TELEDYNE API T300 User manual
Operation Manual
Model T300/T300M
Carbon Monoxide Analyzer
Also supports operation of:
Models T320 and T320U Analyzers
(when used in conjunction with T320/320U Addendum, PN07406)
© Teledyne API (TAPI)
9970 Carroll Canyon Road
San Diego, CA 92131-1106
USA
Toll-free Phone:
800-324-5190
Phone:
+1 858-657-9800
Fax:
+1 858-657-9816
Email:
Website:
http://www.teledyne-api.com/
Copyright 2010-2018 06864D DCN7562
Teledyne API 15 August 2018
i
NOTICE OF COPYRIGHT
© 2010-2018 Teledyne Advanced Pollution Instrumentation, Inc. 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.
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IMPORTANT SAFETY INFORMATION
Important safety messages are provided throughout this manual. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is
associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying
message for specific information.
CAUTION: Hot Surface Warning
Technician Symbol: All operations marked with this symbol are to
be performed by qualified maintenance personnel only.
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.
Electrical Ground: This symbol inside the instrument marks the
central safety grounding point for the instrument.
CAUTION - General Safety Hazard
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).
Note Technical Assistance regarding the use and maintenance of the
T300/T300M or any other Teledyne API product can be obtained by
contacting Teledyne API’s Technical Support Department:
Phone: 800-324-5190
Email: api-[email protected]
or by accessing various service options on our website at
7http://www.teledyne-api.com/.
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Teledyne API – Model T300/T300M CO Analyzer
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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!
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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 can be reviewed at http://www.teledyne-
api.com/terms_and_conditions.asp
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 are can also be found on our website.
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ABOUT THIS MANUAL
Presented here is information regarding the documents that are included with this
manual (Structure), its history of release and revisions (Revision History), how the
content is organized (Organization), a description of other information related to this
manual (Related Information), and the conventions used to present the information in
this manual (Conventions Used).
STRUCTURE
This T300 manual, PN 06864, is comprised of multiple documents, assembled in PDF
format, as listed below.
Note We recommend that this manual be read in its entirety before any attempt
is made to operate the instrument.
CONVENTIONS USED
In addition to the safety symbols as presented in the Important Safety Information page,
this manual provides special notices related to the safety and effective use of the
analyzer and other pertinent information.
Special Notices appear as follows:
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
Could either affect accuracy of instrument readings or cause loss of data.
Note Pertinent information associated with the proper care, operation or
maintenance of the analyzer or its parts.
Part No. Rev Name/Description
068640000 D Operation Manual, T300/T300M Carbon Monoxide Analyzer
049060000 J Appendix A, Menu Trees and related software documentation
069120000 B Interconnect Diagram (in Appendix B of this manual)
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TABLE OF CONTENTS
1. INTRODUCTION, FEATURES AND OPTIONS.................................................................. 17
1.1. T300 Family Overview.................................................................................................................................17
1.2. Features.......................................................................................................................................................18
1.3. T300/T300M Documentation .......................................................................................................................18
1.4. Options.........................................................................................................................................................19
2. SPECIFICATIONS AND APPROVALS............................................................................... 23
2.1. Specifications...............................................................................................................................................23
2.2. EPA Designation..........................................................................................................................................25
2.3. Approvals and Certifications........................................................................................................................25
2.3.1. Safety.....................................................................................................................................................25
2.3.2. EMC .......................................................................................................................................................25
2.3.3. Other Type Certifications.......................................................................................................................26
3. GETTING STARTED........................................................................................................... 27
3.1. Unpacking the T300/T300M Analyzer .........................................................................................................27
3.1.1. Ventilation Clearance.............................................................................................................................28
3.2. Instrument Layout........................................................................................................................................29
3.2.1. Front Panel.............................................................................................................................................29
3.2.2. Rear panel..............................................................................................................................................33
3.2.3. T300/T300M Analyzer Layout................................................................................................................35
3.3. Connections and Setup................................................................................................................................38
3.3.1. Electrical Connections ...........................................................................................................................38
3.3.1.1. Connecting Power..........................................................................................................................38
3.3.1.2. Connecting Analog Inputs (Option)................................................................................................39
3.3.1.3. Connecting Analog Outputs ...........................................................................................................39
3.3.1.4. Current Loop Analog Outputs (Option 41) Setup..........................................................................40
3.3.1.5. Connecting the Status Outputs ......................................................................................................42
3.3.1.6. Connecting the Control Inputs........................................................................................................43
3.3.1.7. Connecting the Concentration Alarm Relay (Option 61)................................................................45
3.3.1.8. Connecting the Communication Interfaces ....................................................................................46
3.3.2. Pneumatic Connections.........................................................................................................................53
3.3.2.1. Pneumatic Connections for Basic Configuration............................................................................55
3.3.2.2. Pneumatic Layout for Basic configuration......................................................................................57
3.3.2.3. Pneumatic Connections for Ambient Zero/Ambient Span Valve Option........................................57
3.3.2.4. Pneumatic Layout for Ambient Zero/Ambient Span Valve Option .................................................59
3.3.2.5. Pneumatic Connections for Ambient Zero/Pressurized Span........................................................59
3.3.2.6. Pneumatic Layout for Ambient Zero/Pressurized Span Option .....................................................61
3.3.2.7. Pneumatic Connections for Zero Scrubber/Pressurized Span Option...........................................62
3.3.2.8. Pneumatic Layout for Zero Scrubber/Pressurized Span Option....................................................63
3.3.2.9. Pneumatic Connections for Zero Scrubber/Ambient Span Option.................................................64
3.3.2.10. Pneumatic Layout for Zero scrubber/ Ambient Span OPTion......................................................66
3.3.2.11. Calibration Gases.........................................................................................................................66
3.4. Startup, Functional Checks, and Initial Calibration......................................................................................67
3.4.1. Startup....................................................................................................................................................68
