the sample gas flow directly to the vacuum manifold, bypassing the reaction cell. During this period, only O3 is present in the reaction cell, effectively turning off the chemiluminescence reaction. Once the cell is completely dark (“zero” light), the analyzer records the output of the PMT and keeps a running average of these Auto Zero (Azero) values. This average offset value is subtracted from the raw PMT readings while the instrument is measuring NO and NOX to arrive at an Auto Zero corrected reading. 166 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 NO/NOX Valve Molybdenum Converter NO2 + Mo NO + MoyO2 at 315 oC NO + NOx (All NO2 converted to NO) Exhaust (Gas flow alternately diverted between Exhaust and Reaction Cell during Auto-Zero) Auto-Zero Valve O3 Generator Sample Gas REACTION CELL: O3 only (when gas flow is diverted during Auto-Zero) O3 Scrubber Exhaust Figure 6-4. Reaction Cell during the Auto Zero Cycle 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 167 MEASUREMENT INTERFERENCES Interferences in the chemiluminescence method come from a number of sources. The analyzer has been successfully tested for its ability to reject interference from most of these sources. Table 6-1 lists the most common types of interferents that could affect the analyzer’s performance. Table 6-1. List of Interferents GAS CO2 SOX H2O NH3 INTERFERENCE TYPE Dilution: Viscosity of CO2 molecules causes them to collect in aperture of Critical Flow Orifice altering flow rate of NO. 3rd Body Quenching: CO2 molecules collide with NO2* molecules absorbing excess energy kinetically and preventing emission of photons. REJECTION METHOD If high concentrations of CO2 are suspected, special calibration methods must be performed to account for the effects of the CO2. Contact Teledyne API’s Technical Support Department (Section 5.9) for details. Some SOX variants can also initiate a chemiluminescence reaction upon exposure to O3 producing excess light. Wavelengths of light produced by chemiluminescence of SOX are screened out by the Optical Filter. Chemically reacts with NH3, O2 and H2O in O3 generator to create (NH3)2SO4 (ammonium sulfate) and NH3NO2 (ammonium nitrate) which form opaque white deposits on optical filter window. Also forms highly corrosive HNO3 (Nitric Acid) Most of the ammonium sulfate and ammonium nitrate produced is removed from the sample gas by the Ozone cleanser located between the O3 Generator and the reaction cell. 3rd Body quenching: SOX molecules collide with NO2* molecules absorbing excess energy kinetically and preventing emission of photons. If high concentrations of SOX are suspected, special calibration methods must be performed to account for the effects of the SO2. Contact Teledyne API’s Technical Support Department (Section 5.9) for details. 3rd Body quenching: H2O molecules collide with NO2* molecules absorbing excess energy kinetically and preventing emission of light. Analyzer’s operating in high humidity areas must have some drying applied to the sample gas (call Sales for information regarding sample dryers). Water also reacts with NH3 and SOX in the O3 generator to create (NH3)2SO4 (ammonium sulfate) and NH3NO2 (ammonium nitrate) which form opaque white deposits on the optical filter window. This also forms highly corrosive HNO3 (nitric acid) Water is effectively removed from the O3 gas stream by the Nafion Dryer (Section 6.2.3.2 for more details). We offer several Sample dryers for the sample stream (call Sales for info). NH3 also reacts with H2O, O2 and SOX in the O3 generator to create (NH3)2SO4 (ammonium sulfate) and NH3NO2 (ammonium nitrate) which form opaque white deposits on optical filter window. Also forms highly corrosive HNO3 (nitric acid). The Sample dryer option is sufficient for removing typical ambient concentration levels of NH3. DIRECT INTERFERENCE Some gases can directly alter the amount of light detected by the PMT due to chemiluminescence in the reaction cell. This can either be a gas that undergoes chemiluminescence by reacting with O3 in the reaction cell or a gas that reacts with other compounds and produces excess NO upstream of the reaction cell. 168 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 THIRD BODY QUENCHING As described by Equation 6-3, other molecules in the reaction cell can collide with the excited NO2*, causing the excited NO2* to return to its ground state without releasing a photon of light. This is known as third party quenching. Quenching is an unwanted phenomenon and the extent to which it occurs depends on the properties of the collision partner. • Larger, more polarized molecules such as H2O and CO2 are the most significant quenching interferents of NO chemiluminescence. • The influence of water vapor on the analyzer’s measurement can be eliminated with an optional, internal sample gas dryer (call Sales for information). • The interference of varying CO2 amounts at low concentrations (less than 0.5%) is negligible. • In cases with excessively high CO2 concentrations (larger than 0.5%), the effect can be calibrated out by using calibration gases with a CO2 content equal to the measured air. • The T200H and T200M analyzers are typically used in high CO2 concentration environments. The pneumatic setup of these two analyzer models minimizes the interference from CO2 such that the analyzers conform to the standards set forth by the US-EPA in Method 20 - NOx from Stationary Gas Turbines, available at http://www.epa.gov/ttn/emc/promgate.html. • Only very high and highly variable CO2 concentrations will then cause a measurable interference. For those applications, it is recommended to use other analyzer models. Please consult Teledyne API's Sales Department or our website (front cover, this manual). • Smaller less polar and electronically “harder” molecules such as N2 and O2 can cause interference of this type as well, however, the concentrations of N2 and O2 are virtually constant in ambient air measurements, hence provide a constant amount of quenching that is accounted for in the calibration of the instrument . LIGHT LEAKS The sensitivity curve includes a small portion of the visible light spectrum (see Figure 6-2), therefore it is important to ensure that the reaction cell is completely sealed with respect to light. To ensure this: • All pneumatic tubing leading into the reaction cell is opaque in order to prevent light from entering the cell. • Light penetration is prevented by stainless steel filters and orifices. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 169 REACTION CELL TEMPERATURE CONTROL The stability of the chemiluminescence reaction between NO and O3 can be affected by changes in the temperature and pressure of the O3 and sample gases in the reaction cell. In order to reduce temperature effects, the reaction cell is maintained at a constant 50° C, just above the high end of the instrument’s operation temperature range. Two AC heaters, one embedded into the bottom of the reaction cell, the other embedded directly above the chamber’s exhaust fitting, provide the heat source. These heaters operate off of the instrument’s main AC power and are controlled by the CPU through a power relay on the relay board (see Section 6.4.4.4). A thermistor, also embedded in the bottom of the reaction cell, reports the cell’s temperature to the CPU through the thermistor interface circuitry of the motherboard (see Section 6.4.3.3). 170 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PNEUMATIC OPERATION Important IMPACT ON READINGS OR DATA The sample gas is the most critical flow path in the analyzer. At any point before and in the reaction cell, the integrity of the sample gas must not be compromised. Therefore, it is important that the sample airflow system is both leak tight and not pressurized over ambient pressure. Regular leak checks should be performed on the analyzer as presented in the maintenance schedule, Table 5-1. Procedures for correctly performing leak checks can be found in Section 5.6.9. SAMPLE GAS FLOW Note In this section of the manual vacuum readings are given in inches of mercury absolute (In-Hg-A). This pressure value is referenced against zero (a perfect vacuum). The sample gas flow is created by an external vacuum pump that is located pneumatically downstream from the rest of the instrument’s components. • The pump creates a vacuum of approximately 5 in-Hg-A which is distributed to various pneumatic components by a vacuum manifold, located just in front of the rear panel (see Figure 2-3). Gas flow is created by keeping the analyzer’s sample gas inlet near ambient pressure, usually by means of a small vent installed in the sample line at the inlet, in effect pulling the gas through the instrument’s pneumatic systems. By placing the pump downstream from the analyzer’s reaction cell, several problems are avoided. • First, the pumping process heats and compresses the sample air complicating the measurement process. • Additionally, certain physical parts of the pump itself are made of materials that might chemically react with the sample gas. • Finally, in certain applications where the concentration of the target gas might be high enough to be hazardous, maintaining a negative gas pressure relative to ambient means that should a minor leak occur, no sample gas would be pumped into the atmosphere surrounding the analyzer. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 171 VACUUM MANIFOLD The vacuum created by the analyzer’s pump is supplied to all of the gas streams for the analyzer through the vacuum manifold (also called the exhaust manifold). Figure 6-5. Vacuum Manifold, Standard Configuration Configurations will vary depending on the optional equipment that is installed. For example: 172 • An optional internal span gas generator installed will add another FT8 connector and orifice assembly to the manifold where the FT28 fitting is as shown in the above drawing. • An optional sample gas dryer will add a Tee-fitting so that two ¼” tubes can be connected to the same port. