Teledyne T802 User manual

OPERATION MANUAL
MODEL T802
PARAMAGNETIC OXYGEN ANALYZER
© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone: [phone]
Phone: [phone]
Fax: [phone]
Email: [email protected]
Website: http://www.teledyne-api.com/
Copyright 2010-2013 07275B DCN6418
Teledyne Advanced Pollution Instrumentation 14 January 2013

i
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)
Teledyne Advanced Pollution Instrumentation, Inc. (TAPI) is a worldwide
market leader in the design and manufacture of precision analytical
instrumentation used for air quality monitoring, continuous emissions monitoring,
and specialty process monitoring applications. Founded in San Diego, California,
in 1988, TAPI introduced a complete line of Air Quality Monitoring (AQM)
instrumentation, which comply with the United States Environmental Protection
Administration (EPA) and international requirements for the measurement of
criteria pollutants, including CO, SO2, NOXand Ozone.
Since 1988 TAPI has combined state-of-the-art technology, proven measuring
principles, stringent quality assurance systems and world class after-sales support
to deliver the best products and customer satisfaction in the business.
For further information on our company, our complete range of products, and the
applications that they serve, please visit www.teledyne-api.com or contact api-
[email protected].
NOTICE OF COPYRIGHT
© 2010-2013 Teledyne Advanced Pollution Instrumentation. 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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SAFETY MESSAGES
Important safety messages are provided throughout this manual for the purpose
of avoiding personal injury or instrument damage. Please read these messages
carefully. Each safety message is associated with a safety alert symbol, and are
placed throughout this manual; the safety symbols are also located inside the
instrument. It is imperative that you pay close attention to these messages, the
descriptions of which are as follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message for
specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or the
instrument.
Technician Symbol: All operations marked with this symbol are to be
performed by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central
safety grounding point for the instrument.
CAUTION
This instrument should only be used for the purpose and in the manner
described in this manual. If you use this instrument in a manner other than
that for which it was intended, unpredictable behavior could ensue with
possible hazardous consequences.
NEVER use any gas analyzer to sample combustible gas(es)!
Note For Technical Assistance regarding use and maintenance of this or any other
Teledyne API product, contact Teledyne API’s Technical Support Department:
Telephone: [phone] Email: [email protected]
or access the service options on our website at http://www.teledyne-api.com/
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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 (02024F)
Teledyne Advanced Pollution Instrumentation (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.
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 “Packing
Components for Return to Teledyne API’s Technical Support” in the Primer on Electro-Static
Discharge section of this manual, and for RMA procedures please refer to our Website at
http://www.teledyne-api.com under Customer Support > Return Authorization.
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ABOUT THIS MANUAL
This operation manual, PN 07275, is comprised of multiple documents in
PDF format, as listed below.
Part No. Rev Name/Description
07275 B T802 Operation manual
06530 C Menu Trees and Software Documentation (inserted as Appendix A in this manual)
07269 A Spare Parts List (located in Appendix B of this manual)
06535 A Expendables Kit (located in Appendix B of this manual)
06532 C Repair Request Form (inserted as Appendix C in this manual)
Appendix D Documents:
0738001 A Interconnect List
07380 A Interconnect Diagram
05803 B SCH, PCA 05802, MOTHERBOARD, GEN-5
06698 D SCH, PCA 06697, INTRFC, LCD TCH SCRN
06882 B SCH, LVDS TRANSMITTER BOARD
06731 A SCH, AUXILLIARY-I/O BOARD
Note We recommend that this manual be read in its entirety before any attempt is
made to operate the instrument.
ORGANIZATION
This manual is divided among three main parts and a collection of appendices at
the end:
Part I contains introductory information that includes an overview of the
analyzer, specifications, descriptions of the available options, installation and
connection instructions, and the initial calibration and functional checks.
Part II comprises the operating instructions, which include setup and calibration,
as well as remote operation, and ends with the specifics of calibrating for use in
monitoring within EPA protocol.
Part III provides detailed technical information starting with maintenance,
troubleshooting and service, frequently asked questions, principles of operation, a
primer on electrostatic discharge, and a glossary.
The appendices at the end of the manual provide support information such as
version-specific software documentation, lists of spare parts* and recommended
stocking levels, and schematics.