3.4.2. Warning Messages ................................................................................................................................68
3.4.3. Functional Checks .................................................................................................................................70
3.4.4. Initial Calibration ....................................................................................................................................71
3.4.4.1. Interferents for CO Measurements.................................................................................................72
3.4.4.2. Initial Calibration Procedure ...........................................................................................................72
3.4.4.3. O2 Sensor Calibration Procedure ..................................................................................................77
3.4.4.4. CO2 Sensor Calibration Procedure................................................................................................77
4. OVERVIEW OF OPERATING MODES............................................................................... 79
4.1. Sample Mode...............................................................................................................................................80
4.1.1. Test Functions .......................................................................................................................................80
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4.1.2. Warning Messages ................................................................................................................................83
4.2. Calibration Mode..........................................................................................................................................84
4.3. Setup MODE................................................................................................................................................85
4.3.1. Password Security.................................................................................................................................85
4.3.2. Primary Setup Menu..............................................................................................................................85
4.3.3. The areas accessible under the Setup mode are shown in Table 4-4 and Secondary Setup Menu
(SETUP>MORE)...................................................................................................................................85
4.3.4. Secondary Setup Menu (SETUP>MORE).............................................................................................86
5. SETUP MENU .................................................................................................................... 87
5.1. SETUP àCFG: Configuration Information .................................................................................................87
5.2. SETUP àACAL: Automatic Calibration......................................................................................................88
5.3. SETUP àDAS: Internal Data Acquisition System.......................................................................................88
5.4. SETUP àRNGE: Analog Output Reporting Range Configuration.............................................................88
5.4.1. Analog Output Ranges for CO Concentration .......................................................................................88
5.4.2. Physical Range vs Analog Output Reporting Ranges...........................................................................90
5.4.3. Reporting Range Modes: Single, Dual, Auto Ranges ...........................................................................90
5.4.3.1. SINGLE Range Mode (SNGL) .......................................................................................................92
5.4.3.2. DUAL Range Mode (DUAL) ...........................................................................................................93
5.4.3.3. AUTO Range Mode (AUTO) ..........................................................................................................95
5.4.4. Range Units ...........................................................................................................................................97
5.4.5. Dilution Ratio (Option)............................................................................................................................98
5.5. SETUP àPASS: Password Protection.......................................................................................................99
5.6. SETUP àCLK: Setting the Internal Time-of-Day Clock and Adjusting Speed.........................................101
5.6.1.1. Setting the Internal Clock’s Time and Day...................................................................................101
5.6.1.2. Adjusting the Internal Clock’s Speed............................................................................................101
5.7. SETUP àComm: Communications Ports .................................................................................................103
5.7.1. ID (Machine Identification)...................................................................................................................103
5.7.2. INET (Ethernet)....................................................................................................................................103
5.7.3. COM1 and COM2 (Mode, Baud Rate and Test Port)..........................................................................103
5.8. SETUP àVARS: Variables Setup and Definition......................................................................................104
5.9. SETUP àDiag: Diagnostics Functions......................................................................................................106
5.9.1. Signal I/O .............................................................................................................................................108
5.9.2. Analog Output......................................................................................................................................109
5.9.3. Analog I/O Configuration......................................................................................................................110
5.9.3.1. Analog Output Voltage / Current Range Selection.......................................................................112
5.9.3.2. Analog Output Calibration ............................................................................................................114
5.9.3.3. Enabling or Disabling the AutoCal for an Individual Analog Output.............................................114
5.9.3.4. Automatic Calibration of the Analog Outputs ...............................................................................116
5.9.3.5. Individual Calibration of the Analog Outputs................................................................................117
5.9.3.6. Manual Calibration of the Analog Outputs Configured for Voltage Ranges.................................118
5.9.3.7. Manual Adjustment of Current Loop Output Span and Offset .....................................................120
5.9.3.8. Turning an Analog Output Over-Range Feature ON/OFF ...........................................................123
5.9.3.9. Adding a Recorder Offset to an Analog Output............................................................................124
5.9.3.10. AIN Calibration ...........................................................................................................................125
5.9.3.11. Analog Inputs (XIN1…XIN8) Option Configuration ....................................................................126
5.9.4. Electrical Test ......................................................................................................................................127
5.9.5. Dark Calibration ...................................................................................................................................127
5.9.6. Pressure Calibration ............................................................................................................................127
5.9.7. Flow Calibration ...................................................................................................................................128
5.9.8. Test Chan Output.................................................................................................................................128
5.9.8.1. Selecting a Test Channel Function for Output A4........................................................................128
5.10. SETUP àMORE àALRM (Option): Using the Gas Concentration Alarms...........................................130
5.10.1. Setting the T300 Concentration Alarm Limits....................................................................................131
6. COMMUNICATIONS SETUP AND OPERATION ............................................................. 133
6.1. Data Terminal/Communication Equipment (DTE DCE).............................................................................133
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6.2. Communication Modes, Baud Rate and Port Testing...................................................................................133
6.2.1. Communication Modes........................................................................................................................134
