API 100A User manual

INSTRUCTION MANUAL
MODEL 100A
SULFUR DIOXIDE ANALYZER
TELEDYNE INSTRUMENTS
ADVANCED POLLUTION INSTRUMENTATION DIVISION
(T-API)
6565 NANCY RIDGE DRIVE
SAN DIEGO, CA 92121-2251
TOLL-FREE: 800-324-5190
FAX: [phone]
TEL: [phone]
E-MAIL: [email protected]
WEB SITE: www.teledyne-api.com
02164
REV. G
Copyright 1994 API Inc. 12/12/98

Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
Table of Contents
1 HOW TO USE THIS MANUAL..................................................................1-1
1.1 SAFETY MESSAGES.................................................................................................... 1-2
2 GETTING STARTED.................................................................................2-1
2.1 INSTALLATION ............................................................................................................ 2-1
2.2 ELECTRICAL AND PNEUMATIC CONNECTIONS................................................................ 2-1
2.3 INITIAL OPERATION..................................................................................................... 2-6
3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY .....................3-1
3.1 SPECIFICATIONS ........................................................................................................ 3-1
3.2 EPA EQUIVALENCY DESIGNATION ............................................................................... 3-2
3.3 WARRANTY................................................................................................................ 3-3
4 THE M100A SO2ANALYZER ...................................................................4-1
4.1 PRINCIPLE OF OPERATION .......................................................................................... 4-1
4.2 INSTRUMENT DESCRIPTION ......................................................................................... 4-4
4.2.1 Sensor Module, Reaction Cell, Detector............................................................ 4-4
4.2.2 Pneumatic Sensor Board................................................................................... 4-4
4.2.3 Computer Hardware and Software .................................................................... 4-4
4.2.4 V/F Board .......................................................................................................... 4-5
4.2.5 Front Panel ........................................................................................................ 4-5
4.2.6 Power Supply Module........................................................................................ 4-8
4.2.7 Pneumatic System............................................................................................. 4-8
5 SOFTWARE FEATURES..........................................................................5-1
5.1 INDEX TO FRONT PANEL MENUS ................................................................................. 5-1
5.1.1 Sample Menu .................................................................................................... 5-3
5.1.2 Set-Up Menu ..................................................................................................... 5-4
5.2 SAMPLE MODE........................................................................................................... 5-7
5.2.1 Test Functions ................................................................................................... 5-7
5.2.2 CAL, CALS, CALZ, Calibration Functions........................................................ 5-10
5.3 SET-UP MODE ......................................................................................................... 5-12
5.3.1 Configuration Information (CFG) ..................................................................... 5-12
5.3.2 Automatic Calibration (AutoCal)....................................................................... 5-12
5.3.3 Data Acquisition System (DAS) ....................................................................... 5-12
5.3.4 Range Menu .................................................................................................... 5-13
5.3.5 Password Enable............................................................................................. 5-17
5.3.6 Time of Day Clock ........................................................................................... 5-17
5.3.7 Diagnostic Mode.............................................................................................. 5-17
5.3.8 Communications Menu .................................................................................... 5-17
5.3.9 Variables Menu (VARS)................................................................................... 5-18
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
6 OPTIONAL HARDWARE AND SOFTWARE............................................6-1
6.1 RACK MOUNT OPTIONS .............................................................................................. 6-1
6.2 ZERO/SPAN VALVES................................................................................................... 6-1