*Part numbers do not reflect real-time updates – contact Sales or Technical
Support).
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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.
REVISION HISTORY
T802 Operation and Maintenance Manual, PN07275
Date Rev DCN Description
2013 January 14 B 6418 Administrative Updates and specs updates
2011 February 18 A 6005 Initial Release
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TABLE OF CONTENTS
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI).......................................................................... i
Safety Messages ...................................................................................................................................................iii
Warranty ................................................................................................................................................................ v
About This Manual................................................................................................................................................vii
Table of Contents ................................................................................................................................................. ix
1. INTRODUCTION, FEATURES AND OPTIONS..................................................................17
1.1. T802 Overview.............................................................................................................................................. 17
1.2. Features........................................................................................................................................................ 17
1.3. Options ......................................................................................................................................................... 18
2. SPECIFICATIONS, APPROVALS & COMPLIANCE................................................................21
2.1. Specifications................................................................................................................................................ 21
2.2. Approvals and Certifications......................................................................................................................... 22
2.2.1. Safety .................................................................................................................................................... 22
2.2.2. EMC....................................................................................................................................................... 22
2.2.3. Other Type Certifications....................................................................................................................... 22
3. GETTING STARTED...........................................................................................................23
3.1. Unpacking the T802 Analyzer ...................................................................................................................... 23
3.1.1. Ventilation Clearance ............................................................................................................................ 25
3.2. Instrument Layout......................................................................................................................................... 25
3.2.1. Front Panel ............................................................................................................................................ 25
3.3. Connections and Setup ................................................................................................................................ 32
3.3.1. Electrical Connections ........................................................................................................................... 32
3.3.2. Pneumatic Connections ........................................................................................................................ 46
3.4. Startup, Functional Checks, and Initial Calibration....................................................................................... 52
3.4.1. Startup ................................................................................................................................................... 52
3.4.2. Functional Checks ................................................................................................................................. 54
3.4.3. Initial Calibration .................................................................................................................................... 55
4. BASIC OPERATION...........................................................................................................63
4.1. Overview of Operating Modes ...................................................................................................................... 63
4.2. Sample Mode................................................................................................................................................ 65
4.3. Calibration Mode........................................................................................................................................... 66
4.4. Setup Mode .................................................................................................................................................. 67
4.4.1. Primary Setup Menu.............................................................................................................................. 67
4.4.2. Secondary Setup Menu (Setup>More).................................................................................................. 68
5. SETUP MENU 69
5.1. SETUP CFG: Configuration Information.................................................................................................. 69
5.2. SETUP ACAL: [NOT USED] .................................................................................................................... 69
5.3. SETUP DAS: Internal Data Acquisition System ...................................................................................... 69
5.4. SETUP RNGE: Analog Output Reporting Range Configuration.............................................................. 70
5.4.1. Physical Range versus Analog Output Reporting Ranges.................................................................... 70
5.4.2. Analog Output Ranges for O2Concentration ........................................................................................71
5.4.3. Reporting Range Modes ....................................................................................................................... 72
5.4.4. SETUP RNGE DIL: Using the Optional Dilution Ratio Feature..................................................... 77
5.5. SETUP PASS: Password Feature ........................................................................................................... 78
5.6. SETUP CLK: Setting the T802 Analyzer’s Internal Clock........................................................................ 81
5.6.1. Setting the Internal Clock’s Time and Day ............................................................................................ 81
5.6.2. Adjusting the Internal Clock’s Speed..................................................................................................... 82
5.7. SETUP MORECOMM: Communication Ports..................................................................................... 83