6.2.2. COM Port Baud Rate...........................................................................................................................136
6.2.3. Com Port Testing.................................................................................................................................137
6.3. RS-232.......................................................................................................................................................137
6.4. RS-485 (Option).........................................................................................................................................138
6.5. Ethernet......................................................................................................................................................138
6.5.1. Configuring Ethernet Communication Manually (Static IP Address)...................................................139
6.5.2. Configuring Ethernet Communication Using Dynamic Host Configuration Protocol (DHCP) .............141
6.5.3. Changing the Analyzer’s HOSTNAME ................................................................................................142
6.6. USB Port (Option) for Remote Access ......................................................................................................143
6.7. Communications Protocols........................................................................................................................145
6.7.1. MODBUS .............................................................................................................................................145
6.7.2. Hessen.................................................................................................................................................147
6.7.2.1. Hessen COMM Port Configuration...............................................................................................147
6.7.2.2. Activating Hessen Protocol ..........................................................................................................148
6.7.2.3. Selecting a Hessen Protocol Type...............................................................................................149
6.7.2.4. Setting The Hessen Protocol Response Mode ............................................................................150
6.7.3. Hessen Protocol Gas List Entries........................................................................................................151
6.7.3.1. Hessen Protocol Gas ID...............................................................................................................151
6.7.3.2. Editing or Adding HESSEN Gas List Entries................................................................................152
6.7.3.3. Deleting HESSEN Gas List Entries..............................................................................................153
6.7.3.4. Setting Hessen Protocol Status Flags..........................................................................................154
6.7.3.5. Instrument ID................................................................................................................................155
7. DATA ACQUISITION SYSTEM (DAS) AND APICOM...................................................... 157
7.1. DAS Structure............................................................................................................................................158
7.1.1. DAS Data Channels.............................................................................................................................159
7.1.2. Default DAS Channels.........................................................................................................................159
7.1.3. Viewing DAS Channels and Individual Records..................................................................................162
7.1.4. Editing DAS Channels .........................................................................................................................163
7.1.4.1. Editing DAS Data Channel Names...............................................................................................164
7.1.5. Editing DAS Triggering Events ............................................................................................................165
7.1.6. Editing DAS Parameters......................................................................................................................166
7.1.7. Sample Period and Report Period.......................................................................................................168
7.1.8. Number of Records..............................................................................................................................171
7.1.9. RS-232 Report Function......................................................................................................................173
7.1.9.1. The Compact Report Feature.......................................................................................................173
7.1.9.2. The Starting Date Feature............................................................................................................174
7.1.10. Disabling/Enabling Data Channels ....................................................................................................174
7.1.11. HOLDOFF Feature ............................................................................................................................175
7.2. Remote DAS Configuration........................................................................................................................176
7.2.1. DAS Configuration via APICOM ..........................................................................................................176
7.2.2. DAS Configuration Using Terminal Emulation Programs....................................................................178
8. REMOTE OPERATION..................................................................................................... 181
8.1. Computer Mode .........................................................................................................................................181
8.1.1. Remote Control via APICOM...............................................................................................................181
8.2. Interactive Mode ........................................................................................................................................182
8.2.1. Remote Control via a Terminal Emulation Program............................................................................182
8.2.1.1. Help Commands in Interactive Mode...........................................................................................182
8.2.1.2. Command Syntax.........................................................................................................................182
8.2.1.3. Data Types ...................................................................................................................................183
8.2.1.4. Status Reporting...........................................................................................................................184
8.2.1.5. General Message Format.............................................................................................................184
8.3. Remote Access by Modem........................................................................................................................184
8.4. Password Security for Serial Remote Communications............................................................................187
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9. CALIBRATION PROCEDURES........................................................................................ 189
9.1. Calibration Preparations ............................................................................................................................189
9.1.1. Required Equipment, Supplies, and Expendables ..............................................................................189
9.1.1.1. Zero Air.........................................................................................................................................190
9.1.1.2. Span Gas......................................................................................................................................190
9.1.1.3. Calibration Gas Standards and Traceability.................................................................................190
9.1.2. Data Recording Devices......................................................................................................................191
9.2. Manual Calibration.....................................................................................................................................191
9.2.1. Setup for Basic Calibration Checks and Calibration............................................................................192
9.2.2. Performing a Basic Manual Calibration Check....................................................................................193
9.2.3. Performing a Basic Manual Calibration ...............................................................................................194
9.2.3.1. Setting the Expected Span Gas Concentration............................................................................194
9.2.3.2. Zero/Span Point Calibration Procedure........................................................................................196
9.3. Manual Calibration with Zero/Span Valves................................................................................................197