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 SAMPLE GAS FLOW VALVES AND ROUTING As discussed in Section 6.1, the measurement of NOx, NO and NO2 requires that the sample gas flow cycles through different routes that include and exclude various scrubbers and converters. There are several valves that perform this function: • The NO/NOX valve directs the sample gas either directly to the reaction cell or through the unit’s NO2 converter, alternating every ~8 sec. • The Auto Zero valve directs the sample gas stream to completely bypass the reaction cell for dark noise measurement once every minute, which is then subtracted as a measurement offset from the raw concentration signal. Table 6-2. Valve Cycle Phases PHASE NO/ NOX VALVE STATUS AUTO ZERO VALVE STATUS NO Measure Open to Auto Zero valve Open to reaction cell NOX Measure Open to NO2 converter Open to reaction cell TIME INDEX ACTIVITY 0-2s Wait period (NO dwell time). Ensures reaction cell has been flushed of previous gas. 2-4s Analyzer measures chemiluminescence in reaction cell. 4–6s Wait period (NOX dwell time). Ensures reaction cell has been flushed of previous gas. 6–8s Analyzer measures NO + O3 chemiluminescence in reaction cell. FIGURE Figure 6-3 Figure 6-3 Cycle repeats every ~8 seconds Auto Zero Open to Auto Zero valve Open to vacuum manifold 0–4s Wait period (AZERO dwell time). Ensures reaction cell has been flushed of sample gas and chemiluminescence reaction is stopped. 4-6s Analyzer measures background noise without sample gas Figure 6-4 Cycle repeats every minute FLOW RATE CONTROL - CRITICAL FLOW ORIFICES Sample gas flow in the analyzer is created via the use of several flow control assemblies (see Figure 6-6 for an example) located in various places in the gas streams of the instrument. These assemblies consist of: • a critical flow orifice • two o-rings, Located just before and after the critical flow orifice, the o-rings seal the gap between the walls of assembly housing and the critical flow orifice • a sintered filter • a spring (applies mechanical force needed to form the seal between the o-rings, the critical flow orifice and the assembly housing) 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 173 Figure 6-6. Flow Control Assembly & Critical Flow Orifice CRITICAL FLOW ORIFICE The most important component of each flow control assembly is the critical flow orifice. Critical flow orifices are a simple means to regulate stable gas flow rates. They operate without moving parts by taking advantage of the laws of fluid dynamics. By restricting the flow of gas through the orifice, a pressure differential is created. This pressure differential, created by the analyzer’s external pump, draws the gas through the orifice. As the pressure on the downstream side of the orifice (the pump side) continues to drop, the speed that the gas flows though the orifice continues to rise. Once the ratio of upstream pressure to downstream pressure is greater than 2:1, the velocity of the gas through the orifice reaches the speed of sound. As long as that ratio stays at least 2:1, the gas flow rate is unaffected by any fluctuations, surges, or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice. The actual flow rate of gas through the orifice (volume of gas per unit of time), depends on the size and shape of the aperture in the orifice. The larger the holes, the more gas molecules (moving at the speed of sound) pass through the orifice. In addition to controlling the gas flow rates into the reaction cell, the two critical flow orifices at the inlets of the reaction cell also maintain an under-pressure inside it, effectively reducing the number of molecules in the chamber and the corresponding incidence of third body quenching (see Section 6.1.5.2), and thereby increasing the chemiluminescence yield. The analyzer reaches its peak sensitivity at about 2 in-Hg-A, below which the sensitivity drops due to there being too few molecules present and a corresponding decrease in chemiluminescence. 174 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 LOCATIONS AND DESCRIPTIONS OF CRITICAL FLOW ORIFICES Several critical flow orifices (Figure 6-7) are used to create and maintain the proper flow rate of gas through its various components. (Please note that Figure 6-7 represents the standard configuration and is provided for reference). FLOW PRESSURE SENSOR PCA SAMPLE GAS INLET NO2 Converter NO/NOX VALVE Gas Flow Control Assemblies SAMPL E PRESS URE SENSO R AUTOZERO VALVE O3 GENERATOR EXHAUST MANIFOLD Orifice Dia. 0.007" NOX Exhaust Scrubber O3 FLOW SENSO R VACUUM PRESS URE SENSO R EX HA UST GAS OUTLET Orifice Dia. 0.003" Orifice Dia. 0.007" O3 Scrubber REACTION CELL Orifice Dia. 0.004" PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 6-7. Location of Flow Control Assemblies for T200H 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 175 NO2 Converter EXHAUST MANIFOLD Gas Flow Control Assemblies VACUUM PRESS URE SENSO R SAMPL E PRESS URE SENSO R AUTOZERO VALVE O3 GENERATOR Orifice Dia. 0.007" Orifice Dia. 0.007" REACTION CELL Orifice Dia. 0.004" O3 FLOW SENSO R EX HA UST GAS OUTLET NOX Exhaust Scrubber FLOW PRESSURE SENSOR PCA NO/NOX VALVE SAMPLE GAS INLET O3 Scrubber PMT Filter PUMP OZONE DRYER INSTRUMENT CHASSIS Figure 6-8. Location of Flow Control Assemblies for T200M Table 6-3. T200H/M Critical Flow Orifice Diameters and Gas Flow Rates LOCATION PURPOSE Bypass manifold 1 out to NO/NOx valve and NO2 converter Vacuum manifold: Bypass manifold 1 Port ORIFICE DIAMETER T200H T200M T200H T200M Controls rate of flow of sample gas into the NO2 converter and reaction cell. 0.003” 0.007” 40 250 Controls rate of sample gas flow that bypasses the analyzer when bypassing the reaction cell during the auto-zero cycle. 0.007” N/A 250 N/A 290 250 80 80 370 330 TOTAL INLET GAS FLOW – Standard Configuration Vacuum manifold: O2 sensor port Controls rate of flow of zero purge gas through the O2 sensor (when installed and enabled) when inactive. 0.004" 0.004" TOTAL INLET GAS FLOW – With O2 Sensor Option 1 NOMINAL FLOWRATE (CM³/MIN) O3 supply inlet of reaction cell. Controls rate of flow of ozone gas into the reaction cell. 0.007” 0.007” 250 250 Dry air return of permeation dryer Controls flow rate of dry air return / purge air of the dryer. 0.004" 0.004" 80 80 Bypass manifold is built into the 3-port reaction cell. 176 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 The necessary 2:1 ratios across the critical flow orifices is largely exceeded by the pumps supplied with the analyzer which are designed to accommodate a wide range of possible variability in atmospheric pressure and age related degradation of the pump itself. Once the pump does degrade the ratio between sample and vacuum pressures may fall to less than 2:1. At this point, the instrument will display an invalid sample flow rate measurement. Note The diameter of a critical flow orifice may change with temperature because of expansion of the orifice material and, hence, the most crucial critical flow orifices (those controlling the sample gas and O3 flow into the cell itself) are located in the reaction cell where they can be maintained at a constant temperature. OZONE GAS GENERATION AND AIR FLOW The excess ozone needed for reaction with NO in the reaction cell is generated inside the analyzer due to the instability and toxicity of ozone. Besides the ozone generator itself, this requires a dry air supply and filtering of the gas before it is introduced into the reaction cell. Because of its toxicity and aggressive chemical behavior, O3 must also be removed from the gas stream before it can be vented through the exhaust outlet. In contrast to the sample flow, the ozone flow is measured with a mass flow sensor, which is mounted on the pneumatic sensor board, just behind the PMT sensor assembly. This mass flow sensor has a full scale range of 0-1000 cm³/min and can be calibrated through software to its span point. As the flow value displayed on the front panel is an actual measurement (and not a calculated value), the flow variability may be higher than that of the sample flow, which is based on a calculation from (more stable) differential pressures. On the other hand, the drift, i.e. long-term change, in the ozone flow rate may be higher and usually indicates a flow problem. As with all other test parameters, we recommend to monitor the ozone flow over time for predictive diagnostics and maintenance evaluation. CAUTION – GENERAL SAFETY HAZARD Ozone (O3) is a toxic gas. Obtain a Material Safety Data Sheet (MSDS) for this gas. Read and rigorously follow the safety guidelines described there. Always ensure that the plumbing of the O3 generation and supply system is maintained and leak-free. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 177 THE O3 GENERATOR The analyzer uses a dual-dielectric, Corona Discharge (CD) tube for creating its O3, which is capable of producing high concentrations of ozone efficiently and with low excess heat (see Figure 6-9). The primary component of the generator is a glass tube with hollow walls of which the outermost and innermost surfaces are coated with electrically conductive material. Air flows through the glass tube, between the two conductive coatings, in effect creating a capacitor with the air and glass acting as the dielectric. The layers of glass also separate the conductive surfaces from the air stream to prevent reaction with the O3. As the capacitor charges and discharges, electrons are created and accelerated across the air gap and collide with the O2 molecules in the air stream splitting them into elemental oxygen. Some of these oxygen atoms recombine with O2 to O3. The quantity of ozone produced is dependent on factors such as the voltage and frequency of the alternating current applied to the CD cells. When enough high-energy electrons are produced to ionize the O2 molecules, a light emitting, gaseous plasma is formed, which is commonly referred to as a corona, hence the name corona discharge generator. Figure 6-9. Ozone Generator Principle OZONE GENERATOR DRY AIR SUPPLY (PERMEATION DRYER) The air supplied to the O3 generation system needs to be as dry as possible. Ambient air usually contains enough water vapor to greatly diminish the yield of ozone produced by the ozone generator. Water also reacts with chemicals inside the O3 Generator to produce caustic substances such as ammonium sulfate or highly corrosive nitric acid that will damage the optical filter located between the reaction cell and the PMT. To prevent this, the air supply for the O3 generator is dried using a special single tube permeation dryer. The dryer consists of a single tube of Nafion® that is mounted within an outer, flexible plastic tube. Nafion® is a co-polymer that absorbs water very well but not most other chemicals. As gas flows