Teledyne 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 92121-5201
USA
Toll-free Phone: [phone]
Phone: [phone]
Fax: [phone]
Email: api-[email protected]
Website: http://www.teledyne-api.com/
Copyright 2010-2012 06864B DCN6314
Teledyne API 14 February 2012

i
ABOUT TELEDYNE API (TAPI)
Teledyne API (TAPI), a business unit of Teledyne Instruments, Inc., 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, NOX and
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
[e-mail].
NOTICE OF COPYRIGHT
© 2010-2012 Teledyne API, 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 Customer Service Department:
Phone: [phone]
Email: [e-mail]
or by accessing various service options on our website at
7http://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 (02024D)
Teledyne API (TAPI), a business unit of Teledyne Instruments, Inc., warrants its
products as follows:
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.
GENERAL During the warranty period, TAPI warrants each Product manufactured by TAPI to be
free from defects in material and workmanship under normal use and service.
Expendable parts are excluded.
If a Product fails to conform to its specifications within the warranty period, TAPI shall
correct such defect by, in TAPI's discretion, repairing or replacing such defective
Product or refunding the purchase price of such Product.
The warranties set forth in this section shall be of no force or effect with respect to any
Product: (i) that has been altered or subjected to misuse, negligence or accident, or (ii)
that has been used in any manner other than in accordance with the instruction provided
by TAPI, or (iii) not properly maintained.
THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES
THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF
MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER
WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED. THE REMEDIES
SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF
ANY WARRANTY CONTAINED HEREIN. API SHALL NOT BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO
THIS AGREEMENT OF TAPI'S PERFORMANCE HEREUNDER, WHETHER FOR
BREACH OF WARRANTY OR OTHERWISE.
TERMS AND CONDITIONS
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.
ATTENTION 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 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
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.
Part No. Rev Name/Description
06864 B Operation Manual, T300 Carbon Monoxide Analyzer
04906 H Appendix A, Menu Trees and related software documentation
06849 A Spare Parts List (in Appendix B of this manual)
04301 E Recommended Spares Stocking Levels List/T300 (in Appendix B of this manual)
04834 G Recommended Spares Stocking Levels List/T300M (in Appendix B of this manual)
04305 G Appendix C, Repair Form
06912 B Interconnect Diagram (in Appendix D of this manual)
069120100 B Interconnect Table (in Appendix D of this manual)
Schematics (in Appendix Dof this manual)
03297 K PCA, 03296, IR Photodetector Preamp and Sync Demodulator
03632 A PCA, 03631, 0-20mA driver
04354 D PCA, 04003, Pressure/Flow Transducer Interface
05033 A PCA, 05032, Opto-Interrupter
04136 B PCA, 04135, Relay Board
04468 B PCA, 04467, Analog Output Isolator
05803 B SCH, PCA 05802, MOTHERBOARD, GEN-5
06698 D SCH, PCA 06670, INTRFC, LCD TCH SCRN,
06882 B SCH, LVDS TRANSMITTER BOARD
06731 B SCH, AUX-I/O BOARD
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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,
descriptions of the available options, specifications, installation and connection
instructions, and the initial calibration and functional checks. The last two sections
contain Frequently Asked Questions (FAQs) followed by a glossary, and a description
of available options.
Part II comprises the operating instructions, which include basic, advanced and remote
operation, calibration, diagnostics, testing, validating and verifying, and ends with
specifics of calibrating for use in EPA monitoring.
Part III provides detailed technical information, such as theory of operation,
maintenance, and troubleshooting and repair. It also contains a section that provides
important information about electro-static discharge and avoiding its consequences.
The appendices at the end of this manual provide support information such as, version-
specific software documentation, lists of spare parts and recommended stocking levels,
and schematics.
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.
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REVISION HISTORY
This section provides information regarding changes to this manual.
2012, February 14, T300/300M Manual, PN06864 Rev B
Document PN Rev DCN Change Summary
Top Assy Manual 06864 B 6314 Administrative changes: restructure to new T-Series format:
•Consolidated Options sections and restructured into tabular
format; moved to Section 1.
•Corrected Safety Compliance (was: IEC 61010-1:90 + A1:92 +
A2:95; is: IEC 61010-1:2001).
•Added North American Certification statement.
•Section 2.1 – added 2nd gas sensor options specs.
•Replaced Fig 3-5 with correct internal layout illustration (was
short box; is long box).
•Move pneumatic illustrations from Options section to
pneumatic setup section.