9.3.1. Setup for Calibration Using Valve Options ..........................................................................................197
9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................200
9.3.3. Manual Calibration Using Valve Options .............................................................................................201
9.3.3.1. Setting the Expected Span Gas Concentration............................................................................201
9.3.3.2. Zero/Span Point Calibration Procedure........................................................................................202
9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................204
9.4. Automatic Zero/Span Cal/Check (AutoCal)...............................................................................................204
9.4.1. SETUP àACAL: Programming and AUTO CAL Sequence...............................................................207
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected...................................................210
9.5. CO Calibration Quality...............................................................................................................................211
9.6. Calibration of the T300/T300M’s Electronic Subsystems..........................................................................212
9.6.1. Dark Calibration Test...........................................................................................................................212
9.6.2. Pressure Calibration ............................................................................................................................213
9.6.3. Flow Calibration ...................................................................................................................................215
9.7. Calibration of Optional Sensors.................................................................................................................216
9.7.1. O2Sensor Calibration ..........................................................................................................................216
9.7.1.1. O2 Pneumatics Connections........................................................................................................216
9.7.1.2. Set O2 Span Gas Concentration..................................................................................................217
9.7.1.3. Activate O2 Sensor Stability Function..........................................................................................218
9.7.1.4. O2 ZERO/SPAN CALIBRATION..................................................................................................219
9.7.2. CO2Sensor Calibration Procedure......................................................................................................220
9.7.2.1. CO2 Pneumatics Connections .....................................................................................................220
9.7.2.2. Set CO2 Span Gas Concentration: ..............................................................................................221
9.7.2.3. Activate CO2 Sensor Stability Function .......................................................................................222
9.7.2.4. CO2 Zero/Span Calibration..........................................................................................................223
9.8. EPA Protocol Calibration ...........................................................................................................................224
10. MAINTENANCE SCHEDULE & PROCEDURES............................................................ 227
10.1. Maintenance Schedule............................................................................................................................227
10.2. Predicting Failures Using the Test Functions..........................................................................................231
10.3. Maintenance Procedures.........................................................................................................................232
10.3.1. Replacing the Sample Particulate Filter.............................................................................................232
10.3.2. Rebuilding the Sample Pump ............................................................................................................233
10.3.3. Performing Leak Checks....................................................................................................................233
10.3.3.1. Vacuum Leak Check and Pump Check......................................................................................233
10.3.3.2. Pressure Leak Check.................................................................................................................233
10.3.4. Performing a Sample Flow Check .....................................................................................................234
10.3.5. Cleaning the Optical Bench ...............................................................................................................234
10.3.6. Cleaning Exterior Surfaces of the T300/T300M ................................................................................234
11. TROUBLESHOOTING AND SERVICE........................................................................... 235
11.1. General Troubleshooting.........................................................................................................................235
11.1.1. Fault Diagnosis with WARNING Messages.......................................................................................236
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11.1.2. Fault Diagnosis with TEST Functions................................................................................................240
11.1.3. the Diagnostic Signal I/O Function ....................................................................................................243
11.1.4. Status LEDs.......................................................................................................................................245
11.1.4.1. Motherboard Status Indicator (Watchdog) .................................................................................245
11.1.4.2. Sync Demodulator Status LEDs.................................................................................................246
11.1.4.3. Relay Board Status LEDs...........................................................................................................247
11.2. Gas Flow Problems .................................................................................................................................249
11.2.1. T300/T300M Internal Gas Flow Diagrams.........................................................................................250
11.2.2. Typical Sample Gas Flow Problems..................................................................................................253
11.2.2.1. Flow is Zero................................................................................................................................253
11.2.2.2. Low Flow ....................................................................................................................................254
11.2.2.3. High Flow....................................................................................................................................254
11.2.2.4. Displayed Flow = “Warnings” .....................................................................................................255
11.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................255
11.2.2.6. Sample Pump.............................................................................................................................255
11.3. Calibration Problems ...............................................................................................................................255
11.3.1. Miscalibrated......................................................................................................................................255
11.3.2. Non-Repeatable Zero and Span........................................................................................................256
11.3.3. Inability to Span – No SPAN Button (CALS)......................................................................................256
11.3.4. Inability to Zero – No ZERO Button (CALZ).......................................................................................256
11.4. Other Performance Problems..................................................................................................................257
11.4.1. Temperature Problems......................................................................................................................257
11.4.1.1. Box or Sample Temperature......................................................................................................257
11.4.1.2. Bench Temperature....................................................................................................................257
11.4.1.3. GFC Wheel Temperature...........................................................................................................258
11.4.1.4. IR Photo-Detector TEC Temperature.........................................................................................259
11.4.2. Excessive Noise.................................................................................................................................259
11.5. Subsystem Checkout...............................................................................................................................260