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5.7.1. ID (Machine Identification)..................................................................................................................... 83
5.7.2. INET (Ethernet) ..................................................................................................................................... 84
5.7.3. COM1[COM2] (Mode, Baude Rate and Test Port) ............................................................................... 85
5.8. SETUP MORE VARS: Internal Variables (VARS)............................................................................... 85
5.9. SETUP MORE DIAG: Diagnostics Functions.................................................................................... 88
5.9.1. Signal I/O............................................................................................................................................... 90
5.9.2. Analog Output........................................................................................................................................ 91
5.9.3. Analog I/O Configuration ....................................................................................................................... 91
5.9.4. Turning an Analog Output Over-Range Feature ON/OFF .................................................................. 103
5.9.5. Adding a Recorder Offset to an Analog Output................................................................................... 104
5.9.6. Selecting a Test Channel Function for Output A4............................................................................... 105
5.9.7. AIN Calibration ....................................................................................................................................107
5.9.8. Analog Inputs (XIN1…XIN8) Option Configuration ............................................................................. 108
5.10. SETUP MORE ALRM: Using the Gas Concentration Alarms (Option 61)....................................... 109
5.10.1. Setting the T802 Option 61 Concentration Alarm Limits...................................................................110
6. COMMUNICATIONS SETUP AND OPERATION.............................................................113
6.1. Data Terminal/Communication Equipment (DTE DCE) ................................................................................... 113
6.2. Communication Modes, Baud Rate and Port Testing ................................................................................ 113
6.2.1. COM Port Communication Modes....................................................................................................... 114
6.2.2. COM Port Baud Rate ..........................................................................................................................116
6.2.3. COM Port Testing................................................................................................................................117
6.3. Remote Access via the Ethernet ................................................................................................................ 118
6.3.1. Configuring the Ethernet Interface using DHCP ................................................................................. 118
6.3.2. Manually Configuring the Network IP Addresses................................................................................ 121
6.4. USB Port for Remote Access .....................................................................................................................124
6.5. Communications Protocols.........................................................................................................................126
6.5.1. MODBUS Setup .................................................................................................................................. 126
6.5.2. Hessen ................................................................................................................................................ 128
7. DATA ACQUISITION SYSTEM (DAS) & APICOM.............................................................138
7.1. DAS Structure............................................................................................................................................. 139
7.1.1. DAS Channels .....................................................................................................................................139
7.1.2. Default DAS Channels.........................................................................................................................140
7.1.3. SETUP DAS VIEW: Viewing DAS Channels and Individual Records......................................... 143
7.1.4. SETUP DAS EDIT: Accessing the DAS Edit Mode .................................................................... 144
7.2. Remote DAS Configuration ........................................................................................................................157
7.2.1. DAS Configuration via APICOM.......................................................................................................... 157
7.2.2. DAS Configuration via Terminal Emulation Programs ........................................................................159
8. REMOTE OPERATION.....................................................................................................160
8.1. Computer Mode..........................................................................................................................................160
8.1.1. Remote Control via APICOM ..............................................................................................................160
8.2. Interactive Mode ......................................................................................................................................... 161
8.2.1. Remote Control via a Terminal Emulation Program............................................................................ 161
8.3. Remote Access by Modem......................................................................................................................... 164
8.4. COM Port Password Security.....................................................................................................................166
9. CALIBRATION PROCEDURES .......................................................................................169
9.1. Before Calibration.......................................................................................................................................170
9.1.1. Required Equipment, Supplies, and Expendables.............................................................................. 170
9.1.2. Calibration Gases................................................................................................................................170
9.1.3. Data Recording Devices......................................................................................................................171
9.2. Manual Calibration Checks and Calibration ...............................................................................................172
9.2.1. Setup for Basic Calibration Checks and Calibration ........................................................................... 172
9.2.2. Performing a Basic Manual Calibration Check.................................................................................... 173
9.2.3. Performing a Basic Manual Calibration............................................................................................... 174