•Gathered communications setup and operation into one group
(Section 6).
•Renamed Part III from “Technical Information” to “Maintenance
and Service”.
•Renamed “Troubleshooting and Repair” to “Troubleshooting
and Service”.
•Renamed section “Theory of Operation” to “Principles of
Operation”.
•Moved “Principles of Operation” section after “Maintenance”
and “Troubleshooting and Service” sections.
•Moved FAQs to end of Troubleshooting/Service section
•Moved Glossary to end of manual before Index.
Technical changes:
•Status Outputs: added connection line for +5V to external
device (Fig 3-11) and corrected DC Power pin description
(Table 3-6, deleted “combined rating w/Control Output if used”).
•Section 3.3.1.8: modify Multidrop connection section to clarify
insructions and add detail.
•Correct COM1 default baud rate value to 115,200 (was:
19,200)
•Added USB driver download instructions (Section 6.6)
•Replaced Appendix D Wiring List Rev A with Rev B.
•Replaced Appendix D Wiring Diagram Rev A with Rev B.
•Swapped Appendix D Prss/Flow Transducer was 04003
(assembly dwg) is 04354 (elec. schematic).
•Replaced Appendix D Schematic 06731 Rev A with Rev B.
2010, September 14, T300 Manual, PN06864 Rev Error! Unknown document property name., DCN6314
Initial Release
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TABLE OF CONTENTS
PART I GENERAL INFORMATION ....................................................................................... 23
1. INTRODUCTION, FEATURES AND OPTIONS.................................................................. 25
1.1. T300 Family Overview.................................................................................................................................25
1.2. Features.......................................................................................................................................................26
1.3. T300/T300M Documentation .......................................................................................................................26
1.4. Options.........................................................................................................................................................27
2. SPECIFICATIONS AND APPROVALS............................................................................... 31
2.1. Specifications...............................................................................................................................................31
2.2. EPA Equivalency Designation .....................................................................................................................33
2.3. Approvals and Certifications........................................................................................................................34
2.3.1. Safety.....................................................................................................................................................34
2.3.2. EmC.......................................................................................................................................................34
2.3.3. Other Type Certifications.......................................................................................................................34
3. GETTING STARTED........................................................................................................... 35
3.1. Unpacking the T300/T300M Analyzer .........................................................................................................35
3.1.1. Ventilation Clearance.............................................................................................................................36
3.2. Instrument Layout........................................................................................................................................37
3.2.1. Front Panel.............................................................................................................................................37
3.2.2. Rear panel..............................................................................................................................................41
3.2.3. T300/T300M Analyzer Layout................................................................................................................43
3.3. Connections and Setup................................................................................................................................46
3.3.1. Electrical Connections ...........................................................................................................................46
3.3.1.1. Connecting Power..........................................................................................................................46
3.3.1.2. Connecting Analog Inputs (Option) ................................................................................................47
3.3.1.3. Connecting Analog Outputs ...........................................................................................................47
3.3.1.4. Current Loop Analog Outputs (Option 41) Setup..........................................................................48
3.3.1.5. Connecting the Status Outputs ......................................................................................................50
3.3.1.6. Connecting the Control Inputs........................................................................................................51
3.3.1.7. Connecting the Concentration Alarm Relay (Option 61)................................................................53
3.3.1.8. Connecting the Communication Interfaces ....................................................................................54
3.3.2. Pneumatic Connections.........................................................................................................................61
3.3.2.1. Pneumatic Connections for Basic Configuration............................................................................63
3.3.2.2. Pneumatic Layout for Basic configuration......................................................................................65
3.3.2.3. Pneumatic Connections for Ambient Zero/Ambient Span Valve Option........................................65
3.3.2.4. Pneumatic Layout for Ambient Zero/Ambient Span Valve Option .................................................67
3.3.2.5. Pneumatic Connections for Ambient Zero/Pressurized Span........................................................67
3.3.2.6. Pneumatic Layout for Ambient Zero/Pressurized Span Option .....................................................69
3.3.2.7. Pneumatic Connections for Zero Scrubber/Pressurized Span Option...........................................70
3.3.2.8. Pneumatic Layout for Zero Scrubber/Pressurized Span Option....................................................71
3.3.2.9. Pneumatic Connections for Zero Scrubber/Ambient Span Option.................................................72
3.3.2.10. Pneumatic Layout for Zero scrubber/ Ambient Span OPTion......................................................74
3.3.2.11. Calibration Gases.........................................................................................................................74
3.4. Startup, Functional Checks, and Initial Calibration......................................................................................76
3.4.1. Startup....................................................................................................................................................76
3.4.2. Warning Messages ................................................................................................................................76
3.4.3. Functional Checks .................................................................................................................................78
3.4.4. Initial Calibration ....................................................................................................................................79
3.4.4.1. Interferents for CO Measurements.................................................................................................80
3.4.4.2. Initial Calibration Procedure ...........................................................................................................80
3.4.4.3. O2 Sensor Calibration Procedure ..................................................................................................85
3.4.4.4. CO2 Sensor Calibration Procedure................................................................................................85
