Teledyne T102 User manual

MANUAL ADDENDUM
MODEL T102
TOTAL REDUCED SULFUR ANALYZER
with
MODEL 501 TRS
THERMAL CONVERTER
(to be used in conjunction with T101 Operation Manual, PN 07266)
© TELEDYNE API (TAPI)
9970 Carroll Canyon Road
SAN DIEGO, CA 92131-1106
USA
Toll-free Phone:
800-324-5190
Phone:
[phone]
Fax:
[phone]
Email:
[e-mail]
Website:
http://www.teledyne-api.com/
Copyright 2011-2012
07267B DCN6485
Teledyne API (TAPI)
11 June 2012

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NOTICE OF COPYRIGHT
© 2011-2012 Teledyne API (TAPI). All rights reserved.
TRADEMARKS
All trademarks, registered trademarks, brand names or product names
appearing in this document are the property of their respective owners
and are used herein for identification purposes only.
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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 the use and maintenance of this instrument or any other
Teledyne API product, contact Teledyne API’s Technical Support Department:
Telephone: [phone]
Email: sda_techsup[email protected]
or access any of 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 (02024 F)
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.
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 Retu
rn 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
Customer Service” 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 T102 Addendum, PN 07267, is comprised of multiple documents as follows.
Part
No. Rev Name/Description
07267 B T102 Addendum
05515 B T102 Menu Trees (inserted as Appendix A in this addendum)
07349 1/7/11 Spare Parts List (located in Appendix B of this addendum)
05517 C Repair Questionnaire (inserted as Appendix C in this addendum)
03404 L Assembly Diagram, M501TS Converter
05764 A Wiring Diagram, M501TS (034040100) (located in Appendix D of this
addendum)
NOTE
Please read this manual in its entirety before making any attempt made to operate the instrument.
REVISION HISTORY
T102/501 TRS Addendum, PN07267
Date
Rev
DCN
Change Summary
2012 June 11
B
6485
Administrative updates
2011 February 4
A
5975
Initial Release
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TABLE OF CONTENTS
1. INTRODUCTION..........................................................................................................................13
1.1. Reference Numbering Convention..............................................................................................14
2. SPECIFICATIONS AND APPROVALS.............................................................................................15
2.1. Specifications..........................................................................................................................15
2.1.1. M501-TRS Specifications....................................................................................................15
2.2. EPA Equivalency Designation ....................................................................................................15
2.3. CE Mark Compliance ................................................................................................................16
3. GETTING STARTED......................................................................................................................17
3.1. Unpacking the T102.................................................................................................................17
3.2. Unpacking the M501-TRS .........................................................................................................17
3.2.1. M501-TRS Ventilation Clearance .........................................................................................17
3.3. Internal Layouts......................................................................................................................19
3.4. T102 and M501-TRS Internal Pneumatic Flow .............................................................................20
3.5. Rear Panel Layout for the T102 & M501-TRS...............................................................................22
3.6. Initial Setup............................................................................................................................23
3.6.1. Electrical Connections........................................................................................................23
3.6.1.1. T102 Analog Output Connections..................................................................................23
3.6.1.2. M501-TRS Alarm Output Connections............................................................................24
4. PNEUMATIC CONNECTIONS ........................................................................................................25
4.1.1.1. Connections with Internal Valve Options Installed...........................................................28
4.2. Initial Operation......................................................................................................................30
4.2.1. Startup / Warm Up of the T102 ..........................................................................................30
4.2.2. Functional Check of the T102 .............................................................................................30
4.2.3. Startup / Warm Up of the M501-TRS...................................................................................31
4.3. Initial Calibration.....................................................................................................................32
5. OPTIONAL HARDWARE AND SOFTWARE .....................................................................................33
5.1. Rack Mount Kits (Options 20a, 20b, 21, 22 & 81)........................................................................33
5.2. Calibration Valves Options........................................................................................................33
5.2.1. Zero/Span Valves (Option 50) & Internal Zero/Span Gas Generator (Option 51).......................33
6. T102 OPERATING INSTRUCTIONS ..............................................................................................37
6.1.1. T102 Analog Output Signals ...............................................................................................37
6.1.2. Setting the T102 Gas Measurement Mode ............................................................................38
6.2. SETUP – DIAG: Using the Diagnostics Functions..........................................................................38
6.2.1. T102 Analog I/O Configuration ...........................................................................................38
6.2.2. T102 Test Channel Output .................................................................................................39
6.3. SETUP – COMM: Setting Up the T102’s Communication Ports........................................................39
6.3.1. T102 ID Code...................................................................................................................39
6.3.2. T102 Ethernet Host Name..................................................................................................39
6.4. Remote Operation of the Analyzer .............................................................................................40