through the inner Nafion® tube, water vapor is absorbed into the membrane walls. The absorbed water is transported through the membrane wall and evaporated into the dry purge gas flowing through the outer tube, countercurrent to the gas in the inner tube. 178 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Figure 6-10. Semi-Permeable Membrane Drying Process The process by which the water vapor molecules are collected and transported through Nafion® material is called pervaporation and is driven by the humidity gradient between the inner and outer tubes as well as the flow rates and pressure difference between inner and outer tubing. Unlike micro-porous membrane permeation, which transfers water through a relatively slow diffusion process, per-evaporation is a simple kinetic reaction. Therefore, the drying process occurs quickly, typically within milliseconds. Because this chemical reaction is based on hydrogen bonds between the water molecule and the Nafion® material most other chemical components of the gas to be dried are usually unaffected. Specifically, the gases of interest, NO and NO2, do not get absorbed and pass the dryer unaltered. On the other hand, other small polar gases that are capable of hydrogen bonds such as ammonia (NH3) can be absorbed this way, too. This is an advantage since gases such as NH3 can cause interference for the measurement of NOx, NO and NO2 (see Table 6-1). Figure 6-11. Sample Dryer 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 179 To provide a dry purge gas for the outer side of the Nafion® tube, the analyzer returns some of the dried air from the inner tube to the outer tube. This means that any time the analyzer is turned on after having been OFF for 30 minutes or more, the humidity gradient between the inner and outer tubes is not very large and the dryer’s efficiency is low. It takes a certain amount of time for the humidity gradient to become large enough for the Sample Dryer operate efficiently, in such cold start cases the O3 Generator is not turned on until 30 minutes has passed in order to ensure that it is not operating until its air supply is properly dry. Note When rebooting the instrument within less than 30 minutes of power-down, the generator is turned on immediately. The Sample Dryer is capable of adequately drying ambient air to a dewpoint of ≤ -5˚C (~4000 ppm residual H2O) at a flow rate of 1 standard liter per minute (slpm) or down to ≤ -15˚C (~1600 ppm residual H2O) at 0.5 slpm. The Sample Dryer is also capable of removing ammonia from the sample gas up to concentrations of approximately 1 ppm. OZONE SUPPLY AIR FILTER The analyzer uses ambient air as the supply gas for the O3 generator and may produce a variety of byproducts. Small amounts of water, ammonia and various sulfur oxides can combine to create ammonium sulfate, ammonium nitrate, nitric acid and other compounds. Whereas sulfates and nitrates can create powdery residues inside the reaction cell causing sensitivity drift, nitric acid is a very aggressive compound, which can deteriorate the analyzer’s components. In order to remove these chemical byproducts from the O3 gas stream, the output of the O3 generator flows through a special filter between the generator and the reaction cell. The small amount of NOX that may be produced in the generator (from the reaction of O2 or O3 and N2 in the air) will not affect the analyzer’s ability to measure NOx, NO and NO2 as it is accounted for and removed from the concentration calculations by the analyzer’s Auto Zero feature (see Section 6.1.4). OZONE DESTRUCT Even though ozone is unstable and typically reacts to form O2, the break-down is not quite fast enough to ensure that it is completely removed from the exhaust gas stream by the time the gas exits the analyzer. Due to the high toxicity and reactivity of O3, a highly efficient catalytic converter scrubs or converts all of the O3 from the gas exiting the reaction cell. The conversion process is very safe: it only converts ozone to oxygen and does not produce any toxic or hazardous gases. The O3 destruct is located just inside the NO2 converter. As this is a true catalytic converter, there are no maintenance requirements as would be required for charcoal-based ozone destructs. 180 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 A certain amount of fine, black dust may exit the catalyst, particularly if the analyzer is subjected to sudden pressure drops (for example, when disconnecting the running pump without letting the analyzer properly and slowly equilibrate to ambient pressure). To prevent the dust from entering the reaction cell or the pump, the ozone destruct is equipped with a quartz wool filter material. PNEUMATIC SENSORS Note The analyzer displays all pressures in inches of mercury absolute (in-Hg-A), i.e. absolute pressure referenced against zero (a perfect vacuum). Three pneumatic sensors verify the flow and pressure levels of the gas streams. They are located on a printed circuit assembly, called the pneumatic pressure/flow sensor board, located just behind the sensor assembly. The measurements made by these sensors are used for a variety of important calculations and diagnostics. VACUUM MANIFOLD The vacuum manifold is the central exit port for all analyzer pneumatics. All gas streams of the analyzer exit through this assembly and connect to the instrument’s pump. Figure 6-12 shows the standard configuration. Configurations will vary depending on the optional equipment that is installed. An IZS option, for example, will add another FT8 connector and orifice assembly to the manifold, an optional sample dryer may add a Tee-fitting so that two ¼” tubes can be connected to the same port. At this time, the vacuum manifold does not yet support the orifice holder shown in Figure 5-11. To exchange the critical orifice installed in the vacuum manifold, the user needs to either blow the orifice out with reversed pressure or remove the entire manifold for this task. However, orifices installed in the vacuum manifold should not have to be cleaned under normal circumstances. Figure 6-12. Vacuum Manifold 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 181 SAMPLE PRESSURE SENSOR An absolute pressure transducer connected to the input of the NO/NOX valve is used to measure the pressure of the sample gas before it enters the analyzer’s reaction cell. • In conjunction with the measurement made by the vacuum pressure sensor, this “upstream” measurement is used to compute the sample gas sample flow rate and to validate the critical flow condition (2:1 pressure ratio) through the sample gas critical flow orifice (Section 6.2.2). • If the Temperature/Pressure Compensation (TPC) feature is turned on (Section 6.10.2), the output of this sensor is also used to supply pressure data for that calculation. VACUUM PRESSURE SENSOR An absolute pressure transducer connected to the exhaust manifold is used to measure the pressure downstream from and inside the instrument’s reaction cell. • The output of the sensor is used by the CPU to calculate the pressure differential between the gas upstream of the reaction cell and the gas downstream from it and is also used as the main diagnostic for proper pump operation. • If the ratio between the upstream pressure and the downstream pressure falls below 2:1, an Alert is triggered, and the sample flow rate will not display an actual value. • If this pressure exceeds 10 in-Hg-A, an Rx Press Alert is issued, even though the analyzer will continue to calculate a sample flow up to ~14 in Hg. • If the Temperature/Pressure Compensation (TPC) feature is turned on (see Section 6.10.2), the output of this sensor is also used to supply pressure data for that calculation. O3 SUPPLY AIR FLOW SENSOR In contrast to the sample gas flow, the ozone flow is measured with a mass flow sensor, which is mounted on the flow/pressure sensor PCA just behind the PMT sensor assembly. Pneumatically, it lies between the sample dryer and the O3 generator. This mass flow sensor has a full scale range of 0-1000 cc/min and can be calibrated through software to its span point (Section 4.5). Since the flow value displayed on the front panel is an actual measurement (and not a calculated value), short term variability in the measurement may be higher than that of the sample flow, which is based on a calculation from (more stable) differential pressures. On the other hand, any sustained drift, i.e. long-term change, in the ozone flow rate may usually indicate a flow problem. This information is used to validate the O3 gas flow rate. 182 • If the flow rate exceeds ±15% of the nominal flow rate (80 cc/min), an O3 Flow message appears in the Alerts page, and the O3 generator is turned off, triggering a corresponding message in the Alerts page. • The value for this flow measurement is viewable as O3 Flow. • As with all other test parameters, we recommend monitoring the ozone flow over time for predictive diagnostics and maintenance evaluation. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 O3 SUPPLY AIR FLOW SENSOR Certain applications require to measure NOX in sample gases that do not contain any oxygen. However, the molybdenum NO2 converter requires a minimum amount of oxygen to operate properly and to ensure constant conversion efficiency. For these special applications, the analyzer may be equipped with a dilution manifold (Figure 6-13) to provide the instrument with an internal sample stream that contains about 2.5% O2. This manifold is mounted between converter housing and vacuum manifold on a small mounting bracket. If the dilution manifold is to be mounted in the T200H/M analyzer. The manifold is equipped with two orifice holders that control the flow of the O2-free sample gas and the bleeds in a small amount of zero air before the combined sample stream goes to the NO/NOX valve for measurement. The zero air is produced by an external zero air scrubber cartridge, mounted on the rear panel. The dilution manifold is not temperature controlled, although the residual heat of the NO2 converter housing provides some temperature stability. Tight temperature stability is not critical to the dilution application. Figure 6-13. Dilution Manifold Please inquire with Teledyne API Sales if the analyzer can be modified to fit your application. O2 SENSOR OPTION MEASUREMENT PRINCIPLE The oxygen sensor used in the T200H/M analyzer utilizes the fact that oxygen is attracted into strong magnetic field (in contrast with most other gases) to obtain fast, accurate oxygen measurements. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 183 The sensor’s core is made up of two nitrogen filled glass spheres, which are mounted on a rotating suspension within a magnetic field (Figure 6-14). A mirror is mounted centrally on the suspension and light is shone onto the mirror, which reflects the light onto a pair of photocells that then generate a signal. The signal generated by the photocells is passed to a feedback loop, which outputs a current to a wire winding (in effect, a small DC electric motor) mounted on the suspended mirror. Oxygen from the sample stream is attracted into the magnetic field, displacing the nitrogenfilled spheres and causing the suspended mirror to rotate. This changes the amount of light reflected onto the photocells and therefore the output levels of the photocells. The feedback loop increases the amount of current fed into the wire winding in order to move the mirror back into its original position. The more O2 present, the more the mirror moves and the more current is fed into the wire winding by the feedback control loop. A sensor measures the amount of current generated by the feedback control loop which is directly proportional to the concentration of oxygen within the sample gas mixture (see Figure 6-14). Figure 6-14. Oxygen Sensor - Principle of Operation 184 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ELECTRONIC OPERATION OVERVIEW Figure 6-15 shows a block diagram of the major electronic components of the analyzer. RS232 COM2 (USB) option Ethernet Analog Outputs A1 Optional 4-20 mA A2 A3 Touchscreen or USB Control Inputs: 1–6 option USB Display Status Outputs: 1–8 A4 Analog Outputs (D/A) LVDS transmitter board External Digital I/O) COM2 (RS–232 or RS–485) COM1 (RS–232 ONLY) A/D Converter( V/F) Power-Up Circuit Box Temp Disk On Module MOTHER BOARD Flash Chip PC 104 Bus PMT Temperature Sensor PMT TEMPERATURE PMT OUTPUT (PMT DET) O2 OPTION TEMPERATURE OPTIC TEST CONTROL ELECTRIC TEST CONTROL REACTION CELL TEMPERATURE PUMP Analog Sensor Inputs Internal Digital I/O HIGH VOLTAGE POWER SUPPLY LEVEL Thermistor Interface Pneumatic Sensor Board TEC Drive PCA I2C Status LED Sample Pressure Sensor Vacuum Pressure Sensor O3 Flow Sensor CPU Status LED RELAY BOARD TEMPERATURE SIGNAL NO/NOx Valve Reaction Cell Heater Autozero Valve MOLYBDENUM CONVERTER Molybdenum Converter Heater PREAMP PCA PMT TEC (Externally Powered) I2C Bus PMT PMT PC 104 CPU Card O2 Sensor Option Sample Cal Valve Option Option MOLYBDENUM CONVERTER TEMPERATURE Figure 6-15. Electronic Block Diagram 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 185 The core of the analyzer is a microcomputer/central processing unit (CPU) that controls various internal processes, interprets data, makes calculations, and reports results using specialized firmware developed by Teledyne API. It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices via a separate printed circuit assembly onto which the CPU is mounted: the motherboard. The motherboard is directly mounted to the inside rear panel and collects data, performs signal conditioning duties and routes incoming and outgoing signals between the CPU and the analyzer’s other major components. Data are generated by the sensor module which outputs an analog signal corresponding to the amount of chemiluminescence present in the reaction cell. This signal is converted into digital data by a unipolar, analog-to-digital converter, located on the motherboard. A variety of sensors report the physical and operational status of the analyzer’s major components, again through the signal processing capabilities of the motherboard. These status reports are used as data for the various concentration calculations and as trigger events for certain warning messages and control commands issued by the CPU. This information is stored in memory by the CPU and in most cases can be viewed by the user via the front panel display. The CPU issues commands via a series of relays and switches (also over the I2C bus) located on a separate printed circuit assembly, called the Relay PCA, to control the function of key electromechanical devices such as heaters and valves. It also issues some commands directly to the Sensor module (e.g. initiate Electric Test or Optical Test). By controlling the state of various valves the CPU directs the flow of sample gas through the various gas paths of the analyzer (NO measurement path; NOx measurement path; Auto Zero Path). Based on which path is active, the CPU interprets the sensor output to derive raw data representing concentrations for NOx, NO and zero (dark condition), accesses the operational data stored in memory then calculates final concentrations for NOX, NO and NO2. The CPU communicates with the user and the outside world in several ways: 186 • Through the analyzer’s front panel LCD touch-screen interface • Through the serial I/O channels • Various analog voltage and current outputs • Several sets of Digital I/O channels • Ethernet Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 CPU The unit’s CPU card, installed on the motherboard located inside the rear panel, is a low power (5 VDC, 720mA max), high performance, Vortex86SX-based microcomputer running Windows CE. Its operation and assembly conform to the PC 104 specification. The CPU includes two types of non-volatile data storage: a Disk-on-Module (DOM) and an embedded flash chip. The DOM is a 44-pin IDE flash drive with storage a 512 MB capacity. It is used to store the computer’s operating system, the Teledyne API firmware, and most of the operational data generated by the analyzer’s internal data acquisition system (DAS). The non-volatile, embedded flash chip includes 2MB of storage for calibration data as well as a backup of the analyzer configuration. Figure 6-16. CPU Board 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 187 MOTHERBOARD This PCA provides a multitude of functions including, A/D conversion, digital input/output, PC-104 to I2C translation, temperature sensor signal processing and is a pass through for the RS-232 and RS-485 signals. A TO D CONVERSION Analog signals, such as the voltages received from the analyzer’s various sensors, are converted into digital signals that the CPU can understand and manipulate by the analog to digital (A/D) converter. Under the control of the CPU, this functional block selects a particular signal input and then coverts the selected voltage into a digital word. The A/D converter consists of a Voltage-to-Frequency (V-F) converter, a Programmable Logic Device (PLD), three multiplexers, several amplifiers and other associated devices. The V-F converter produces a frequency proportional to its input voltage. The PLD counts the output of the V-F during a specified time, and sends the result of that count, in the form of a binary number, to the CPU. The A/D can be configured for several different input modes and ranges, but in this analyzer it is used in unipolar mode with a +5V full scale. The converter includes a 1% over and under-range. This allows signals from –0.05V to +5.05V to be fully converted. For calibration purposes, two reference voltages are supplied to the A/D converter: Reference ground and +4.096 VDC. During calibration, the device measures these two voltages, outputs their digital equivalent to the CPU. The CPU uses these values to compute the converter’s offset and slope and uses these factors for subsequent conversions. SENSOR INPUTS The key analog sensor signals are coupled to the A/D through the master multiplexer from two connectors on the motherboard. 100K terminating resistors on each of the inputs prevent cross talk from appearing on the sensor signals. PMT DETECTOR OUTPUT: The PMT detector output from the PMT preamplifier is used in the computation of the NO, NOX and NO2 concentrations displayed in the Dashboard and reported through the instrument’s analog outputs and COM ports. HIGH VOLTAGE POWER SUPPLY (HVPS) LEVEL: The PMT high voltage is based on the drive voltage from the preamplifier board. It is digitized and sent to the CPU which then calculates the voltage setting of the HVPS. PMT TEMPERATURE: The PMT temperature is measured with a thermistor inside the PMT cold block. Its signal is amplified by the PMT temperature feedback circuit on the preamplifier board and is digitized and sent to the CPU which calculates the current temperature of the PMT. SAMPLE GAS PRESSURE SENSOR: Located on the flow/pressure sensor PCA, this sensor measures the sample chamber’s gas pressure. 188 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 VACUUM PRESSURE SENSOR: Also located on the flow/pressure sensor PCA, this sensor measures the pressure of the gas mixture inside the reaction cell. O3 FLOW SENSOR: Located on the flow/pressure sensor PCA as well, this sensor measures the flow rate of the O3 gas stream as it is supplied to the reaction cell. THERMISTOR INTERFACE This circuit provides excitation, termination and signal selection for several negative coefficient, thermistor temperature sensors located inside the analyzer. REACTION CELL TEMPERATURE (Rx Cell Temp) SENSOR: A thermistor that measures the temperature inside the reaction cell manifold, which is used by the CPU to control the reaction cell heating circuit and as a parameter in the temperature/pressure compensation algorithm. BOX TEMPERATURE (Box Temp) SENSOR: A thermistor that measures the analyzer’s inside temperature, which is then reported through the front panel display. It is also used as part of the NO, NOx and NO2 calculations when the instrument’s Temperature/Pressure Compensation feature is enabled (Setup>Vars>TPC Enable). Note There are two thermistors that monitor the temperature of the PMT assembly: One is embedded in the cold block of the PMT’s TEC. Its signal is conditioned by the PMT preamplifier PCA and reported to the CPU via the motherboard (see Section 6.4.3.2). The second is located on the PMT Preamplifier PCA and is used only as a reference for the preamplifier circuitry. Its output is neither reported nor stored. ANALOG OUTPUTS The analyzer comes equipped with four configurable analog outputs on the instrument’s rear panel analog connector, labeled A1, A2, A3 and A4. A variety of scaling measurement and electronic factors apply to these signals. OUTPUT LOOP-BACK: All of the functioning analog outputs are connected back to the A/D converter through a Loop-back circuit. This permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures. EXTERNAL DIGITAL I/O The external digital I/O controls the Status Outputs and the Control Inputs. INTERNAL DIGITAL I/O The internal Digital I/O controls some subsystems, such as the electrical and optical tests, the PMT preamplifier range control, and the O3 Generator. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 189 I2C DATA BUS I2C is a two-way, clocked, bi-directional digital serial I/O bus that is used widely in commercial and consumer electronic systems. A transceiver on the Motherboard converts data and control signals from the PC-104 bus to I2C format. The data are then fed to the relay board and valve driver board circuitry. POWER-UP CIRCUIT This circuit monitors the +5V power supply during start-up and sets the analog outputs, external digital I/O ports, and I2C circuitry to specific values until the CPU boots and the instrument software can establish control. RELAY PCA The CPU issues commands via a series of relays and switches located on a separate printed circuit assembly, called the Relay PCA (Figure 6-17), to control the function of key electromechanical devices such as heaters and valves. The Relay PCA receives instructions in the form of digital signals over the I2C bus, interprets these digital instructions and activates its various switches and relays appropriately. The Relay PCA is located in the right-rear quadrant of the analyzer and is mounted vertically on the backside of the same bracket as the instrument’s DC power supplies. 190 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Status LED’s (D2 through D16) Thermocouple Signal Output Watchdog Status LED (D1) (JP5) Thermocouple Configuration Jumpers J3 J15 TP6 TP7 I2C Connector TP1 TP2 TP3 TP4 TP5 TC1 Input DC Power Supply Test Points J21 J19 J14 R16 JP7 U6 JP6 J12 JP2 Pump Power Output Main AC Heater Configuration Jumpers J17 Valve Control Drivers U5 J4 J11 J10 AC Power IN J9 J2 J13 Pump AC Configuration Jumper J16 J5 TC2 Input Power Connection for DC Heaters Valve Control Connector J8 AC Heater Power Output J7 Solid State AC Power Relays AC Power Output for Optional O2 Sensor DC Power Distribution Connectors Figure 6-17. Relay PCA Layout (P/N 045230100) WARNING – ELECTRICAL SHOCK HAZARD Only those relays actually required by the configuration of the analyzer are populated. A protective retainer plate is installed over the AC power relays to keep them securely seated in their sockets and prevent accidental contact with those sockets that are not populated see Figure 6-18). Never remove this retainer while the instrument is plugged in and turned on. The contacts of the AC relay sockets beneath the shield carry high AC voltages even when no relays are present. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 191 Figure 6-18. Relay PCA P/N 045230100 with AC Relay Retainer in Place STATUS LED’S Sixteen LEDs are located on the analyzer’s Relay PCA to show the current status on the various control functions performed by the Relay PCA (see Figure 5-14). Their functions and fault descriptions were presented in Table 5-6. WATCHDOG CIRCUITRY The most important of the status LED’s on the relay board is the red I2C bus watch-dog LED. It is controlled directly by the analyzer’s CPU over the I2C bus. Special circuitry on the Relay PCA watches the status of D1. Should this LED ever stay ON or OFF for 30 seconds, indicating that the CPU or I2C bus has stopped functioning, this Watchdog Circuit automatically shuts all valves and turns off all heaters. VALVE CONTROL The relay board also hosts two valve driver chips, each of which can drive up four valves. The main valve assembly is the NO/NOX - Auto-zero solenoid valve component mounted right in front of the NO2 converter housing. • These two valves are actuated with 12 V supplied from the relay board and under the control of the CPU through the I2C bus. A second set of valves may be installed if the zero/span valve is enabled in the analyzer. Specialty manifold valves may be present in the analyzer. 192 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 HEATER CONTROL The heater control loop is illustrated in Figure 6-19. Two thermocouples (T/C) inputs can be configured for either type-J or type-K thermocouples. Additionally: • Both T/C’s can be configured as either grounded or ungrounded thermocouples. • Standard configuration of the both type of thermocouples is 10 mV/°C. In order to accommodate the T200H’s Mini High-Con converter option, a type-K; 5mV/°C output configuration has been added. All of the heaters used are AC powered which are turned ON/OFF by AC relays located on the Relay PCA in response to commands issued by the CPU. Thermistor(s) – Low Temperature Sensing: (e.g. Sample Chamber and Reaction Cell temperatures) MOTHER BOARD A/D Converter (V/F) RELAY PCA Preamplifiers and Signal Conditioning THERMOCOUPLE CONFIGURATION JUMPER (JP5) Themocouple(s) (High Temperature Sensing; e.g. Moly and HiCon Converter temperatures) CPU Cold Junction Compensation DC Control Logic Solid State AC Relays DC HEATERS AC HEATERS Figure 6-19. Heater Control Loop Block Diagram. Note The PMT temperature is maintained by a separate control loop that does not involve the relay PCA (see Section 6.6.2). THERMOCOUPLE INPUTS AND CONFIGURATION JUMPER (JP5) Although the Relay PCA supports two thermocouple inputs, these analyzers only utilize one. It is used to sense the temperature of the Ozone Destruct. • This single thermocouple input is plugged into the TC1 input (J15). • TC2 (J16) is currently not used (see Figure 6-17 for location of J15 and J16). • The type and operating parameters of this thermocouple are set using a jumper plug (JP5). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 193 Table 6-4. Thermocouple Configuration Jumper (JP5) Pin-Outs TC INPUT TC1 TC2 JUMPER PAIR DESCRIPTION FUNCTION 1 – 11 Gain Selector Selects preamp gain factor for J or K TC OUT = K TC gain factor; IN = J TC gain factor 2 – 12 Output Scale Selector Selects preamp gain factor for J or K TC OUT = 10 mV / °C; IN = 5 mV / °C 3 – 13 Type J Compensation When present, sets Cold Junction Compensation for J type Thermocouple 4 – 14 Type K Compensation When present, sets Cold Junction Compensation for K type Thermocouple 5 – 15 Termination Selector Selects between Isolated and grounded TC IN = Isolate TC; OUT = Grounded TC 6 – 16 Gain Selector Same as Pins 1 – 11 above. 7 – 17 Output Scale Selector Same as Pins 2 – 12 above. 8 – 18 Type J Compensation Same as Pins 3 – 13 above. 9 – 19 Type K Compensation Same as Pins 4 – 14 above 10 – 20 Termination Selector Same as Pins 5 – 15 above. ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY The correct Thermocouple Type must be used if there is ever the need for replacement. If in doubt please consult Teledyne API Technical Support. Figure 6-20. Thermocouple Configuration Jumper (JP5) Pin-Outs 194 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Table 6-5. Typical Thermocouple Settings TC TYPE TERMINATION TYPE OUTPUT SCALE TYPE JUMPER BETWEEN PINS USED ON JUMPER COLOR INPUT TC1 (J15) K GROUNDED 5mV / °C 2 – 12 4 – 14 T200H/M with Mini HiCon Converter BROWN K ISOLATED 5mV / °C 2 – 12 4 – 14 5 – 15 T200H/M with Mini HiCon Converter GREY K ISOLATED 10mV / °C T200H/M models with Moly Converter PURPLE J ISOLATED 10mV / °C T200H/M models with Moly Converter RED J GROUNDED 10mV / °C T200H/M models with Moly Converter GREEN 4 – 14 5 – 15 1 – 11 3 – 13 5 – 15 1 – 11 3 – 13 SENSOR MODULE The sensor assembly (Figure 5-19) consists of several subassemblies, each with different tasks: • The Photo Multiplier Tube (PMT) detects the intensity of the light from the chemiluminescence reaction between NO and O3 in the reaction cell. It outputs a current signal that varies in relationship with the amount of light in the reaction cell. • The PMT Preamplifier PCA converts the current output by the PMT into a voltage and amplifies it to a signal strong enough to be usable by the motherboard’s A à D converter. It also supplies the drive voltage and gain adjustment for the PMT’s High Voltage Power Supply (HVPS) • The Thermo-Electric Cooler (TEC) controls the temperature of the PMT to ensure the accuracy and stability of the measurements. PHOTO MULTIPLIER TUBE (PMT) The analyzers use a photo multiplier tube (Figure 5-19) to detect the amount of chemiluminescence created in the Reaction Cell. A typical PMT is a vacuum tube containing a variety of specially designed electrodes. Photons from the reaction are filtered by an optical high-pass filter, enter the PMT and strike a negatively charged photo cathode causing it to emit electrons. A high voltage potential across these focusing electrodes directs the electrons toward an array of high voltage dynodes. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 195 The dynodes in this electron multiplier array are designed so that each stage multiplies the number of emitted electrons by emitting multiple, new electrons. The greatly increased numbers of electrons emitted from one end of the electron multiplier are collected by a positively charged anode at the other end, which creates a useable current signal. This current signal is amplified by the preamplifier board and then reported to the motherboard. Figure 6-21. Basic PMT Design A significant performance characteristic of the PMT is the voltage potential across the electron multiplier. The higher the voltage, the greater the number of electrons emitted from each dynode of the electron multiplier, in effect, making the PMT more sensitive and responsive to smaller variations in light intensity, but also more noisy (this is referred to as “dark noise”). • The gain voltage of the PMT is usually set between 400 V and 800 V. • This parameter is viewable in the Dashboard as HVPS. • For information on when and how to set this voltage, see Section 5.7.10.4. The PMT is housed inside the PMT module assembly (see Figure 5-19). This assembly also includes the high voltage power supply required to drive the PMT, an LED used by the instrument’s optical test function, a thermistor that measures the temperature of the PMT and various components of the PMT cooling system including the TEC. PMT PREAMPLIFIER The PMT preamplifier board provides a variety of functions: 196 • Amplifies the PMT Signal into a useable analog voltage that can be processed by the motherboard into a digital signal to be used by the CPU to calculate the NO, NO2 and NOx concentrations of the gas in the sample chamber. • Supplies the drive voltage for the HVPS. • Includes the circuitry for switching between the two physical ranges. • Amplifies the signal output by the PMT Temperature sensor and feeds it back to the thermoelectric cooler driver PCA. This amplified signal is also sent to the Motherboard to be digitized and forwarded to the CPU. • Provides the means for adjusting the electronic signal output from the PMT. Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 PMT Preamplifier PCA Optical Test Control Optical Test Generator from CPU Electric Test Control From CPU Electric Test Generator Optical Test LED PMT X MUX High Voltage Power Supply HI Range Select From CPU PMT Output Gain Adjustment Physical Range Select Circuitry Amp à Volts Converter and Amplifier Low Pass Noise Filter X X X HVPS Fine Gain Adjustment To PMT HVPS Motherboard Drive Voltage PMT Temp Sensor (Rotary) DàA Converter PMT Temperature Feedback Circuit (Thermistor) TEC Control PCA X PMT Temp Analog Signal X PMT Output Signal (PMT DET) HVPS Coarse Gain Adjustment (Rotary) To Motherboard to Motherboard Figure 6-22. PMT Preamp Block Diagram The PMT preamplifier PCA also operates two different tests used to calibrate and check the performance of the sensor module. • The electrical test (Utilities>Diagnostics>OE Test, ETest) circuit generates a constant, electronic signal intended to simulate the output of the PMT (after conversion from current to voltage). By bypassing the detector’s actual signal, it is possible to test most of the signal handling and conditioning circuitry on the PMT preamplifier board. See Section 5.7.9.11 for instructions on performing this test. • The optical test (Utilities>Diagnostics>OE Test, OTest) feature causes an LED inside the PMT cold block to create a light signal that can be measured with the PMT. If zero air is supplied to the analyzer, the entire measurement capability of the sensor module can be tested including the PMT and the current to voltage conversion circuit on the PMT preamplifier board. See Section 5.7.9.11 for instructions on performing this test. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 197 PMT COOLING SYSTEM The performance of the analyzer’s PMT is significantly affected by temperature. Variations in PMT temperature are directly reflected in the signal output of the PMT. Also the signal to noise ratio of the PMT output is radically influenced by temperature as well. The warmer the PMT is, the noisier its signal becomes until the noise renders the concentration signal useless. To alleviate this problem, the instrument uses a special cooling system called a thermoelectric cooler (TEC), which is a solid-state active heat pump that transfers heat from a heat absorbing “cool” side to a heat releasing “hot” side via a series of DC powered semiconductor junctions. The effectiveness of the pump at moving heat away from the cold side is reliant on the amount of current flowing through the semiconductor junctions and how well the heat from the hot side can be removed. Figure 6-23. Typical Thermo-Electric Cooler In this case, the current flow is controlled by the TEC Control PCA which adjusts the amount of current applied to the TEC based on the temperature sensed by a thermistor embedded in the PMT’s cold block. The higher the temperature of the PMT, the more current is pumped through the TEC. The “hot” side of the TEC is cooled by a constant flow of ambient air that is directed across a set of heat sinks by a fan. 198 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 Preamp PCA sends buffered and amplified thermistor signal to TEC PCA TEC PCA sets appropriate drive voltage for cooler TEC Control PCA PMT Preamp PCA Thermo-Electric Cooler Heat Sink PMT Temperature Sensor Thermistor outputs temp of cold block to preamp PCA PMT Cold Block Cooling Fan Heat form PMT is absorbed by the cold block and transferred to the heat sink via the TEC then bled off into the cool air stream. Figure 6-24. PMT Cooling System Block Diagram The target temperature at which the TEC system keeps the PMT is approximately 8.0ºC. Arriving at this temperature may take up to 30 minutes after the instrument is turned on. The actual temperature of the PMT can be viewed in the Dashboard. TEC CONTROL BOARD The TEC control PCA is located on the sensor housing assembly, under the slanted shroud, next to the cooling fins and directly above the cooling fan. Using the amplified PMT temperature signal from the PMT preamplifier board (see Section 6.6.1), it sets the drive voltage for the thermoelectric cooler. The warmer the PMT gets, the more current is passed through the TEC causing it to pump more heat to the heat sink. • A red LED located on the top edge of this circuit board indicates that the control circuit is receiving power. • Four test points are also located at the top of this assembly. • For the definitions and acceptable signal levels of these test points see Section 5.7.9.14. 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 199 PNEUMATIC SENSOR BOARD The flow and pressure sensors of the analyzer are located on a printed circuit assembly just behind the PMT sensor. The signals of this board are supplied to the motherboard for further signal processing. All sensors are linearized in the firmware and can be span calibrated from the front panel. POWER SUPPLY/CIRCUIT BREAKER The analyzer operates on 100 VAC, 115 VAC or 230 VAC power at either 50 Hz or 60Hz. Individual instruments are set up at the factory to accept any combination of these five attributes. A 6.75 amp circuit breaker is built into the ON/OFF switch. In case of a wiring fault or incorrect supply power, the circuit breaker will automatically turn off the analyzer. • Under normal operation, the analyzer draws about 1.5 A at 115 V and 2.0 A during start-up. WARNING – ELECTRICAL SHOCK HAZARD Should the AC power circuit breaker trip, investigate and correct the condition causing this situation before turning the analyzer back on. Power enters the analyzer through a standard International Electrotechnical Commission (IEC) 320 power receptacle located on the rear panel of the instrument. From there it is routed through the ON/OFF Switch located in the lower right corner of the front panel. AC Line power is stepped down and converted to DC power by two DC power supplies (PS). • One PS provides +5 VDC (3 A) and ±15 VDC (1.5/0.5 A) for logic and analog circuitry as well as the power for the O3 generator. • The second PS provides +12 VDC (5 A), for the PMT’s thermoelectric cooler, fans and as well as the various gas stream valves (both standard and optional). All AC and DC Voltages, except for the dedicated 24 VDC, are distributed via the relay PCA. 200 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 SENSOR MODULE ANALOG SENSORS (e.g. Temp Sensors, Flow Sensors) Pre-Amplifiers & Amplifiers HVPS KEY PMT AC POWER Sensor Control & I/O Logic DC POWER LOGIC DEVICES (e.g. CPU, I2C bus, MotherBoard, etc.) Photolytic Converter O3 Generator PS 3 (+24 VDC) PS 1 +5 VDC ±15 VDC AC HEATERS (O3 Destruct & Reaction Cell) ON / OFF SWITCH Configuration Jumpers Optional AC HEATERS ( Internal Span Generator Perm Tube Heater) RELAY PCA MODEL SPECIFIC VALVES (e.g. NOX – NO Valves, Auto-zero valves, etc.) Solenoid Drivers OPTIONAL VALVES (e.g. Sample/Cal, Zero/Span, Shutoff, etc.) PS 2 (+12 VDC) Fans: TEC and Chassis AC POWER IN Figure 6-25. Power Distribution Block Diagram 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 201 AC POWER CONFIGURATION The analyzer’s digital components will operate with any of the specified power regimes. As long as instrument is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz. Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. However, some of the analyzer’s non-digital components, such as the AC-powered heaters for the NO2 – NO converter or the reaction cell, must be properly configured for the type of power being supplied to the instrument. Configuration of the power circuits is set using several jumper sets located on the instrument’s Relay PCA. RELAY PCA JP6 Configuration Jumpers for Optional AC Heaters (Internal Perm Tube Oven Heater) JP2 Configuration Jumpers for AC Heaters (O3 Destruct, Reaction Cell) Figure 6-26. Location of AC power Configuration Jumpers 202 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 AC CONFIGURATION – STANDARD HEATERS (JP2) Power configuration for the AC the standard heaters is set using Jumper set JP2 (see Figure 6-27 for the location of JP2). Table 6-6. Power Configuration for Standard AC Heaters (JP2) LINE VOLTAGE JUMPER COLOR JUMPER BETWEEN PINS FUNCTION 1 to 8 Common 2 to 7 Neutral to Load 4 to 9 Neutral to Load 3 to 10 Common 4 to 9 Neutral to Load 6 to 11 Neutral to Load Reaction Cell / Sample Chamber Heaters 1 to 7 Load Moly Converter Heater 3 to 9 Load HEATER(S) Reaction Cell / Sample Chamber Heaters 110 VAC / 115 VAC 50Hz & 60 Hz WHITE Moly Converter Heater 220 VAC / 240 VAC 50Hz & 60 Hz Reaction Cell Heaters O3 Destruct Heater BLUE 1 7 1 7 2 8 2 8 Reaction Cell Heaters 3 9 3 9 4 10 4 10 5 11 5 11 6 12 6 12 110 VAC /115 VAC O3 Destruct Heater 220 VAC / 240 VAC Figure 6-27. Typical Set Up of AC Heater Jumper Set (JP2) 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 203 AC CONFIGURATION – HEATERS FOR OPTION PACKAGES (JP6) The IZS valve option includes an AC heater that maintains an optimum operating temperature for key components of those options. Jumper set JP6 is used to connect the heaters associated with those options to AC power. Since these heaters work with either 110/155 VAC or 220/240 VAC, there is only one jumper configuration. Table 6-7. Power Configuration for Optional Heaters (JP6) JUMPER COLOR HEATER(S) RED Internal Permeation Tube Oven Heater JUMPER BETWEEN PINS FUNCTION 1 to 8 Common 2 to 7 Neutral to Load 10 IZS Permeation Tube 12 Heater 11 6 5 4 9 3 8 7 2 1 Figure 6-28. Typical Jumper Set (JP2) Set Up of Heaters 204 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE Users can input data and receive information directly through the front panel touchscreen display. The LCD display is controlled directly by the CPU board. The touchscreen is interfaced to the CPU by means of a touchscreen controller that connects to the CPU via the internal USB bus and emulates a