6.3 INTERNAL ZERO/SPAN (IZS)........................................................................................ 6-3
6.4 AUTOCAL - SETUP OF IZS AND ZERO/SPAN VALVES ..................................................... 6-3
6.5 PERMEATION TUBE (USED WITH IZS OPTION) ............................................................... 6-6
6.6 4-20 MA, CURRENT LOOP OUTPUT ............................................................................. 6-9
6.7 STATUS OUTPUT ........................................................................................................ 6-9
6.8 RS-232 INTERFACE ................................................................................................. 6-10
6.8.1 Setting Up the RS-232 Interface...................................................................... 6-10
6.8.2 Command Summary........................................................................................ 6-13
6.8.3 TEST Commands and Messages.................................................................... 6-17
6.8.4 WARNING Commands And Messages ........................................................... 6-18
6.8.5 CALIBRATION Commands and Messages ..................................................... 6-19
6.8.6 DIAGNOSTIC Commands and Messages....................................................... 6-20
6.8.7 DAS Commands and Reports ......................................................................... 6-21
6.8.8 VARIABLES Commands and Messages ......................................................... 6-24
7 CALIBRATION AND ZERO/SPAN CHECKS ...........................................7-1
7.1 MANUAL ZERO/SPAN CHECK OR CALIBRATION THROUGH THE SAMPLE PORT .................. 7-4
7.2 MANUAL ZERO/SPAN CHECK OR CALIBRATION WITH ZERO/SPAN VALVES OPTION ........... 7-6
7.3 MANUAL ZERO/SPAN CHECK WITH IZS OPTION ............................................................ 7-7
7.4 AUTOMATIC ZERO/SPAN CHECK .................................................................................. 7-7
7.5 AUTOMATIC ZERO/SPAN CALIBRATION ......................................................................... 7-7
7.6 CALIBRATE ON SO2PERMEATION TUBE ....................................................................... 7-8
7.7 USE OF IZS OR ZERO/SPAN VALVES WITH REMOTE CONTACT CLOSURE ........................ 7-8
7.8 EPA PROTOCOL CALIBRATION .................................................................................... 7-9
7.8.1 Calibration of Equipment ................................................................................... 7-9
7.8.2 Calibration Gas Sources.................................................................................. 7-10
7.8.3 Data Recording Device.................................................................................... 7-12
7.8.4 Dynamic Multipoint Span Calibration ............................................................... 7-12
7.8.5 SO2Calibration Procedure............................................................................... 7-13
7.8.6 Calibration Frequency...................................................................................... 7-19
7.8.7 Other Quality Assurance Procedures .............................................................. 7-19
7.8.8 Summary of Quality Assurance Checks .......................................................... 7-21
7.8.9 ZERO and SPAN Checks ................................................................................ 7-22
7.8.10 Recommended Standards for Establishing Traceability ................................ 7-23
7.9 SPECIAL CALIBRATION REQUIREMENTS FOR DUAL RANGE OR AUTO RANGE.................. 7-24
7.10 CALIBRATION QUALITY............................................................................................ 7-25
7.11 REFERENCES......................................................................................................... 7-26
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
8 MAINTENANCE ........................................................................................8-1
8.1 MAINTENANCE SCHEDULE........................................................................................... 8-1
8.2 REPLACING THE SAMPLE PARTICULATE FILTER ............................................................. 8-2
8.3 REPLACING THE PERMEATION TUBE (OPTION)............................................................... 8-4
8.4 REPLACING THE IZS ZERO AIR SCRUBBER (OPTION)..................................................... 8-4
8.5 CLEANING ORIFICE AND ORIFICE FILTER ...................................................................... 8-5
8.6 CLEANING THE REACTION CELL ................................................................................... 8-6
8.7 PNEUMATIC LINE INSPECTION...................................................................................... 8-6
8.8 LEAK CHECK PROCEDURE .......................................................................................... 8-9
8.9 LIGHT LEAK CHECK PROCEDURE ............................................................................... 8-10