11.5.1. AC Mains Configuration.....................................................................................................................260
11.5.2. DC Power Supply...............................................................................................................................261
11.5.3. I2C Bus...............................................................................................................................................261
11.5.4. Touchscreen Interface.......................................................................................................................262
11.5.5. LCD Display Module ..........................................................................................................................262
11.5.6. Relay Board .......................................................................................................................................262
11.5.7. Sensor Assembly...............................................................................................................................263
11.5.7.1. Sync/Demodulator Assembly.....................................................................................................263
11.5.7.2. Electrical Test.............................................................................................................................263
11.5.7.3. Opto Pickup Assembly ...............................................................................................................264
11.5.7.4. GFC Wheel Drive .......................................................................................................................264
11.5.7.5. IR Source....................................................................................................................................264
11.5.7.6. Pressure/Flow Sensor Assembly ...............................................................................................265
11.5.8. Motherboard.......................................................................................................................................266
11.5.8.1. A/D Functions.............................................................................................................................266
11.5.8.2. Test Channel / Analog Outputs Voltage.....................................................................................266
11.5.8.3. Analog Outputs: Current Loop....................................................................................................267
11.5.8.4. Status Outputs............................................................................................................................268
11.5.8.5. Control Inputs – Remote Zero, Span..........................................................................................268
11.5.9. CPU....................................................................................................................................................269
11.5.10. RS-232 Communications.................................................................................................................269
11.5.10.1. General RS-232 Troubleshooting.............................................................................................269
11.5.10.2. Troubleshooting Analyzer/Modem or Terminal Operation .......................................................270
11.5.11. The Optional CO2Sensor ................................................................................................................270
11.6. Repair Procedures...................................................................................................................................271
11.6.1. Repairing Sample Flow Control Assembly ........................................................................................271
11.6.2. Removing/Replacing the GFC Wheel................................................................................................272
11.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................274
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11.6.3.1. Checking the Sync/Demodulator Circuit Gain............................................................................274
11.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain...........................................................................275
11.6.4. Disk-On-Module Replacement...........................................................................................................276
11.7. Frequently Asked Questions ...................................................................................................................277
11.8. Technical Assistance...............................................................................................................................278
12. THEORY OF OPERATION.............................................................................................. 279
12.1. Measurement Method..............................................................................................................................280
12.1.1. Beer’s Law .........................................................................................................................................280
12.2. Measurement Fundamentals...................................................................................................................280
12.2.1. Gas Filter Correlation.........................................................................................................................281
12.2.1.1. The GFC Wheel..........................................................................................................................281
12.2.1.2. The Measure Reference Ratio ...................................................................................................282
12.2.1.3. Summary Interference Rejection................................................................................................285
12.3. Flow Rate Control....................................................................................................................................286
12.3.1.1. Critical Flow Orifice.....................................................................................................................287
12.3.2. Particulate Filter.................................................................................................................................288
12.3.3. Pneumatic Sensors............................................................................................................................288
12.3.3.1. Sample Pressure Sensor ...........................................................................................................288
12.3.3.2. Sample Flow Sensor ..................................................................................................................288
12.4. Electronic Operation................................................................................................................................288
12.4.1. CPU....................................................................................................................................................291
12.4.1.1. Disk-On-Module (DOM)..............................................................................................................291
12.4.1.2. Flash Chip ..................................................................................................................................291
12.4.2. Optical Bench & GFC Wheel .............................................................................................................292
12.4.2.1. Temperature Control ..................................................................................................................292
12.4.2.2. IR Source....................................................................................................................................292
12.4.2.3. GFC Wheel.................................................................................................................................292
12.4.2.4. IR Photo-Detector.......................................................................................................................294
12.4.3. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................294
12.4.3.1. Signal Synchronization and Demodulation ................................................................................295
12.4.3.2. Sync/Demod Status LEDs..........................................................................................................296
12.4.3.3. Photo-Detector Temperature Control.........................................................................................297
12.4.3.4. Dark Calibration Switch..............................................................................................................297
12.4.3.5. Electric Test Switch....................................................................................................................297
12.4.4. Relay Board .......................................................................................................................................297
12.4.4.1. Heater Control ............................................................................................................................297
12.4.4.2. GFC Wheel Motor Control..........................................................................................................297
12.4.4.3. Zero/Span Valve Options ...........................................................................................................298