6.4.1. Control Inputs ..................................................................................................................40
6.4.2. Using the T102 with a Hessen Protocol Network....................................................................41
6.4.2.1. T102 Hessen Protocol Gas ID List. ................................................................................41
6.4.2.2. Setting Hessen Protocol Status Flags ............................................................................42
7. M501-TRS OPERATING INSTRUCTIONS ......................................................................................43
7.1. Basic M501-TRS Controls..........................................................................................................43
7.2. To Display The Current Temperature..........................................................................................45
7.3. To Manually Adjust the Converter Oven Temperature...................................................................45
7.4. Autotune the Temperature Controller.........................................................................................46
7.4.1. Initiating the Autotune Process...........................................................................................46
7.4.2. Aborting the Autotune Process............................................................................................47
7.5. M501TRS Alarm Relay Adjustment.............................................................................................47
8. CALIBRATION PROCEDURES.......................................................................................................49
8.1. T102 Calibration......................................................................................................................49
8.2. M501-TRS Calibration ..............................................................................................................49
9.1. Additional and Updated Maintenance Procedures .........................................................................53
9.1.1. Maintaining the SO2Scrubber.............................................................................................53
9.1.1.1. Predicting When to Replace the SO2Scrubber ................................................................53
9.1.1.2. Checking the Function of the SO2Scrubber....................................................................54
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TABLE OF CONTENTS Teledyne API - T102/501 TRS, Addendum to T101 Operation Manual
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9.1.1.3. Changing the SO2Scrubber Material .............................................................................54
10. THEORY OF OPERATION............................................................................................................55
10.1. Measurement Principle ...........................................................................................................55
10.1.1. TRS Conversion ..............................................................................................................55
10.1.2. SO2Ultraviolet Fluorescence.............................................................................................56
10.2. The UV Light Path..................................................................................................................58
10.2.1. UV Lamp Shutter & PMT Offset .........................................................................................58
10.3. Pneumatic Operation..............................................................................................................59
10.3.1. Sample gas Flow.............................................................................................................59
10.3.2. M501 SO2Scrubber.........................................................................................................59
10.4. Electronic Operation...............................................................................................................60
10.4.1. Sensor Module................................................................................................................60
10.4.1.1. Sample Chamber......................................................................................................61
10.4.1.2. Sample Chamber Heating Circuit ................................................................................61
10.4.2. M501-TRS Electronics......................................................................................................62
10.4.2.1. Thermal Switch ........................................................................................................62
10.4.2.2. Temperature Alarms and Alarm Output .......................................................................63
11. TROUBLESHOOTING AND REPAIR.............................................................................................65
11.1.1. Fault Diagnosis with Warning Messages .............................................................................65
11.1.1.1. T102 Warning Messages............................................................................................65
11.1.1.2. M501-TRS Error Codes..............................................................................................65
11.1.2. Fault Diagnosis with Test Functions ...................................................................................66
11.2. M501-TRS Troubleshooting.....................................................................................................67
11.2.1. TRS Converter Not Heating: .............................................................................................67
11.3. Other Performance Problems...................................................................................................68
11.3.1. Excessive noise...............................................................................................................68
11.4. Subsystem Checkout..............................................................................................................68
11.4.1. Checking the Efficiency of the M501-TRS SO2Scrubber........................................................68
11.4.2. Checking the Efficiency of the M501-TRS TRS SO2Converter ............................................68
11.5. Additional Repair Procedures...................................................................................................70
11.5.1. UV Lamp Adjustment and/or Replacement..........................................................................71
11.5.1.1. Adjusting the UV Lamp (Peaking the Lamp) .................................................................71
11.5.1.2. Replacing the UV Lamp..............................................................................................72
11.5.2. Replacing the UV Filter/Lens ..............................................................................................73
11.5.3. Replacing the PMT, HVPS or TEC.......................................................................................74