computer mouse. Figure 6-29. Front Panel and Display Interface Block Diagram 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 205 LVDS TRANSMITTER BOARD The LVDS (low voltage differential signaling) transmitter board converts the parallel display bus to a serialized, low voltage, differential signal bus in order to transmit the video signal to the LCD interface PCA. FRONT PANEL TOUCHSCREEN/DISPLAY INTERFACE PCA The front panel interface PCA controls the various functions of the display and touchscreen. For driving the display it provides connection between the CPU video controller and the LCD display module. This PCA also contains: • power supply circuitry for the LCD display module • USB hub for communications with the touchscreen controller and the two front panel USB device ports • circuitry for powering the display backlight SOFTWARE OPERATION The analyzer has a high performance, 86-based microcomputer running Windows CE. Inside the WINDOWS CE shell, special software developed by Teledyne API interprets user commands via the various interfaces, performs procedures and tasks, stores data in the CPU’s various memory devices and calculates the concentration of the sample gas. Windows CE API FIRMWARE MEMORY HANDLING DAS Records Calibration Data System Status Data ANALYZER OPERATIONS Calibration Procedures Configuration Procedures Autonomic Systems Diagnostic Routines PC-104 BUSS ANALYZER HARDWARE INTERFACE HANDLING MEASUREMENT ALGORITHM Sensor input Data Display Messages Touchscreen Analog Output Data RS232 & RS485 External Digital I/O PC-104 BUSS Figure 6-30. Basic Software Operation 206 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 ADAPTIVE FILTER The analyzer software processes sample gas concentration data through a built-in adaptive filter. Unlike other analyzers that average the output signal over a fixed time period, these analyzers average over a defined number of samples. This technique is known as boxcar filtering. During operation, the software may automatically switch between two different filter lengths based on the conditions at hand. During constant or nearly constant concentrations, the software, by default, computes an average sample value using the long filter. This provides smooth and stable readings and averages out a considerable amount of random noise for an overall less noisy concentration reading. If the filter detects rapid changes in concentration, the filter reduces its size thus allowing the analyzer to respond more quickly. Two conditions must be simultaneously met to switch to the short filter. First, the instantaneous concentration must differ from the average in the long filter by an absolute amount. Second, the instantaneous concentration must differ from the average in the long filter by at least a set percentage of the average in the long filter. TEMPERATURE/PRESSURE COMPENSATION (TPC) The software includes a feature that compensates for some temperature and pressure changes that might affect measurement of NO and NOX concentrations. When the TPC feature is enabled (default setting), the analyzer divides the value of the PMT output signal (PMT Signal) by a value called TP_FACTOR, which is calculated using the following four parameters: • Box Temp: The temperature inside the analyzer’s case measured in K. This is typically about 5 K higher than room temperature. • Rx Cell Temp: The temperature of the reaction cell, measured in K. • Rx Cell Press: The pressure of the gas in the vacuum manifold, measured in in-Hg-A. • Sample Press: The pressure of the sample gas before it reaches the reaction cell, measured in in-Hg-A. This measurement is ~1 in-Hg-A lower than atmospheric pressure. As Rx Cell Temp, Box Temp, Rx Cell Press and Sample Press increase, the value of TP_FACTOR increases and, hence, the PMT Signal value decreases. These adjustments are meant to counter-act changes in the concentrations caused by these parameters. • The current value of each of these measurements is viewable in the editable Dashboard (see Sections 2.4.2 and 2.5.3). • The preset gain parameters are set at the factory and may vary from analyzer to analyzer. The TPC feature is enabled or disabled by setting the value of the variable TPC Enable in the Setup>Vars menu. (see Section 2.5.5). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 207 CALIBRATION - SLOPE AND OFFSET Calibration of the analyzer is performed exclusively in the software. During instrument calibration, (see Section 4) the user enters expected values for zero and span via the front panel touchscreen control and commands the instrument to make readings of calibrated sample gases for both levels. • The readings taken are adjusted, linearized and compared to the expected values. • With this information, the software computes values for instrument slope and offset and stores these values in memory for use in calculating the NOx, NO and NO2 concentrations of the sample gas. The instrument slope and offset values recorded during the last calibration can be viewed in the Dashboard. 208 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 GLOSSARY TERM DESCRIPTION/DEFINITION an Ethernet standard that uses twisted (“T”) pairs of copper wires to transmit at 10 10BaseT megabits per second (Mbps) 100BaseT same as 10BaseT except ten times faster (100 Mbps) APICOM name of a remote control program offered by Teledyne-API to its customers Assembly ASSY Code-Activated Switch CAS Corona Discharge, a frequently luminous discharge, at the surface of a conductor or CD between two conductors of the same transmission line, accompanied by ionization of the surrounding atmosphere and often by a power loss Converter Efficiency, the percentage of the total amount that is actually converted CE (e.g., light energy into electricity; NO2 into NO, etc.) Continuous Emission Monitoring CEM Chemical elements that may be included in this document: CO2 carbon dioxide C3H8 propane CH4 methane H2O water vapor HC general abbreviation for hydrocarbon HNO3 nitric acid H2S hydrogen sulfide NO nitric oxide NO2 nitrogen dioxide NOX nitrogen oxides, here defined as the sum of NO and NO2 nitrogen oxides, often called odd nitrogen: the sum of NOX plus other NOy compounds such as HNO3 (definitions vary widely and may include nitrate (NO3), PAN, N2O and other compounds as well) NH3 ammonia O2 molecular oxygen O3 ozone SO2 sulfur dioxide metric abbreviation for cubic centimeter (replaces the obsolete abbreviation “cc”) cm3 Central Processing Unit CPU Digital-to-Analog Converter DAC Data Acquisition System DAS Data Communication Equipment DCE Disposable Filter Unit DFU Dynamic Host Configuration Protocol. A protocol used by LAN or Internet servers to DHCP automatically set up the interface protocols between themselves and any other addressable device connected to the network Disk On Module, a 44-pin IDE flash drive with up to 128MB storage capacity for DOM instrument’s firmware, configuration settings and data Disk Operating System DOS Dynamic Random Access Memory DRAM 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 209 TERM DR-DOS DTE EEPROM ESD ETEST Ethernet FEP Flash FPI GFC I2C bus IC IP IZS LAN LCD LED LPM MFC M/R NDIR MOLAR MASS DESCRIPTION/DEFINITION Digital Research DOS Data Terminal Equipment Electrically Erasable Programmable Read-Only Memory also referred to as a FLASH chip or drive Electro-Static Discharge Electrical Test a standardized (IEEE 802.3) computer networking technology for local area networks (LANs), facilitating communication and sharing resources Fluorinated Ethylene Propylene polymer, one of the polymers that Du Pont markets as Teflon® non-volatile, solid-state memory Fabry-Perot Interface: a special light filter typically made of a transparent plate with two reflecting surfaces or two parallel, highly reflective mirrors Gas Filter Correlation a clocked, bi-directional, serial bus for communication between individual analyzer components Integrated Circuit, a modern, semi-conductor circuit that can contain many basic components such as resistors, transistors, capacitors, etc., in a miniaturized package used in electronic assemblies Internet Protocol Internal Zero Span Local Area Network Liquid Crystal Display Light Emitting Diode Liters Per Minute Mass Flow Controller Measure/Reference Non-Dispersive Infrared the mass, expressed in grams, of 1 mole of a specific substance. Conversely, one mole is the amount of the substance needed for the molar mass to be the same number in grams as the atomic mass of that substance. EXAMPLE: The atomic weight of Carbon is 12 therefore the molar mass of Carbon is 12 grams. Conversely, one mole of carbon equals the amount of carbon atoms that weighs 12 grams. NDIR NIST-SRM PC PCA PC/AT PCB PFA PLC 210 Atomic weights can be found on any Periodic Table of Elements. Non-Dispersive Infrared National Institute of Standards and Technology - Standard Reference Material Personal Computer Printed Circuit Assembly, the PCB with electronic components, ready to use Personal Computer / Advanced Technology Printed Circuit Board, the bare board without electronic component Per-Fluoro-Alkoxy, an inert polymer; one of the polymers that Du Pont markets as Teflon® Programmable Logic Controller, a device that is used to control instruments based on a logic level signal coming from the analyzer Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 TERM PLD PLL PMT P/N (or PN) PSD PTFE PVC Rdg RS-232 RS-485 SAROAD SLAMS SLPM STP TCP/IP TEC TPC USB VARS V-F Z/S 083730210A DCN8164 DESCRIPTION/DEFINITION Programmable Logic Device Phase Lock Loop Photo Multiplier Tube, a vacuum tube of electrodes that multiply electrons collected and charged to create a detectable current signal Part Number Prevention of Significant Deterioration Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases that may react on other surfaces; one of the polymers that Du Pont markets as Teflon® Poly Vinyl Chloride, a polymer used for downstream tubing Reading specification and standard describing a serial communication method between DTE (Data Terminal Equipment) and DCE (Data Circuit-terminating Equipment) devices, using a maximum cable-length of 50 feet specification and standard describing a binary serial communication method among multiple devices at a data rate faster than RS-232 with a much longer distance between the host and the furthest device Storage and Retrieval of Aerometric Data State and Local Air Monitoring