12.4.4.4. IR Source....................................................................................................................................298
12.4.4.5. Status LEDs................................................................................................................................299
12.4.4.6. I2C Watch Dog Circuitry.............................................................................................................299
12.4.5. MotherBoard ......................................................................................................................................300
12.4.5.1. A to D Conversion ......................................................................................................................300
12.4.5.2. Sensor Inputs .............................................................................................................................300
12.4.5.3. Thermistor Interface ...................................................................................................................301
12.4.5.4. Analog Outputs...........................................................................................................................301
12.4.5.5. Internal Digital I/O.......................................................................................................................301
12.4.5.6. External Digital I/O......................................................................................................................301
12.4.6. I2C Data Bus ......................................................................................................................................302
12.4.7. Power Supply/ Circuit Breaker...........................................................................................................302
12.4.8. Front Panel Touchscreen/Display Interface.......................................................................................304
12.4.8.1. LVDS Transmitter Board ............................................................................................................304
12.4.8.2. Front Panel Touchscreen/Display Interface PCA.......................................................................304
12.5. Software Operation..................................................................................................................................305
12.5.1. Adaptive Filter....................................................................................................................................305
12.5.2. Calibration - Slope and Offset............................................................................................................306
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12.5.3. Measurement Algorithm.....................................................................................................................306
12.5.4. Temperature and Pressure Compensation........................................................................................306
12.5.5. Internal Data Acquisition System (DAS)............................................................................................306
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
APPENDIX B - WIRING DIAGRAM
LIST OF FIGURES
Figure 3-1: Front Panel Layout.......................................................................................................................29
Figure 3-2: Display Screen and Touch Control..............................................................................................30
Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts .............................................................32
Figure 3-4: Rear Panel Layout .......................................................................................................................33
Figure 3-5: Internal Layout – T300.................................................................................................................35
Figure 3-6: Internal Layout – T300M..............................................................................................................36
Figure 3-7: Optical Bench Layout (shorter bench, T300M, shown) ...............................................................37
Figure 3-8: Analog In Connector ....................................................................................................................39
Figure 3-9: Analog Output Connector ............................................................................................................40
Figure 3-10: Current Loop Option Installed on Motherboard ...........................................................................41
Figure 3-11: Status Output Connector .............................................................................................................42
Figure 3-12: Control Input Connector...............................................................................................................44
Figure 3-13: Concentration Alarm Relay..........................................................................................................45
Figure 3-14: Rear Panel Connector Pin-Outs for RS-232 Mode......................................................................48
Figure 3-15: Default Pin Assignments for CPU COM Port connector (RS-232)..............................................49
Figure 3-16: Jumper and Cables for Multidrop Mode.......................................................................................51
Figure 3-17: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram.....................................................52
Figure 3-18: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas.....................................55
Figure 3-19: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator.............................55
Figure 3-20: T300/T300M Internal Gas Flow (Basic Configuration) ................................................................57
Figure 3-21: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves........................................58
Figure 3-22: Internal Pneumatic Flow OPT 50A – Zero/Span Valves..............................................................59
Figure 3-23: Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves .....60
Figure 3-24: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves.................................................61
Figure 3-25: Pneumatic Connections – Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E) .......62
Figure 3-26: Internal Pneumatic Flow OPT 50E – Zero Scrubber/Pressurized Span......................................63
Figure 3-27: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .......................................64
Figure 3-28: Internal Pneumatic Flow OPT 50H – Zero Scrubber/Ambient Span ...........................................66
Figure 3-29: Zero/Span Calibration Procedure ................................................................................................76
Figure 4-1: Front Panel Display......................................................................................................................79
Figure 4-2: Viewing T300/T300M Test Functions ..........................................................................................81
Figure 4-3: Viewing and Clearing T300/T300M WARNING Messages .........................................................84
Figure 5-1: Analog Output Connector Pin Out ...............................................................................................89
Figure 5-2: COMM– Machine ID ..................................................................................................................103
Figure 5-3: Accessing the Analog I/O Configuration Submenus..................................................................111
Figure 5-4: Setup for Checking / Calibrating DCV Analog Output Signal Levels.........................................118
Figure 5-5: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter..................120
Figure 5-6: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ................122
Figure 5-7. DIAG – Analog Inputs (Option) Configuration Menu .................................................................126
Figure 6-1: COM1[2] – Communication Modes Setup .................................................................................135
Figure 6-2: COMM Port Baud Rate..............................................................................................................136
Figure 6-3: COMM – COM1 Test Port..........................................................................................................137
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Figure 6-4: COMM – LAN / Internet Manual Configuration..........................................................................140
Figure 6-5 : COMM – LAN / Internet Automatic Configuration (DHCP)........................................................141
Figure 7-1: Default DAS Channel Setup ......................................................................................................161
Figure 7-2: APICOM Remote Control Program Interface.............................................................................176
Figure 7-3: APICOM User Interface for Configuring the DAS......................................................................177
Figure 7-4: DAS Configuration Through a Terminal Emulation Program.....................................................178
Figure 9-1: Pneumatic Connections – Basic Configuration – Using Bottled Span Gas...............................192