11.5.4. T102 PMT Hardware Calibration (FACTORY CAL)..................................................................77
11.5.5. Replacing the TRS Converter Heating Tube.........................................................................80
11.5.6. Replacing the Thermocouple.............................................................................................81
11.6. Manually Programming the M501-TRS Temperature Controller ....................................................84
11.6.1. Temperature Controller Primary Menu Parameters...............................................................85
11.7. Technical Assistance ..............................................................................................................87
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
APPENDIX A-1: T102 Software Menu Trees, Revision A.2
APPENDIX A-2: Setup Variables For Serial I/O, Revision A.2
APPENDIX A-3: Warnings and Test Functions, Revision A.2
APPENDIX A-4: T102 Signal I/O Definitions, Revision A.2
APPENDIX A-5: T102 iDAS Functions, Revision A.2
APPENDIX B - T102 SPARE PARTS LIST
APPENDIX C - T102 REPAIR REQUEST FORM
APPENDIX D - ELECTRONIC SCHEMATICS
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Teledyne API - T102/501 TRS, Addendum to T101 Operation Manual TABLE OF CONTENTS
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LIST OF FIGURES
Figure 3-1. T102 Internal Layout..........................................................................................19
Figure 3-2. M501-TRS Internal Layout ..................................................................................20
Figure 3-3. Internal Pneumatic Diagram of the T102 Standard Configuration .............................21
Figure 3-4. T102 Rear Panel (with Zero Air Scrubber attached) ................................................22
Figure 3-5. M501-TRS Rear Panel Layout...............................................................................22
Figure 3-6. Analog Output Connector....................................................................................23
Figure 4-1. Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator................26
Figure 4-2. Pneumatic Connections–Basic Configuration–Using Bottled Span Gas .......................26
Figure 4-3. Basic Pneumatic Connections for Units with Zero/Span Valve Option ........................28
Figure 4-4. Pneumatic Connections for Formal Calibration of Units w/ IZS Valve Option ..............29
Figure 4-5. Pneumatic Connections for Informal Calibration Checks of Units with IZS Valve Option29
Figure 4-6. M501-TRS Temperature Controller Startup............................................................31
Figure 5-1. Internal Pneumatic Diagram of the T102 With Z/S Option Installed ..........................34
Figure 5-2. Internal Pneumatic Diagram of the T102 with IZS Options Installed .........................35
Figure 6-1. Analog Output Connector....................................................................................37
Figure 6-2. Control Inputs with Local 5 V Power Supply...........................................................40
Figure 6-3. Control Inputs with External 5 V Power Supply ......................................................41
Figure 7-1. M501-TRS Temperature Controls .........................................................................43
Figure 10-1. UV Absorption in the T102 Reaction Cell..............................................................56
Figure 10-2. T102 Sensor Module.........................................................................................60
Figure 10-3. T102 Sample Chamber .....................................................................................61
Figure 10-4. M501-TRS Electronic Block Diagram ...................................................................62
Figure 11-1. Shutter Assembly - Exploded View .....................................................................72
Figure 11-2. Disassembling the Shutter Assembly ..................................................................73
Figure 11-3. PMT Assembly - Exploded View..........................................................................74
Figure 11-4. Pre-Amplifier Board Layout................................................................................78
Figure 11-5. Thermocouple..................................................................................................82
Figure 11-6. Cavity for Thermocouple ...................................................................................82
Figure 11-7. Thermocouple Installed.....................................................................................83
Figure 11-8. Tie-Wrap Hold-Down Location............................................................................83
LIST OF TABLES
Table 2-1: Model 501 Basic Unit Specifications.......................................................................15
Table 3-1. TRS – SO2Switching Valve Operating Modes ..........................................................21
Table 3-2. Analog output Pin Outs ........................................................................................23
Table 4-1. Table 3-3: Inlet / Outlet Connector Labels and Functions .....................................25
Table 4-2. NIST-SRM's Available for Traceability of H2S & SO2 Calibration Gases.......................28
Table 5-1. Zero/Span Valve Operating States.........................................................................34
Table 5-2. IZS Valve Operating States ..................................................................................35
Table 6-1. T102 Gas Measurement Modes .............................................................................38
Table 6-2. Analog Output Pin Assignments ............................................................................38
Table 6-3. Test Parameters Available for Analog Output A4......................................................39
Table 6-4. T102 Control Input Pin Assignments......................................................................40
Table 6-5. T102 Default Hessen Gas ID’s...............................................................................41
Table 6-6. Default Hessen Status Bit Assignments..................................................................42
Table 7-1. M501-TRS Temperature Controls and Definitions.....................................................44
Table 8-1. T102 Preventive Maintenance Schedule..................................................................51
Table 11-1. Test Functions - Possible Causes for Out-Of-Range Values......................................66
Table 11-2. Test Functions - Possible Causes for Out-Of-Range Values......................................66
Table 11-3. Temperature Controller – Primary Parameter Settings............................................86
Table 11-4. Temperature Controller – Secondary Parameter Settings........................................87
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1. INTRODUCTION
NOTE
The information contained in this addendum is pertinent to T102 analyzers running
software revision G.4. Some or all of the information may not be applicable to
previous revision of that software.