9.3. Assessing Calibration Quality.....................................................................................................................176
9.4. Calibration of the T802’s Electronic Subsystems ....................................................................................... 176
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9.4.1. Pressure Calibration............................................................................................................................176
9.4.2. Flow Calibration................................................................................................................................... 178
9.5. Calibration of the Optional CO2Sensor......................................................................................................179
9.5.1. CO2Calibration Setup .........................................................................................................................179
9.5.2. Set CO2Span Gas Concentration....................................................................................................... 179
9.5.3. Activate CO2Sensor Stability Function ...............................................................................................180
9.5.4. CO2Zero/Span Calibration:................................................................................................................. 181
10. MAINTENANCE SCHEDULE & PROCEDURES...........................................................185
10.1. Maintenance Schedule .............................................................................................................................185
10.2. Predictive Diagnostics ..............................................................................................................................189
10.3. Maintenance Procedures..........................................................................................................................189
10.3.1. Replacing the Sample Particulate Filter ............................................................................................189
10.3.2. Rebuilding the Sample Pump............................................................................................................190
10.3.3. Performing Leak Checks ...................................................................................................................191
10.3.4. Performing a Sample Flow Check..................................................................................................... 192
10.3.5. Cleaning the Optical Bench...............................................................................................................193
10.3.6. Cleaning Exterior Surfaces of the T802 ............................................................................................ 193
11. TROUBLESHOOTING AND SERVICE ..........................................................................195
11.1. General Troubleshooting ..........................................................................................................................195
11.1.1. Fault Diagnosis with WARNING Messages ...................................................................................... 196
11.1.2. Fault Diagnosis with TEST Functions ............................................................................................... 199
11.1.3. DIAG SIGNAL I/O: Using the Diagnostic Signal I/O Function ..................................................... 200
11.2. Using the Internal Electronic Status LEDs ...............................................................................................202
11.2.1. CPU Status Indicator.........................................................................................................................202
11.2.2. Relay PCA Status Indicators .............................................................................................................202
11.3. Gas Flow Problems ..................................................................................................................................203
11.3.1. T802 Internal Gas Flow Diagrams..................................................................................................... 204
11.3.2. Typical Sample Gas Flow Problems .................................................................................................205
11.4. Calibration Problems ................................................................................................................................207
11.4.1. Miscalibrated .....................................................................................................................................207
11.4.2. Non-Repeatable Zero and Span ....................................................................................................... 207
11.4.3. Inability to Span – No SPAN Button .................................................................................................. 208
11.4.4. Inability to Zero – No ZERO Button................................................................................................... 208
11.5. Other Performance Problems...................................................................................................................208
11.5.1. Temperature Problems...................................................................................................................... 208
11.6. Subsystem Checkout................................................................................................................................209
11.6.1. AC Mains Configuration ....................................................................................................................209
11.6.2. DC Power Supply ..............................................................................................................................209
11.6.3. I2C Bus...............................................................................................................................................210
11.6.4. Touchscreen Interface.......................................................................................................................210
11.6.5. LCD Display Module.......................................................................................................................... 210
11.6.6. Relay Board.......................................................................................................................................211
11.6.7. Sensor Assembly............................................................................................................................... 211
11.6.8. Pressure/Flow Sensor Assembly ......................................................................................................211
11.6.9. Motherboard ......................................................................................................................................212
11.6.10. CPU .................................................................................................................................................213
11.6.11. RS-232 Communications ................................................................................................................214
11.6.12. Optional CO2Sensor ....................................................................................................................... 215
11.7. Repair Procedures....................................................................................................................................215