Figure 9-2: Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator.......................192
Figure 9-3: Pneumatic Connections – Option 50A: Ambient Zero/Ambient Span Calibration Valves.........197
Figure 9-4: Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves ...198
Figure 9-5: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .....................................198
Figure 9-6: Pneumatic Connections – Option 50E: Zero/Span Calibration Valves......................................199
Figure 9-7: O2Sensor Calibration Set Up....................................................................................................216
Figure 9-8: CO2Sensor Calibration Set Up..................................................................................................220
Figure 10-1: Sample Particulate Filter Assembly...........................................................................................232
Figure 11-1: Viewing and Clearing Warning Messages.................................................................................238
Figure 11-2: Example of Signal I/O Function .................................................................................................244
Figure 11-3: CPU Status Indicator .................................................................................................................245
Figure 11-4: Sync/Demod Board Status LED Locations................................................................................246
Figure 11-5: Relay Board Status LEDs..........................................................................................................247
Figure 11-6: T300/T300M – Basic Internal Gas Flow ....................................................................................250
Figure 11-7: Internal Pneumatic Flow OPT 50A – Zero/Span Valves (OPT 50A & 50B) ..............................250
Figure 11-8: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves...............................................251
Figure 11-9: Internal Pneumatic Flow OPT 50H – Zero/Span Valves with Internal Zero Air Scrubber .........251
Figure 11-10: Internal Pneumatic Flow OPT 50E – Zero/Span/Shutoff w/ Internal Zero Air Scrubber............252
Figure 11-11: T300/T300M – Internal Pneumatics with O2Sensor Option 65A ..............................................252
Figure 11-12: T300/T300M – Internal Pneumatics with CO2Sensor Option 67A............................................253
Figure 11-13: Location of Diagnostic LEDs onCO2Sensor PCA.....................................................................270
Figure 11-14: Critical Flow Restrictor Assembly/Disassembly.........................................................................271
Figure 11-15: Opening the GFC Wheel Housing .............................................................................................272
Figure 11-16: Removing the Opto-Pickup Assembly.......................................................................................273
Figure 11-17: Removing the GFC Wheel Housing...........................................................................................273
Figure 11-18: Removing the GFC Wheel.........................................................................................................274
Figure 11-19: Location of Sync/Demod Housing Mounting Screws.................................................................275
Figure 11-20: Location of Sync/Demod Gain Potentiometer............................................................................275
Figure 12-1: Measurement Fundamentals.....................................................................................................281
Figure 12-2: GFC Wheel ................................................................................................................................281
Figure 12-3: Measurement Fundamentals with GFC Wheel..........................................................................282
Figure 12-4: Effect of CO in the Sample on CO MEAS & CO REF ...............................................................283
Figure 12-5: Effects of Interfering Gas on CO MEAS & CO REF ..................................................................284
Figure 12-6: Chopped IR Signal.....................................................................................................................284
Figure 12-7: Internal Pneumatic Flow – Basic Configuration.........................................................................286
Figure 12-8: Flow Control Assembly & Critical Flow Orifice...........................................................................287
Figure 12-9: Electronic Block Diagram...........................................................................................................290
Figure 12-10. CPU Board.................................................................................................................................291
Figure 12-11: GFC Light Mask.........................................................................................................................293
Figure 12-12: Segment Sensor and M/R Sensor Output.................................................................................294
Figure 12-13: T300/T300M Sync/Demod Block Diagram ................................................................................295
Figure 12-14: Sample & Hold Timing...............................................................................................................296
Figure 12-15: Location of relay board Status LEDs .........................................................................................299
Figure 12-16: Power Distribution Block Diagram .............................................................................................303
Figure 12-17: Front Panel and Display Interface Block Diagram.....................................................................304
Figure 12-18: Basic Software Operation..........................................................................................................305
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LIST OF TABLES
Table 1-1: Analyzer Options..........................................................................................................................19
Table 2-1: T300/T300M Basic Unit Specifications........................................................................................23
Table 2-2: O2Sensor Option Specifications..................................................................................................24
Table 2-3: CO2Sensor Option Specifications...............................................................................................25
Table 3-1: Ventilation Clearance...................................................................................................................28
Table 3-2: Display Screen and Touch Control Description...........................................................................31
Table 3-3: Rear Panel Description................................................................................................................34
Table 3-4: Analog Input Pin Assignments.....................................................................................................39
Table 3-5: Analog Output Pin-Outs...............................................................................................................40
Table 3-6: Status Output Signals ..................................................................................................................43
Table 3-7: Control Input Signals....................................................................................................................44
Table 3-8: Zero/Span Valve Operating States for Option 50A......................................................................59
Table 3-9: Zero/Span Valve Operating States for Option 50B......................................................................61
Table 3-10: Zero/Span Valve Operating States for Option 51E......................................................................63
Table 3-11: Zero/Span Valve Operating States for Option 50H .....................................................................66
Table 3-12: NIST-SRM's Available for Traceability of CO Calibration Gases..................................................67
Table 3-13: Possible Warning Messages at Start-Up.....................................................................................69
Table 3-14: Possible Startup Warning Messages – T300 Analyzers with Options.........................................70
Table 4-1: Analyzer Operating Modes ..........................................................................................................80
Table 4-2: Test Functions Defined................................................................................................................82
Table 4-3: List of Warning Messages............................................................................................................83
Table 4-4: Primary Setup Mode Features and Functions.............................................................................85
Table 4-5: Secondary Setup Mode (SETUP>MORE) Features and Functions............................................86
Table 5-1: T300 Family Physical Range by Model .......................................................................................90
Table 5-2: Password Levels..........................................................................................................................99
Table 5-3: Variable Names (VARS)............................................................................................................104