This addendum is based on the Model T101 Operators Manual (PN 07266). In most
ways the T102 is identical to the T101 in design and operation; therefore most of the
basic set up information, operating instructions as well as calibration, maintenance,
troubleshooting and repair methods are found in that manual.
This addendum documents only those areas where the T102 is different in design or
operating method from the T101.
Specifically:
•Areas where updates and improvements to the Model T10X software
have been implemented since the publication date of the T101 Manual -
PN 07266.
•EXTERNAL TRS CONVERSION: Like the T101, which converts H2S to
SO2, then measures the amount of SO2present using a UV fluorescence
technique, the T102 converts total reduced sulfur (TRS) gases into SO2
before measuring the SO2using the same UV fluorescence method.
Unlike the T101, which performs the H2S SO2conversion internally, the T102
requires an external TRS converter, in this case a TAPI M501-TRS.
Therefore this addendum includes instructions and information regarding:
•Areas of operation and setup of the T102 that depart from the
method described by the T101 operator’s manual due to the TRS 
SO2 conversion being performed externally.
•The proper setup and operation on the M501-TRS.
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INTRODUCTION Teledyne API - T102/501 TRS, Addendum to T101 Operation Manual
14
1.1. Reference Numbering Convention
Unless otherwise specified, chapter, section, figure and table reference numbers referred
to within this text are relative to this document.
EXAMPLE: “Figure 2-1” refers to the figure, within this document, labeled
as 2-1.
References to chapters, sections, figures and tables in the original document will be
labeled as such.
EXAMPLE: “Front Panel Display Figure in Overview of Operating modes
section of the T101 Operators Manual (PN 07266)”.
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2. SPECIFICATIONS AND APPROVALS
2.1. Specifications
As there are no significant differences between the performance specifications for the
T102 and the T101 please refer to in the Specification section of the T101 Manual - PN
07266. However, the AC power specifications for the T102 are as follows:
T102 AC Power: 100V – 120V, 60Hz (200W); 220V – 240V, 50Hz (211W)
2.1.1. M501-TRS Specifications
Table 2-1: Model 501 Basic Unit Specifications
Minimum Converter Efficiency H2S >95%
COS >90%
CS2>90%
Maximum TS Concentration for
specified conversion efficiency 20 ppmv
Sample Flow Rate 650cc/min. ±10% - driven by T102 pneumatic system
Optimum Converter
Temperature 850°C (factory setup)
Maximum Converter
Temperature 1100°C
Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)
Weight
16 lbs (7.3 kg) 26 lbs (11.8 kg) CE version
AC Power Rating 115 V, 50/60 Hz - 400 Watts;
230 V, 50/60 Hz - 575 Watts; CE Version
Internal Alarms High Alarm Point: 900°C
Low Alarm Point: 800°C
Alarm Output Relay SPST - 1 point: Alarm output is energized should either the temperature
controller’s high or low internal alarm set points be activated.