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PART II OPERATING INSTRUCTIONS.................................................................................. 87
4. OVERVIEW OF OPERATING MODES............................................................................... 89
4.1. Sample Mode...............................................................................................................................................90
4.1.1. Test Functions .......................................................................................................................................90
4.1.2. Warning Messages ................................................................................................................................93
4.2. Calibration Mode..........................................................................................................................................94
4.3. Setup MODE................................................................................................................................................95
4.3.1. Password Security.................................................................................................................................95
4.3.2. Primary Setup Menu ..............................................................................................................................95
4.3.3. The areas accessible under the Setup mode are shown in Table 4-4 and Secondary Setup Menu
(SETUP>MORE)..............................................................................................................................................95
4.3.4. Secondary Setup Menu (SETUP>MORE).............................................................................................96
5. SETUP MENU 97
5.1. SETUP àCFG: Configuration Information .................................................................................................97
5.2. SETUP àACAL: Automatic Calibration......................................................................................................98
5.3. SETUP àDAS: Internal Data Acquisition System.......................................................................................98
5.4. SETUP àRNGE: Analog Output Reporting Range Configuration.............................................................98
5.4.1. Analog Output Ranges for CO Concentration .......................................................................................98
5.4.2. Physical Range vs Analog Output Reporting Ranges.........................................................................100
5.4.3. Reporting Range Modes: Single, Dual, Auto Ranges .........................................................................100
5.4.3.1. SINGLE Range Mode (SNGL) .....................................................................................................102
5.4.3.2. DUAL Range Mode (DUAL) .........................................................................................................103
5.4.3.3. AUTO Range Mode (AUTO) ........................................................................................................105
5.4.4. Range Units .........................................................................................................................................107
5.4.5. Dilution Ratio (Option)..........................................................................................................................108
5.5. SETUP àPASS: Password Protection.....................................................................................................109
5.6. SETUP àCLK: Setting the Internal Time-of-Day Clock and Adjusting Speed.........................................111
5.6.1.1. Setting the Internal Clock’s Time and Day...................................................................................111
5.6.1.2. Adjusting the Internal Clock’s Speed............................................................................................111
5.7. SETUP àComm: Communications Ports .................................................................................................113
5.7.1. ID (Machine Identification)...................................................................................................................113
5.7.2. INET (Ethernet)....................................................................................................................................113
5.7.3. COM1 and COM2 (Mode, Baud Rate and Test Port)..........................................................................113
5.8. SETUP àVARS: Variables Setup and Definition......................................................................................114
5.9. SETUP àDiag: Diagnostics Functions......................................................................................................116
5.9.1. Signal I/O .............................................................................................................................................118
5.9.2. Analog Output......................................................................................................................................119
5.9.3. Analog I/O Configuration......................................................................................................................120
5.9.3.1. Analog Output Voltage / Current Range Selection.......................................................................122
5.9.3.2. Analog Output Calibration ............................................................................................................124
5.9.3.3. Enabling or Disabling the AutoCal for an Individual Analog Output.............................................124
5.9.3.4. Automatic Calibration of the Analog Outputs ...............................................................................126
5.9.3.5. Individual Calibration of the Analog Outputs................................................................................127
5.9.3.6. Manual Calibration of the Analog Outputs Configured for Voltage Ranges.................................128
5.9.3.7. Manual Adjustment of Current Loop Output Span and Offset .....................................................130
5.9.3.8. Turning an Analog Output Over-Range Feature ON/OFF ...........................................................133
5.9.3.9. Adding a Recorder Offset to an Analog Output............................................................................134
5.9.3.10. AIN Calibration ...........................................................................................................................135
5.9.3.11. Analog Inputs (XIN1…XIN8) Option Configuration....................................................................136
5.9.4. Electrical Test ......................................................................................................................................137
5.9.5. Dark Calibration ...................................................................................................................................137
5.9.6. Pressure Calibration ............................................................................................................................137
5.9.7. Flow Calibration ...................................................................................................................................138
5.9.8. Test Chan Output.................................................................................................................................138
5.9.8.1. Selecting a Test Channel Function for Output A4........................................................................138
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5.10. SETUP àMORE àALRM (Option): Using the Gas Concentration Alarms...........................................140
5.10.1. Setting the T300 Concentration Alarm Limits....................................................................................141
6. COMMUNICATIONS SETUP AND OPERATION ............................................................. 143
6.1. Data Terminal/Communication Equipment (DTE DCE).............................................................................143
6.2. Communication Modes, Baud Rate and Port Testing...................................................................................143
6.2.1. Communication Modes........................................................................................................................144
6.2.2. COM Port Baud Rate...........................................................................................................................146