8.10 EPROM REPLACEMENT PROCEDURE ..................................................................... 8-10
9 DIAGNOSTIC, TROUBLESHOOTING......................................................9-1
9.1 OPERATION VERIFICATION - M100A DIAGNOSTIC TECHNIQUES ..................................... 9-3
9.1.1 Fault Diagnosis with TEST Variables................................................................. 9-3
9.1.2 Fault Diagnosis with WARNING Messages ....................................................... 9-9
9.1.3 Fault Diagnosis using DIAGNOSTIC Mode ..................................................... 9-11
9.1.4 M100A Internal Variables ................................................................................ 9-18
9.1.5 Test Channel Analog Output ........................................................................... 9-20
9.1.6 Factory Calibration Procedure (Quick Cal) ...................................................... 9-21
9.2 PERFORMANCE PROBLEMS ....................................................................................... 9-23
9.2.1 AC Power Check ............................................................................................. 9-23
9.2.2 Flow Check...................................................................................................... 9-24
9.2.3 No Response to Sample Gas .......................................................................... 9-24
9.2.4 Negative Concentration Display....................................................................... 9-25
9.2.5 Excessive Noise .............................................................................................. 9-25
9.2.6 Unstable Span ................................................................................................. 9-26
9.2.7 Unstable Zero .................................................................................................. 9-27
9.2.8 Inability to Span ............................................................................................... 9-27
9.2.9 Inability to Zero ................................................................................................ 9-28
9.2.10 Non-Linear Response.................................................................................... 9-28
9.2.11 Slow Response.............................................................................................. 9-29
9.2.12 Analog Output Doesn't Agree With Display Concentration ............................ 9-29
9.3 ELECTRONIC SUBSYSTEM TROUBLESHOOTING AND ADJUSTMENTS............................... 9-30
9.3.1 Computer, Display, Keyboard.......................................................................... 9-30
9.3.2 RS-232 Communications................................................................................. 9-33
9.3.3 Voltage/Frequency (V/F) Board ....................................................................... 9-36
9.3.4 Status/Temp Board.......................................................................................... 9-42
9.3.5 Power Supply Module...................................................................................... 9-45
9.3.6 Flow/Pressure Sensor ..................................................................................... 9-49
9.3.7 Reaction Cell Temp ......................................................................................... 9-53
9.3.8 Preamp Board ................................................................................................. 9-53
9.3.9 PMT Cooler ..................................................................................................... 9-53
9.3.10 HVPS (High Voltage Power Supply) .............................................................. 9-56
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
9.4 OPTICAL SENSOR MODULE TROUBLESHOOTING.......................................................... 9-58
9.4.1 PMT ................................................................................................................. 9-58
9.4.2 UV Lamp Adjust or Replacement .................................................................... 9-58
9.4.3 UV Filter Replacement..................................................................................... 9-59
9.4.4 Shutter System ................................................................................................ 9-59
9.5 PNEUMATIC SYSTEM TROUBLESHOOTING ................................................................... 9-60
9.5.1 Leak Check...................................................................................................... 9-60
9.5.2 Pump ............................................................................................................... 9-60
9.5.3 Kicker............................................................................................................... 9-60
9.5.4 Z/S Valves & IZS Permeation Tube Oven ....................................................... 9-62
10 TELEDYNE API M100A SPARE PARTS LIST.....................................10-1