Network Plan Standard Liters Per Minute of a gas at standard temperature and pressure Standard Temperature and Pressure Transfer Control Protocol / Internet Protocol, the standard communications protocol for Ethernet devices Thermal Electric Cooler Temperature/Pressure Compensation Universal Serial Bus: a standard connection method to establish communication between peripheral devices and a host controller, such as a mouse and/or keyboard and a personal computer or laptop Variables, the variable settings of the instrument Voltage-to-Frequency Zero / Span Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 211 APPENDIX A – MODBUS REGISTERS MODBUS DESCRIPTION 10 REGISTER ADDRESS (DECIMAL, 0-BASED) MODBUS Floating Point Input Registers UNITS (32-bit IEEE 754 format; read in high-word, low-word order; read-only) 0 Instantaneous PMT detector reading mV 2 NOX slope for range #1 — 4 NOX slope for range #2 — 6 NO slope for range #1 — 8 NO slope for range #2 mV 10 NOX offset for range #1 mV 12 NOX offset for range #2 mV 14 NO offset for range #1 mV 16 NO offset for range #2 mV 18 NOX concentration for range #1 during zero/span calibration, just before computing new slope and offset PPB 20 NOX concentration for range #2 during zero/span calibration, just before computing new slope and offset PPB 22 NO concentration for range #1 during zero/span calibration, just before computing new slope and offset PPB 24 NO concentration for range #2 during zero/span calibration, just before computing new slope and offset PPB 26 NO2 concentration for range #1 during zero/span calibration, just before computing new slope and offset PPB 28 NO2 concentration for range #2 during zero/span calibration, just before computing new slope and offset PPB 30 NOX concentration for range #1 PPB 32 NOX concentration for range #2 PPB 34 NO concentration for range #1 PPB 36 NO concentration for range #2 PPB 38 NO2 concentration for range #1 PPB 40 NO2 concentration for range #2 PPB 42 Concentration stability PPB 44 Auto zero offset (range de-normalized) Pre React 11 mV 46 Ozone flow rate cc/m 48 Reaction cell pressure "Hg 212 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MODBUS REGISTER ADDRESS (DECIMAL, 0-BASED) DESCRIPTION 10 UNITS 50 Reaction cell temperature °C 52 Manifold temperature °C 54 Converter efficiency factor for range #1 — 56 Converter efficiency factor for range #2 — 58 Converter temperature °C 60 PMT temperature °C 62 Sample flow rate cc/m 64 Sample pressure “Hg 66 Internal box temperature °C 68 High voltage power supply output Volts 70 Ground reference (REF_GND) mV 72 4096 mV reference (REF_4096_MV) mV 74 Diagnostic test input (TEST_INPUT_13) mV 76 Diagnostic temperature input (TEMP_INPUT_6) °C 78 IZS temperature °C 80 9 Sample restrictor temperature °C 82 9 Remote box temperature °C 80 Diagnostic test input (TEST_INPUT_11) mV 82 Diagnostic temperature input (TEMP_INPUT_5) °C 84 1 Raw PMT detector reading for NOX mV 86 1 Raw PMT detector reading for NO mV 100 3 NOX slope for range #3 — 102 3 NO slope for range #3 mV 104 3 NOX offset for range #3 mV 106 3 NO offset for range #3 mV 108 3 NOX concentration for range #3 during zero/span calibration, just before computing new slope and offset PPB 110 3 NO concentration for range #3 during zero/span calibration, just before computing new slope and offset PPB 112 3 NO2 concentration for range #3 during zero/span calibration, just before computing new slope and offset PPB 114 3 NOX concentration for range #3 PPB 116 3 NO concentration for range #3 PPB 118 3 NO2 concentration for range #3 PPB 120 3 Converter efficiency factor for range #3 — 130 12 External analog input 1 value Volts 132 12 External analog input 1 slope eng unit /V 134 12 External analog input 1 offset eng unit 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 213 MODBUS REGISTER ADDRESS (DECIMAL, 0-BASED) DESCRIPTION 10 UNITS 136 12 External analog input 2 value Volts 138 12 External analog input 2 slope eng unit /V 140 12 External analog input 2 offset eng unit 142 12 External analog input 3 value Volts 144 12 External analog input 3 slope eng unit /V 146 12 External analog input 3 offset eng unit 148 12 External analog input 4 value Volts 150 12 External analog input 4 slope eng unit /V 152 12 External analog input 4 offset eng unit 154 12 External analog input 5 value Volts 156 12 External analog input 5 slope eng unit /V 158 12 External analog input 5 offset eng unit 160 12 External analog input 6 value Volts 162 12 External analog input 6 slope eng unit /V 164 12 External analog input 6 offset eng unit 166 12 External analog input 7 value Volts 168 12 External analog input 7 slope eng unit /V 170 12 External analog input 7 offset eng unit 172 12 External analog input 8 value Volts 174 12 External analog input 8 slope eng unit /V 176 12 External analog input 8 offset eng unit 188 13 Converter efficiency factor slope for range #1 — 190 13 Converter efficiency factor offset for range #1 — 192 13 Converter efficiency factor slope for range #2 — 194 13 Converter efficiency factor offset for range #2 — 196 13, 3 Converter efficiency factor slope for range #3 — 198 13, 3 Converter efficiency factor offset for range #3 — 200 5 O2 concentration % 202 O2 concentration during zero/span calibration, just before computing new slope and offset % 204 5 O2 slope — 206 5 O2 offset % 208 5 O2 sensor cell temperature °C 300 6 5 CO2 concentration % 302 6 CO2 concentration during zero/span calibration, just before computing new slope and offset % 304 6 CO2 slope — 306 6 CO2 offset % 214 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MODBUS REGISTER ADDRESS (DECIMAL, 0-BASED) DESCRIPTION 10 UNITS 308 6 CO2 sensor cell temperature °C 400 14 O3 concentration PPB 402 14 O3 concentration during zero/span calibration, just before computing new slope and offset PPB 404 14 O3 slope — 406 14 O3 offset PPB 408 14 O3 sensor cell temperature °C 410 14 O3 photometer reference potential mV 412 14 O3 photometer measurement potential mV 414 14 O3 cell pressure PSIA 416 14 O3 lamp temperature °C 418 14 + 15 O3 bench serial number — 420 14 O3 bench firmware revision — MODBUS Floating Point Holding Registers (32-bit IEEE 754 format; read/write in high-word, low-word order; read/write) 0 Maps to NOX_SPAN1 variable; target conc. for range #1 Conc. units 2 Maps to NO_SPAN1 variable; target conc. for range #1 Conc. units 4 Maps to NOX_SPAN2 variable; target conc. for range #2 Conc. units 6 Maps to NO_SPAN2 variable; target conc. for range #2 Conc. units 100 3 Maps to NOX_SPAN3 variable; target conc. for range #3 Conc. units 102 3 Maps to NO_SPAN3 variable; target conc. for range #3 Conc. units 200 5 Maps to O2_TARG_SPAN_CONC variable; target conc. for range O2 gas % 300 6 Maps to CO2_TARG_SPAN_CONC variable; target conc. for range CO2 gas % 400 14 Maps to ID_VAR_O3_TARG_SPAN_CONC variable; O3 target span concentration PPB 402 14 Maps to ID_VAR_O3_PRESSURE_OFFSET variable; O3 cell pressure compensation offset PSIA 404 14 Maps to ID_VAR_O3_PRESSURE_SLOPE variable; O3 cell pressure slope compensation — 406 14 Maps to ID_VAR_O3_TEMP_SET variable; O3 temperature setpoint °C 408 14 Maps to ID_VAR_O3_DWELL variable; O3 dwell time Seconds 410 14 Maps to ID_VAR_O3_RANGE variable; O3 analog output range PPB 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 215 MODBUS REGISTER ADDRESS (DECIMAL, 0-BASED) MODBUS Discrete Input Registers DESCRIPTION 10 UNITS (single-bit; read-only) 0 Manifold temperature warning 1 Converter temperature warning 2 Auto-zero warning 3 Box temperature warning 4 PMT detector temperature warning 5 Reaction cell temperature warning 6 Sample flow warning 7 Ozone flow warning 8 Reaction cell pressure warning 9 HVPS warning 10 System reset warning 11 Rear board communication warning 12 Relay board communication warning 13 Front panel communication warning 14 Analog calibration warning 15 Dynamic zero warning 16 Dynamic span warning 17 Invalid concentration 18 In zero calibration mode 19 In span calibration mode 20 In multi-point calibration mode 21 System is OK (same meaning as SYSTEM_OK I/O signal) 22 Ozone generator warning 23 24 IZS temperature warning In low span calibration mode 8 25 7 NO concentration alarm limit #1 exceeded 26 7 NO concentration alarm limit #2 exceeded 27 7 NO2 concentration alarm limit #1 exceeded 28 7 NO2 concentration alarm limit #2 exceeded 29 7 NOX concentration alarm limit #1 exceeded 30 7 NOX concentration alarm limit #2 exceeded 200 5 Calibrating O2 gas 201 5 O2 sensor cell temperature warning 202 5+7 O2 concentration alarm limit #1 exceeded 203 5+7 O2 concentration alarm limit #2 exceeded 216 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 083730210A DCN8164 MODBUS REGISTER ADDRESS (DECIMAL, 0-BASED) DESCRIPTION 10 300 6 Calibrating CO2 gas 301 6 CO2 sensor cell temperature warning 302 6+7 CO2 concentration alarm limit #1 exceeded 303 6+7 CO2 concentration alarm limit #2 exceeded 400 14 Calibrating O3 gas 401 14 O3 cell temperature warning 402 14 O3 concentration alarm limit #1 exceeded 403 14 O3 concentration alarm limit #2 exceeded UNITS MODBUS Coil Registers (single-bit; read/write) 0 Maps to relay output signal 36 (MB_RELAY_36 in signal I/O list) 1 Maps to relay output signal 37 (MB_RELAY_37 in signal I/O list) 2 Maps to relay output signal 38 (MB_RELAY_38 in signal I/O list) 3 Maps to relay output signal 39 (MB_RELAY_39 in signal I/O list) 20 2 Triggers zero calibration of NOX range #1 (on enters cal.; off exits cal.) 21 2 Triggers span calibration of NOX range #1 (on enters cal.; off exits cal.) 22 2 Triggers zero calibration of NOX range #2 (on enters cal.; off exits cal.) 23 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Triggers span calibration of NOX range #2 (on enters cal.; off exits cal.) Engineering firmware only. Set DYN_ZERO or DYN_SPAN variables to ON to enable calculating new slope or offset. Otherwise a calibration check is performed. Triple-range option. Optional. O2 option. CO2 option. Concentration alarm option. Low span option. M200EUP. All NOX references become NOy for M200EU_NOy. M200EU and M200EU_NOy. External analog input option. M200EU_PHOTO. O3 option. 32-bit integer value stored in high/low word order (i.e. not a floating-point value). 083730210A DCN8164 Teledyne API T200H/M Nitrogen Oxides Analyzers with NumaView™ Software 217 APPENDIX B 083730210A DCN8164 B-1
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