6.2.3. Com Port Testing.................................................................................................................................147
6.3. RS-232.......................................................................................................................................................147
6.4. RS-485 (Option).........................................................................................................................................148
6.5. Ethernet......................................................................................................................................................148
6.5.1. Configuring Ethernet Communication Manually (Static IP Address)...................................................149
6.5.2. Configuring Ethernet Communication Using Dynamic Host Configuration Protocol (DHCP) .............151
6.5.3. Changing the Analyzer’s HOSTNAME ................................................................................................152
6.6. USB Port (Option) for Remote Access ......................................................................................................153
6.7. Communications Protocols........................................................................................................................155
6.7.1. MODBUS .............................................................................................................................................155
6.7.2. Hessen.................................................................................................................................................156
6.7.2.1. Hessen COMM Port Configuration...............................................................................................157
6.7.2.2. Activating Hessen Protocol ..........................................................................................................159
6.7.2.3. Selecting a Hessen Protocol Type...............................................................................................160
6.7.2.4. Setting The Hessen Protocol Response Mode ............................................................................161
6.7.3. Hessen Protocol Gas List Entries........................................................................................................162
6.7.3.1. Hessen Protocol Gas ID...............................................................................................................162
6.7.3.2. Editing or Adding HESSEN Gas List Entries................................................................................163
6.7.3.3. Deleting HESSEN Gas List Entries..............................................................................................164
6.7.3.4. Setting Hessen Protocol Status Flags..........................................................................................165
6.7.3.5. Instrument ID................................................................................................................................166
7. DATA ACQUISITION SYSTEM (DAS) AND APICOM...................................................... 167
7.1. DAS Structure............................................................................................................................................168
7.1.1. DAS Data Channels.............................................................................................................................169
7.1.2. Default DAS Channels.........................................................................................................................169
7.1.3. Viewing DAS Channels and Individual Records..................................................................................172
7.1.4. Editing DAS Channels .........................................................................................................................173
7.1.4.1. Editing DAS Data Channel Names...............................................................................................174
7.1.5. Editing DAS Triggering Events ............................................................................................................175
7.1.6. Editing DAS Parameters......................................................................................................................176
7.1.7. Sample Period and Report Period.......................................................................................................178
7.1.8. Number of Records..............................................................................................................................181
7.1.9. RS-232 Report Function......................................................................................................................183
7.1.9.1. The Compact Report Feature.......................................................................................................183
7.1.9.2. The Starting Date Feature............................................................................................................184
7.1.10. Disabling/Enabling Data Channels ....................................................................................................184
7.1.11. HOLDOFF Feature ............................................................................................................................185
7.2. Remote DAS Configuration........................................................................................................................186
7.2.1. DAS Configuration via APICOM ..........................................................................................................186
7.2.2. DAS Configuration Using Terminal Emulation Programs....................................................................188
8. REMOTE OPERATION..................................................................................................... 189
8.1. Computer Mode .........................................................................................................................................189
8.1.1. Remote Control via APICOM...............................................................................................................189
8.2. Interactive Mode ........................................................................................................................................190
8.2.1. Remote Control via a Terminal Emulation Program............................................................................190
8.2.1.1. Help Commands in Interactive Mode...........................................................................................190
8.2.1.2. Command Syntax.........................................................................................................................190
8.2.1.3. Data Types ...................................................................................................................................191
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8.2.1.4. Status Reporting...........................................................................................................................192
8.2.1.5. General Message Format.............................................................................................................192
8.3. Remote Access by Modem........................................................................................................................192
8.4. Password Security for Serial Remote Communications............................................................................195
9. CALIBRATION PROCEDURES........................................................................................ 197
9.1. Calibration Preparations ............................................................................................................................197
9.1.1. Required Equipment, Supplies, and Expendables..............................................................................197
9.1.1.1. Zero Air.........................................................................................................................................198
9.1.1.2. Span Gas......................................................................................................................................198
9.1.1.3. Calibration Gas Standards and Traceability.................................................................................198
9.1.2. Data Recording Devices......................................................................................................................199
9.2. Manual Calibration.....................................................................................................................................199