Table 5-4: Diagnostic Mode (DIAG) Functions ...........................................................................................106
Table 5-5: DIAG - Analog I/O Functions .....................................................................................................110
Table 5-6: Analog Output Voltage Ranges .................................................................................................112
Table 5-7: Voltage Tolerances for the TEST CHANNEL Calibration..........................................................118
Table 5-8: Current Loop Output Check.......................................................................................................122
Table 5-9: Test Channels Functions available on the T300/T300M’s Analog Output ................................128
Table 5-10: CO Concentration Alarm Default Settings .................................................................................130
Table 6-1: COMM Port Communication Modes..........................................................................................134
Table 6-2: Ethernet Status Indicators..........................................................................................................138
Table 6-3: LAN/Internet Default Configuration Properties ..........................................................................139
Table 6-4: RS-232 Communication Parameters for Hessen Protocol........................................................147
Table 6-5: Teledyne API’s Hessen Protocol Response Modes..................................................................150
Table 6-6: Default Hessen Status Flag Assignments .................................................................................154
Table 7-1: Front Panel LED Status Indicators for DAS...............................................................................157
Table 7-2: DAS Data Channel Properties...................................................................................................159
Table 7-3: DAS Data Parameter Functions ................................................................................................166
Table 8-1: Interactive Mode Software Commands......................................................................................182
Table 8-2: Teledyne API’s Serial I/O Command Types..............................................................................183
Table 9-1: NIST-SRMs Available for Traceability of CO Calibration Gases ................................................190
Table 9-2: AUTOCAL Modes ......................................................................................................................204
Table 9-3: AutoCal Attribute Setup Parameters..........................................................................................205
Table 9-4: Example AutoCal Sequence......................................................................................................206
Table 9-5: Calibration Data Quality Evaluation...........................................................................................211
Table 10-1: T300/T300M Maintenance Schedule.........................................................................................229
Table 10-2: T300/T300M Test Function Record...........................................................................................230
Table 10-3: Predictive uses for Test Functions.............................................................................................231
Table 11-1: Warning Messages - Indicated Failures ....................................................................................239
Table 11-2: Test Functions - Indicated Failures............................................................................................241
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Table 11-3: Sync/Demod Board Status Failure Indications..........................................................................246
Table 11-4: I2C Status LED Failure Indications.............................................................................................247
Table 11-5: Relay Board Status LED Failure Indications..............................................................................248
Table 11-6: DC Power Test Point and Wiring Color Codes..........................................................................261
Table 11-7: DC Power Supply Acceptable Levels ........................................................................................261
Table 11-8: Relay Board Control Devices.....................................................................................................262
Table 11-9: Opto Pickup Board Nominal Output Frequencies......................................................................264
Table 11-10: Analog Output Test Function - Nominal Values Voltage Outputs .............................................266
Table 11-11: Analog Output Test Function - Nominal Values Voltage Outputs .............................................267
Table 11-12: Status Outputs Check................................................................................................................268
Table 12-1: Absorption Path Lengths for T300 and T300M..........................................................................280
Table 12-2: Sync DEMOD Sample and Hold Circuits...................................................................................296
Table 12-3: Sync/Demod Status LED Activity...............................................................................................296
Table 12-4: Relay Board Status LEDs..........................................................................................................299
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1. INTRODUCTION, FEATURES AND OPTIONS
This section provides an overview of Teledyne API’s Model T300 or T300M Analyzer,
its features and its options.
1.1. T300 FAMILY OVERVIEW
The family includes the T300 and the T300M Gas Filter Correlation Carbon Monoxide
Analyzer. The T300 family of analyzers is a microprocessor-controlled analyzer that
determines the concentration of carbon monoxide (CO) in a sample gas drawn through
the instrument. It uses a method based on the Beer-Lambert law, an empirical
relationship that relates the absorption of light to the properties of the material through
which the light is traveling over a defined distance. In this case the light is infrared
radiation (IR) traveling through a sample chamber filled with gas bearing a varying
concentration of CO.
The T300/T300M uses Gas Filter Correlation (GFC) to overcome the interfering effects
of various other gases (such as water vapor) that also absorb IR. The analyzer passes the
IR beam through a spinning wheel made up of two separate chambers: one containing a
high concentration of CO known as the reference, and the other containing a neutral gas
known as the measure. The concentration of CO in the sample chamber is computed by
taking the ratio of the instantaneous measure and reference values and then
compensating the ratio for sample temperature and pressure.
The T300/T300M Analyzer’s multi-tasking software gives the ability to track and report
a large number of operational parameters in real time. These readings are compared to
diagnostic limits kept in the analyzers memory and should any fall outside of those
limits the analyzer issues automatic warnings.
Built-in data acquisition capability, using the analyzer's internal memory, allows the
logging of multiple parameters including averaged or instantaneous concentration
values, calibration data, and operating parameters such as pressure and flow rate. Stored
data are easily retrieved through the serial port or Ethernet port via our APICOM
software or from the front panel, allowing operators to perform predictive diagnostics
and enhanced data analysis by tracking parameter trends. Multiple averaging periods of
one minute to 365 days are available for over a period of one year.
06864D DCN7562
Introduction, Features and Options Teledyne API – Model T300/T300M CO Analyzer
18
1.2. FEATURES
Some of the common features of your T300 family of analyzers include:
•LCD color graphics with touch screen interface
•Microprocessor controlled for versatility
•Multi-tasking software allows viewing of test variables during operation
•Continuous self checking with alarms
•Bi-directional USB, RS-232, and 10/100Base-T Ethernet ports for remote operation
(optional RS-485)
•Front panel USB ports for peripheral devices and software downloads
•Digital status outputs indicate instrument operating condition
•Adaptive signal filtering optimizes response time
•Gas Filter Correlation (GFC) Wheel for CO specific measurement
•GFC Wheel guaranteed against leaks for 5 years
•Temperature and pressure compensation
•Comprehensive internal data logging with programmable averaging periods
•Remote operation when used with Teledyne API’s APICOM software
T300 FEATURES:
•Ranges, 0-1 ppm to 0-1000 ppm, user selectable
•14 meter path length for sensitivity
T300MFEATURES:
•Ranges, 0-1 ppm; Max: 0-5000 ppm, user selectable
•2.5 meter path length for dynamic range
1.3. T300/T300M DOCUMENTATION
In addition to this operation manual (part number 06807), other manuals are available
for download from Teledyne API’s website at http://www.teledyne-api.com/manuals/, to
support the operation of this instrument:
•APICOM software manual, part number 07463
•Hessen Protocol Manual, part number 04585
•Fundamentals of ESD Manual, part number 04786
06864D DCN7562
Other manuals for T300
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