11.7.1. Repairing Sample Flow Control Assembly........................................................................................ 215
11.7.2. Disk-On-Module Replacement Procedure ........................................................................................ 216
11.8. FAQ’s........................................................................................................................................................217
11.9. Technical Assistance................................................................................................................................218
12. PRINCIPLES OF OPERATION ......................................................................................219
12.1. Paramagnetic Oxygen Measurement....................................................................................................... 219
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12.1.1. Magnetic Properties of O2Gas..........................................................................................................219
12.1.2. Principle of Measurement..................................................................................................................219
12.2. NDIR Measurement of CO2......................................................................................................................221
12.2.1. Operation within the T802 Analyzer ..................................................................................................222
12.3. Pneumatic Operation................................................................................................................................ 222
12.3.1. Pneumatic Operation of the CO2Sensor ..........................................................................................223
12.4. Flow Rate Control.....................................................................................................................................224
12.4.1. Critical Flow Orifice............................................................................................................................224
12.4.2. Particulate Filter.................................................................................................................................225
12.4.3. Pneumatic Sensors ........................................................................................................................... 225
12.5. Electronic Operation .................................................................................................................................226
12.5.1. Overview............................................................................................................................................226
12.5.2. Electronic Operation of the CO2Sensor............................................................................................ 227
12.5.3. Central Processing Unit (CPU)..........................................................................................................228
12.5.4. Relay Board.......................................................................................................................................229
12.5.5. Heater Control ...................................................................................................................................232
12.5.6. Motherboard ......................................................................................................................................232
12.5.7. Front Panel Touch Screen/Display Interface .................................................................................... 235
12.5.8. Software Operation............................................................................................................................237
12.5.9. Adaptive Filter....................................................................................................................................237
12.5.10. Calibration - Slope and Offset ......................................................................................................... 238
12.5.11. Temperature and Pressure Compensation ..................................................................................... 238
12.5.12. Internal Data Acquisition System (DAS) ......................................................................................... 238
13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................239
13.1. How Static Charges are Created..............................................................................................................239
13.2. How Electro-Static Charges Cause Damage ........................................................................................... 240
13.3. Common Myths About ESD Damage ....................................................................................................... 241
13.4. Basic Principles of Static Control..............................................................................................................242
13.4.1. General Rules....................................................................................................................................242
13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance.................................................. 244
LIST OF FIGURES
Figure 3-1: Front Panel Layout ......................................................................................................... 25
Figure 3-2. Display Screen and Touch Control................................................................................. 26
Figure 3-3.: Display/Touch Control Screen Mapped to Menu Charts................................................ 28
Figure 3-4: Rear Panel Layout.......................................................................................................... 29
Figure 3-5: Internal Layout................................................................................................................ 31
Figure 3-6: Analog In Connector....................................................................................................... 33
Figure 3-7: Analog Output Connector............................................................................................... 34
Figure 3-8: Current Loop Option Installed ........................................................................................ 35
Figure 3-9: Status Output Connector................................................................................................ 37
Figure 3-10: Control Input Connector ................................................................................................. 38
Figure 3-11: Concentration Alarm Relay ............................................................................................ 39
Figure 3-12: Default Pin Assignments, Rear Panel COM Port Connectors ....................................... 41
Figure 3-13. CPU Connector Pin-Outs for RS-232 Mode................................................................... 42
Figure 3-14: Jumper and Cables for Multidrop Mode ......................................................................... 44
Figure 3-15: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram........................................ 45
Figure 3-16: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ....................... 48
Figure 3-17: T802 Internal Gas Flow (Basic Configuration) ............................................................... 50
Figure 3-18: T802 – Internal Gas Flow with CO2Sensor Option........................................................ 51