9.2.1. Setup for Basic Calibration Checks and Calibration............................................................................200
9.2.2. Performing a Basic Manual Calibration Check....................................................................................201
9.2.3. Performing a Basic Manual Calibration ...............................................................................................202
9.2.3.1. Setting the Expected Span Gas Concentration............................................................................202
9.2.3.2. Zero/Span Point Calibration Procedure........................................................................................204
9.3. Manual Calibration with Zero/Span Valves................................................................................................205
9.3.1. Setup for Calibration Using Valve Options ..........................................................................................205
9.3.2. Manual Calibration Checks with Valve Options Installed ....................................................................208
9.3.3. Manual Calibration Using Valve Options .............................................................................................209
9.3.3.1. Setting the Expected Span Gas Concentration............................................................................209
9.3.3.2. Zero/Span Point Calibration Procedure........................................................................................210
9.3.3.3. Use of Zero/Span Valve with Remote Contact Closure ...............................................................212
9.4. Automatic Zero/Span Cal/Check (AutoCal)...............................................................................................212
9.4.1. SETUP àACAL: Programming and AUTO CAL Sequence...............................................................215
9.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected...................................................217
9.5. CO Calibration Quality...............................................................................................................................218
9.6. Calibration of the T300/T300M’s Electronic Subsystems..........................................................................219
9.6.1. Dark Calibration Test...........................................................................................................................219
9.6.2. Pressure Calibration ............................................................................................................................220
9.6.3. Flow Calibration ...................................................................................................................................222
9.7. Calibration of Optional Sensors.................................................................................................................223
9.7.1. O2Sensor Calibration ..........................................................................................................................223
9.7.1.1. O2 Pneumatics Connections........................................................................................................223
9.7.1.2. Set O2 Span Gas Concentration..................................................................................................224
9.7.1.3. Activate O2 Sensor Stability Function..........................................................................................225
9.7.1.4. O2 ZERO/SPAN CALIBRATION..................................................................................................226
9.7.2. CO2Sensor Calibration Procedure......................................................................................................227
9.7.2.1. CO2 Pneumatics Connections .....................................................................................................227
9.7.2.2. Set CO2 Span Gas Concentration: ..............................................................................................228
9.7.2.3. Activate CO2 Sensor Stability Function .......................................................................................229
9.7.2.4. CO2 Zero/Span Calibration..........................................................................................................230
10. EPA CALIBRATION PROTOCOL .................................................................................. 231
10.1. Calibration Requirements........................................................................................................................231
10.1.1. Calibration of Equipment - General Guidelines .................................................................................231
10.1.2. Calibration Equipment, Supplies, and Expendables..........................................................................232
10.1.2.1. Data Recording Device ..............................................................................................................232
10.1.2.2. Spare Parts and Expendable Supplies.......................................................................................232
10.1.3. Recommended Standards for Establishing Traceability....................................................................233
10.1.4. Calibration Frequency........................................................................................................................234
10.1.5. Level 1 Calibrations versus Level 2 Checks......................................................................................234
10.2. ZERO and SPAN Checks........................................................................................................................235
10.2.1. Zero/Span Check Procedures ...........................................................................................................236
10.2.2. Precision Check.................................................................................................................................236
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10.3. Precisions Calibration..............................................................................................................................237
10.3.1. Precision Calibration Procedures ......................................................................................................237
10.4. Auditing Procedure..................................................................................................................................237
10.4.1. Calibration Audit.................................................................................................................................237
10.4.2. Data Reduction Audit.........................................................................................................................238
10.4.3. System Audit/Validation.....................................................................................................................238
10.5. Dynamic Multipoint Calibration Procedure ..............................................................................................238
10.5.1. Linearity test.......................................................................................................................................238
10.6. References ..............................................................................................................................................240
PART III TECHNICAL INFORMATION................................................................................ 241
11. MAINTENANCE SCHEDULE & PROCEDURES............................................................ 245
11.1. Maintenance Schedule............................................................................................................................245
11.2. Predicting Failures Using the Test Functions..........................................................................................249
11.3. Maintenance Procedures.........................................................................................................................250
11.3.1. Replacing the Sample Particulate Filter.............................................................................................250
11.3.2. Rebuilding the Sample Pump ............................................................................................................251
11.3.3. Performing Leak Checks....................................................................................................................251
11.3.3.1. Vacuum Leak Check and Pump Check......................................................................................251