APPENDIX A MAINTENANCE SCHEDULE FOR M100A ......................... A-1
APPENDIX B ELECTRICAL SCHEMATICS .............................................. B-1
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
List of Figures
FIGURE 2-1: REMOVAL OF SHIPPING SCREWS ...................................................................2-3
FIGURE 2-2: REAR PANEL ................................................................................................2-4
FIGURE 2-3: REAR PANEL PNEUMATIC RECOMMENDATIONS ...............................................2-5
FIGURE 2-4: FRONT PANEL ............................................................................................2-10
FIGURE 2-5: ASSEMBLY LAYOUT.....................................................................................2-11
FIGURE 4-1: M100A SULFUR DIOXIDE ANALYZER..............................................................4-3
FIGURE 4-2: FRONT PANEL DISPLAY.................................................................................4-7
FIGURE 5-1: SAMPLE MENU .............................................................................................5-1
FIGURE 5-2: SETUP MENU TREE ......................................................................................5-2
FIGURE 6-1: PERMEATION TUBE INSTALLATION..................................................................6-8
FIGURE 7-1: MODEL 100A CALIBRATION SETUP ................................................................7-3
FIGURE 7-2: DIAGRAM OF CALIBRATION SYSTEM.............................................................7-15
FIGURE 7-3: DIAGRAM F PERMEATION CALIBRATION SYSTEM ...........................................7-17
FIGURE 8-1: REPLACING THE PARTICULATE FILTER............................................................8-3
FIGURE 8-2: REACTION CELL ...........................................................................................8-7
FIGURE 8-3: PNEUMATIC DIAGRAM ...................................................................................8-8
FIGURE 9-1: CPU BOARD JUMPER SETTINGS..................................................................9-32
FIGURE 9-2: RS-232 PIN ASSIGNMENTS.........................................................................9-34
FIGURE 9-3: V/F BOARD DIP SWITCH SETTINGS..............................................................9-41
FIGURE 9-4: POWER SUPPLY MODULE LAYOUT ...............................................................9-46
FIGURE 9-5: ELECTRICAL BLOCK DIAGRAM .....................................................................9-47
FIGURE 9-6: FLOW/PRESSURE SENSOR ..........................................................................9-50
FIGURE 9-7: SO2SENSOR MODULE................................................................................9-51
FIGURE 9-8: SO2SENSOR MODULE................................................................................9-52
FIGURE 9-9: PMT COOLER SUBSYSTEM .........................................................................9-55
FIGURE 9-10: HIGH VOLTAGE POWER SUPPLY ................................................................9-57
FIGURE 9-11: KICKER LEAK CHECK ................................................................................9-61
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
List of Tables
TABLE 2-1: FINAL TEST AND CALIBRATION VALUES ..........................................................2-12
TABLE 2-1: FINAL TEST AND CALIBRATION VALUES (CONTINUED)......................................2-13
TABLE 4-1: SYSTEM MODES DISPLAY ...............................................................................4-6
TABLE 4-2: FRONT PANEL STATUS LED'S.........................................................................4-7
TABLE 5-1: M100A SAMPLE MENU STRUCTURE................................................................5-3
TABLE 5-2: M100A SETUP MENU STRUCTURE ..................................................................5-4
TABLE 5-3: M100A MENU STRUCTURE - SETUP MENU #2 .................................................5-5
TABLE 5-4: M100A MENU STRUCTURE - SETUP MENU #3 .................................................5-6
TABLE 5-5: CALIBRATE, SETUP PASSWORDS...................................................................5-17
TABLE 6-1: ZERO/SPAN VALVE OPERATION .......................................................................6-2
TABLE 6-2: SETUP AUTOMATIC ZERO/SPAN CALIBRATION ..................................................6-4
TABLE 6-3: STATUS OUTPUT PIN ASSIGNMENTS ................................................................6-9
TABLE 6-4: RS-232 PORT SETUP - FRONT PANEL...........................................................6-11
TABLE 6-5: RS-232 SWITCHING FROM TERMINAL MODE TO COMPUTER MODE..................6-12
TABLE 6-6: RS-232 TERMINAL MODE EDITING KEYS .......................................................6-13
TABLE 6-7: RS-232 COMMAND SUMMARY ......................................................................6-14
TABLE 6-8: RS-232 COMMAND SUMMARY ......................................................................6-15