Figure 3-19: Viewing and Clearing T802 WARNING Messages ........................................................ 53
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Figure 4-1: Front Panel Touchscreen and Display ........................................................................... 64
Figure 4-2: Viewing Test Functions .................................................................................................. 65
Figure 5-1: Analog Output Connector Pin Out.................................................................................. 71
Figure 5-2: Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 98
Figure 5-3: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter .... 100
Figure 5-4: Alternative Setup Using 250ΩResistor for Checking Current Output Signal Levels... 102
Figure 7-1: Default DAS Channel Setup......................................................................................... 142
Figure 7-2: APICOM Remote Control Program Interface ............................................................... 157
Figure 7-3: APICOM User Interface for Configuring the DAS ........................................................ 158
Figure 7-4: DAS Configuration through a Terminal Emulation Program ........................................ 159
Figure 9-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................... 172
Figure 9-2: CO2Sensor Calibration Set Up .................................................................................... 179
Figure 10-1: Sample Particulate Filter Assembly.............................................................................. 190
Figure 11-1: Viewing and Clearing Warning Messages ................................................................... 198
Figure 11-2: Example of Signal I/O Function.................................................................................... 201
Figure 11-3: CPU Status Indicator.................................................................................................... 202
Figure 11-4: Relay PCA Status LEDS Used for Troubleshooting..................................................... 203
Figure 11-5: T802– Basic Internal Gas Flow .................................................................................... 204
Figure 11-6: T802 – Internal Pneumatics with CO2Sensor Option 67 ............................................. 205
Figure 11-7: Location of Diagnostic LEDs on CO2Sensor PCA....................................................... 215
Figure 11-8: Critical Flow Restrictor Assembly / Disassembly ......................................................... 216
Figure 12-1: Paramagnetic O2Sensor Design ................................................................................. 220
Figure 12-2: Paramagnetic O2Sensor Block Diagram ..................................................................... 220
Figure 12-3: CO2Sensor Theory of Operation ................................................................................. 221
Figure 12-4: T802 – Internal Pneumatic Flow – Basic Configuration ............................................... 223
Figure 12-5: T802 – Internal Pneumatic Flow with CO2Sensor Option ........................................... 224
Figure 12-6: Flow Control Assembly & Critical Flow Orifice ............................................................. 225
Figure 12-7: T802 Electronic Block Diagram .................................................................................... 227
Figure 12-8: CO2Sensor Option PCA Layout and Electronic Connections ..................................... 228
Figure 12-9. CPU Card ..................................................................................................................... 229
Figure 12-10: Relay PCA Layout (PN 04135)..................................................................................... 230
Figure 12-11: Relay PCA with AC Relay Retainer in Place................................................................ 231
Figure 12-12: Status LED Locations – Relay PCA ............................................................................. 232
Figure 12-13: Power Distribution Block Diagram................................................................................ 235
Figure 12-14: Front Panel and Display Interface Block Diagram ....................................................... 236
Figure 12-15: Basic Software Operation............................................................................................. 237
Figure 13-1: Triboelectric Charging .................................................................................................. 239
Figure 13-2: Basic Anti-ESD Workbench.......................................................................................... 242
LIST OF TABLES
Table 1-1. Analyzer Options ............................................................................................................ 18
Table 2-1: T802 Specifications ........................................................................................................ 21
Table 3-1: Ventilation Clearance ..................................................................................................... 25
Table 3-2. Display Screen and Touch Control Description ............................................................. 27
Table 3-3. Rear Panel Component Descriptions............................................................................. 30
Table 3-4. Analog Input Pin Assignments ....................................................................................... 33
Table 3-5: Analog Output Pin-Outs ................................................................................................. 34
Table 3-6: Status Output Signals..................................................................................................... 37
Table 3-7: Control Input Signals ...................................................................................................... 38
Table 3-8: NISTSRMs Available for Traceability of O2Calibration Gases ....................................... 47
Table 3-9: Front Panel Display during System Warm-Up ............................................................... 52
Table 4-1: Analyzer Operating Modes............................................................................................. 64
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Table 4-2: Test Functions Defined .................................................................................................. 66
Table 6-4: Primary Setup Mode Features and Functions................................................................ 67
Table 6-5: Secondary Setup Mode Features and Functions........................................................... 68
Table 5-2: Variable Names (VARS)................................................................................................. 86
Table 5-3: Diagnostic Mode (DIAG) Functions................................................................................ 88
Table 5-4: DIAG - Analog I/O Functions.......................................................................................... 91
Table 5-5: Analog Output Voltage Range Min/Max......................................................................... 93
Table 5-6: Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 98
Table 5-7: Current Loop Output Check ......................................................................................... 102
Table 5-8: Test Channels Functions available on the T802’s Analog Output ............................... 105