Alarm Output Rating 220V AC/30V DC, 1A (resistive load)
Environmental Installation category (over-voltage category) II; Pollution degree 2
Certifications IEC 1010-1 / 61010-1:93 (includes A1) + A2:95,
For indoor use at altitudes ≤ 2000m only
2.2. EPA Equivalency Designation
No EPA equivalency standards exist for TRS measurement, however, the T102 analyzer
qualifies for EPA equivalency designation as Reference Method Number EQSA-0495-
100 per 40 CFR Part 53 when operated under the following conditions:
•Measurement Mode: SO2single gas mode.
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SPECIFICATIONS AND APPROVALS Teledyne API - T102/501 TRS, Addendum to T101 Operation Manual
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•Range: Any range from 50 parts per billion (ppb) to 10 parts per million
(ppm).
•Ambient temperature range of 5 oC to 40 oC.
•Line voltage range of 105-125 VAC or 220-240 VAC, at 50 or 60 Hz.
•Sample filter: Equipped with PTFE filter element in the internal filter
assembly.
•Sample flow of 650 +/- 65 cc/min.
•Vacuum pump (internal or external) capable of 14"Hg Absolute pressure
@ 1 slpm or better.
•Software settings:
Dynamic span
OFF
Dynamic zero
OFF
Dilution factor
OFF
AutoCal
ON or OFF
Dual range
ON or OFF
Auto-range
ON or OFF
Temp/Pressure compensation
ON
Under the designation, the analyzer may be operated with or without the following
optional equipment:
•Rack mount with chassis slides.
•Rack mount without slides, ears only.
•Zero/span valve options.
•Internal zero/span (IZS) option with either:
•SO2 permeation tube - 0.4 ppm at 0.7 liter per minute;
certified/uncertified.
•SO2 permeation tube - 0.8 ppm at 0.7 liter per minute;
certified/uncertified. Under the designation, the IZS option cannot be
used as the source of calibration.
•4-20mA isolated analog outputs.
•Status outputs.
•Control inputs.
•RS-232 output.
•Ethernet output.
•Zero air scrubber.
•4-20mA, isolated output.
2.3. CE Mark Compliance
See Section titled CE Mark Compliance in the T101 Manual - PN 07266
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3. GETTING STARTED
3.1. Unpacking the T102
Unpack the T102 as per the directions in section titled Unpacking and Initial Setup in
the T101 Manual - PN 07266.
There are no shipping screws to be removed in the T102.
3.2. Unpacking the M501-TRS
There are no shipping screws to be removed in the M501-TRS.
1. Inspect the shipping package for external damage. If damaged, please
advise the shipper first, then Teledyne API (TAPI).
2. Carefully remove the top cover of the converter and check for internal
shipping damage.
a. Remove the screws fastening the top cover to the unit (four per
side).
b. Lift the cover straight up.
WARNING
Never disconnect electronic circuit boards, wiring harnesses or
electronic subassemblies while the unit is under power.
3. Inspect the interior of the instrument to make sure all components are in
good shape and properly seated.
4. Check the connectors of the various internal wiring harnesses and
pneumatic hoses to make sure they are firmly and properly seated.
5. Replace the top cover and fasten with original screws.
NOTE
The M501-TRS will not operate properly with the top cover removed.
The air cooling required to stabilize the temperature of the converter tube is
dependent on air flow patterns that only exist with the top cover in place.
Without the top cover in place, the thermal cutout may overheat and shut off the
heating element.
3.2.1. M501-TRS Ventilation Clearance
Whether the M501-TRS is set up on a bench or installed into an instrument rack, be sure
to leave sufficient ventilation clearance.
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GETTING STARTED Teledyne API - T102/501 TRS, Addendum to T101 Operation Manual
18
AREA MINIMUM REQUIRED CLEARANCE
Behind the instrument 10 cm / 4 inches
Sides of the instrument 2.5 cm / 1 inch
Above and below the instrument. 2.5 cm / 1 inch
NOTE
If the M501-TRS is installed in an instrument rack or any type of enclosure, make
sure that the rack/enclosure itself is adequately ventilated.
Failure to provide proper ventilation can result in the ambient temperature exceeding
the maximum operating temperature specification for the T102 (40
°
C)
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