TABLE 6-9: RS-232 INTERFACE COMMAND TYPES ..........................................................6-16
TABLE 6-10: RS-232 TEST MESSAGES ..........................................................................6-17
TABLE 6-11: RS-232 WARNING MESSAGES....................................................................6-18
TABLE 6-12: RS-232 CALIBRATION MESSAGES...............................................................6-19
TABLE 6-13: RS-232 CALIBRATION COMMANDS ..............................................................6-20
TABLE 6-14: RS-232 DIAGNOSTIC COMMAND SUMMARY .................................................6-21
TABLE 6-15: RS-232 DAS COMMANDS..........................................................................6-21
TABLE 6-16: RS-232 OPERATING MODES ......................................................................6-24
TABLE 7-1: TYPES OF ZERO/SPAN CHECKS AND CALIBRATIONS ..........................................7-2
TABLE 7-2: MANUAL ZERO CALIBRATION PROCEDURE - ZERO GAS THROUGH SAMPLE
PORT............................................................................................................7-4
TABLE 7-3: ENTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE...........................7-5
TABLE 7-4: MANUAL SPAN CALIBRATION PROCEDURE - SPAN GAS THROUGH SAMPLE
PORT............................................................................................................7-5
TABLE 7-5: MANUAL ZERO CALIBRATION PROCEDURE - Z/S VALVES...................................7-6
TABLE 7-6: MANUAL SPAN CALIBRATION PROCEDURE - Z/S VALVES...................................7-6
TABLE 7-7: IZS OR Z/S VALVES MODES WITH REMOTE CONTACT CLOSURE........................7-9
TABLE 7-8: ACTIVITY MATRIX FOR CALIBRATION EQUIPMENT & SUPPLIES..........................7-11
TABLE 7-9: ACTIVITY MATRIX FOR CALIBRATION PROCEDURE ...........................................7-12
TABLE 7-10: EPA ZERO CALIBRATION PROCEDURE.........................................................7-14
TABLE 7-11: EPA EXPECTED SPAN GAS CONCENTRATION PROCEDURE ...........................7-15
TABLE 7-12: EPA SPAN CALIBRATION PROCEDURE.........................................................7-16
TABLE 7-13: DEFINITION OF LEVEL 1 AND LEVEL 2 ZERO AND SPAN CHECKS .....................7-20
TABLE 7-14: ACTIVITY MATRIX .......................................................................................7-21
TABLE 7-15: NIST-SRM'S AVAILABLE FOR TRACEABILITY OF CALIBRATION AND AUDIT
GAS STANDARDS ......................................................................................7-24
TABLE 7-16: CALIBRATION QUALITY CHECK ....................................................................7-25
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Teledyne API Model 100A SO2Analyzer Instruction Manual, 02164, Rev. G
TABLE 8-1: PREVENTATIVE MAINTENANCE SCHEDULE ........................................................8-1
TABLE 9-1: TEST FUNCTIONS ...........................................................................................9-3
TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-4
TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-5
TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-6
TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-7
TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-8
TABLE 9-2: FRONT PANEL WARNING MESSAGES ...............................................................9-9
TABLE 9-2: FRONT PANEL WARNING MESSAGES (CONTINUED).........................................9-10
TABLE 9-3: SUMMARY OF DIAGNOSTIC MODES ................................................................9-12
TABLE 9-4: DIAGNOSTIC MODE - SIGNAL I/O ...................................................................9-13
TABLE 9-5: MODEL 100A VARIABLES..............................................................................9-19
TABLE 9-6: TEST CHANNEL OUTPUT ...............................................................................9-20
TABLE 9-7: POWER SUPPLY MODULE SUBASSEMBLIES.....................................................9-45
TABLE 9-8: POWER SUPPLY MODULE LED OPERATION....................................................9-48
TABLE 10-1: TELEDYNE API M100A SPARE PARTS LIST .................................................10-1
TABLE 10-1: TELEDYNE API M100A SPARE PARTS LIST (CONTINUED) .............................10-2
TABLE 10-1: TELEDYNE API M100A SPARE PARTS LIST (CONTINUED) .............................10-3
TABLE 10-1: TELEDYNE API M100A SPARE PARTS LIST (CONTINUED) .............................10-4
TABLE 10-2: TELEDYNE API M100A LEVEL 1 SPARES KIT...............................................10-4
TABLE 10-3: TELEDYNE API M100A 37 MM EXPENDABLES KIT ........................................10-5
TABLE 10-4: TELEDYNE API M100A 47 MM EXPENDABLES KIT ........................................10-5
TABLE 10-5: TELEDYNE API M100A EXPENDABLES KIT - IZS..........................................10-5
TABLE 10-6: TELEDYNE API M100A SPARES KIT FOR 1 UNIT..........................................10-6
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