Table 5-9: O2 Concentration Alarm Default Settings ..................................................................... 109
Table 6-1: COM Port Communication Modes................................................................................ 114
Table 6-2: Ethernet Status Indicators ............................................................................................ 118
Table 6-3: LAN/Internet Configuration Properties ......................................................................... 119
Table 6-4: RS-232 Communication Parameters for Hessen Protocol........................................... 128
Table 6-5: Teledyne API Hessen Protocol Response Modes ....................................................... 131
Table 6-6: Default Hessen Status Flag Assignments.................................................................... 135
Table 7-1: Front Panel LED Status Indicators for DAS ................................................................. 138
Table 7-2: DAS Data Channel Properties...................................................................................... 140
Table 7-3: DAS Data Parameter Functions ................................................................................... 147
Table 8-2: Teledyne API Serial I/O Command Types ................................................................... 162
Table 9-1: NISTSRM's Available for Traceability of O2Calibration Gases..................................... 171
Table 9-2: Calibration Data Quality Evaluation.............................................................................. 176
Table 10-1. T802 Maintenance Schedule........................................................................................ 187
Table 10-2: T802 Test Function Record.......................................................................................... 188
Table 10-3: Predictive uses for Test Functions ............................................................................... 189
Table 11-1: Warning Messages - Indicated Failures....................................................................... 198
Table 11-2: Test Functions - Indicated Failures .............................................................................. 200
Table 11-3: Relay PCA Watchdog LED Failure Indications ............................................................ 202
Table 11-4: Relay PCA Status LED Failure Indications .................................................................. 203
Table 11-5: DC Power Test Point and Wiring Color Codes ............................................................ 209
Table 11-6: DC Power Supply Acceptable Levels........................................................................... 210
Table 11-7: Analog Output Test Function - Nominal Values Current Outputs ................................ 212
Table 11-8: Status Outputs Check .................................................................................................. 213
Table 12-1: Relay PCA Status LEDs............................................................................................... 231
Table 13-1: Static Generation Voltages for Typical Activities.......................................................... 240
Table 13-2: Sensitivity of Electronic Devices to Damage by ESD................................................... 240
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
A-1 - T802 Software Menu Trees
A-2 - T802 Setup Variables for Serial I/O
A-3 - T802 Warnings and Test Functions
A-4 - T802 Signal I/O Definitions
A-5 - T802 DAS Functions
A-6 - T802 Terminal Command Designators
A-7 - T802 MODBUS®Register Map
APPENDIX B - T802 SPARE PARTS LIST
APPENDIX C – T802 REPAIR QUESTIONNAIRE
APPENDIX D – T802 ELECTRONIC SCHEMATICS
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PART I
–
GENERAL INFORMATION AND SETUP
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Section 1 General Information Teledyne API T802 Paramagnetic O2Analyzer Operation Manual
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1. INTRODUCTION, FEATURES AND OPTIONS
1.1. T802 OVERVIEW
The Model T802 (also referred to as T802) Paramagnetic Oxygen Analyzer is a
microprocessor-controlled analyzer that determines the concentration of
molecular oxygen (O2) in a sample gas drawn through the instrument. It uses a
paramagnetic sensor that relies on the relatively high reactivity of O2molecules
to magnetic fields to generate a current that is proportional to the amount of O2
present in the sensor chamber.
The T802 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 analyzer’s memory where, 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 optional
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.
1.2. FEATURES
Some exceptional features of your T802 Paramagnetic Oxygen Analyzer are:
Non-depleting, paramagnetic sensor for O2specific measurement:
Virtually no cross-sensitivities
Rapid response times
No consumable parts
Consistent performance over time
No susceptibility to CO2 poisoning (unlike electromechanical O2 sensors)
Microprocessor controlled for versatility
LCD Graphical User Interface with capacitive touch screen
Multi-tasking software for viewing of test variables during operation
Continuous self checking with alarms
Bi-directional USB, RS-232, and 10BaseT/100BaseT Ethernet ports for
remote operation (optional RS-485)
Front panel USB ports for peripheral devices
Digital status outputs to indicate instrument operating condition
Adaptive signal filtering to optimize response time
Internal data logging with 1 min to 365-day multiple average
Remote operation when used with Teledyne API’s APICOM software
Temperature and Pressure Compensation
Ranges, 0-1% to 0-100.0%, user adjustable
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Introduction, Features and Options Teledyne API T802 Paramagnetic O2Analyzer Operation Manual
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HAZARD
Strong Oxidizer
OXYGEN IS A STRONG OXIDIZER.
This is a general purpose instrument designed for usage in nonhazardous areas. Ensure
that all safety precautions related combustible gases are followed.
Before working with the casing open, be sure to turn off power to the analyzer, and
perform air or N2gas purging of not only the analyzer inside, but also the sample gas line.
In addition, carefully prevent oil and grease from adhering to any tubing. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.
1.3. OPTIONS
Table 1-1 presents the options available with the T802 analyzer. For assistance
with ordering, please contact the Sales department of Teledyne API at:
PHONE (toll free,
North America)
800-324-5190
FAX: [phone]
PHONE (Direct): 858-657-9800
E-MAIL: [email protected]
WEB SITE www.teledyne-api.com
Table 1-1. Analyzer Options
Option Option
Number Description/Notes Reference
Pumps Pumps meet all typical AC power supply standards while exhibiting same pneumatic
performance.
10A External Pump 100V - 120V @ 60 Hz N/A
10B External Pump 220V - 240V @ 50 Hz N/A
10C External Pump 220V - 240V @ 60 Hz N/A
10D External Pump 100V – 120V @ 50 Hz N/A
10E External Pump 100V @ 60 Hz N/A
14 Internal Pump N/A
13 High Voltage Internal Pump 240V @ 50Hz N/A
Rack Mount
Kits Options for mounting the analyzer in standard 19” racks
20A Rack mount brackets with 26 in. chassis slides N/A
20B Rack mount brackets with 24 in. chassis slides N/A
21 Rack mount brackets only (compatible with carrying strap, Option 29) N/A
23 Rack mount for external pump pack (no slides) N/A
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