11.3.3.2. Pressure Leak Check.................................................................................................................251
11.3.4. Performing a Sample Flow Check .....................................................................................................252
11.3.5. Cleaning the Optical Bench ...............................................................................................................252
11.3.6. Cleaning Exterior Surfaces of the T300/T300M ................................................................................252
12. TROUBLESHOOTING AND SERVICE........................................................................... 253
12.1. General Troubleshooting.........................................................................................................................253
12.1.1. Fault Diagnosis with WARNING Messages.......................................................................................254
12.1.2. Fault Diagnosis with TEST Functions................................................................................................258
12.1.3. the Diagnostic Signal I/O Function ....................................................................................................261
12.1.4. Status LEDs.......................................................................................................................................263
12.1.4.1. Motherboard Status Indicator (Watchdog) .................................................................................263
12.1.4.2. Sync Demodulator Status LEDs.................................................................................................264
12.1.4.3. Relay Board Status LEDs...........................................................................................................265
12.2. Gas Flow Problems .................................................................................................................................267
12.2.1. T300/T300M Internal Gas Flow Diagrams.........................................................................................268
12.2.2. Typical Sample Gas Flow Problems..................................................................................................271
12.2.2.1. Flow is Zero................................................................................................................................271
12.2.2.2. Low Flow ....................................................................................................................................272
12.2.2.3. High Flow....................................................................................................................................272
12.2.2.4. Displayed Flow = “Warnings” .....................................................................................................273
12.2.2.5. Actual Flow Does Not Match Displayed Flow ............................................................................273
12.2.2.6. Sample Pump.............................................................................................................................273
12.3. Calibration Problems ...............................................................................................................................273
12.3.1. Miscalibrated......................................................................................................................................273
12.3.2. Non-Repeatable Zero and Span........................................................................................................274
12.3.3. Inability to Span – No SPAN Button (CALS)......................................................................................274
12.3.4. Inability to Zero – No ZERO Button (CALZ).......................................................................................274
12.4. Other Performance Problems..................................................................................................................275
12.4.1. Temperature Problems......................................................................................................................275
12.4.1.1. Box or Sample Temperature......................................................................................................275
12.4.1.2. Bench Temperature....................................................................................................................275
12.4.1.3. GFC Wheel Temperature...........................................................................................................276
12.4.1.4. IR Photo-Detector TEC Temperature.........................................................................................277
12.4.2. Excessive Noise.................................................................................................................................277
12.5. Subsystem Checkout...............................................................................................................................278
12.5.1. AC Mains Configuration.....................................................................................................................278
12.5.2. DC Power Supply...............................................................................................................................279
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12.5.3. I2C Bus...............................................................................................................................................279
12.5.4. Touchscreen Interface.......................................................................................................................280
12.5.5. LCD Display Module ..........................................................................................................................280
12.5.6. Relay Board .......................................................................................................................................280
12.5.7. Sensor Assembly...............................................................................................................................281
12.5.7.1. Sync/Demodulator Assembly.....................................................................................................281
12.5.7.2. Electrical Test.............................................................................................................................281
12.5.7.3. Opto Pickup Assembly ...............................................................................................................282
12.5.7.4. GFC Wheel Drive .......................................................................................................................282
12.5.7.5. IR Source....................................................................................................................................282
12.5.7.6. Pressure/Flow Sensor Assembly ...............................................................................................283
12.5.8. Motherboard.......................................................................................................................................284
12.5.8.1. A/D Functions.............................................................................................................................284
12.5.8.2. Test Channel / Analog Outputs Voltage.....................................................................................284
12.5.8.3. Analog Outputs: Current Loop....................................................................................................285
12.5.8.4. Status Outputs............................................................................................................................286
12.5.8.5. Control Inputs – Remote Zero, Span..........................................................................................286
12.5.9. CPU....................................................................................................................................................287
12.5.10. RS-232 Communications.................................................................................................................287
12.5.10.1. General RS-232 Troubleshooting.............................................................................................287
12.5.10.2. Troubleshooting Analyzer/Modem or Terminal Operation .......................................................288
12.5.11. The Optional CO2Sensor ................................................................................................................288
12.6. Repair Procedures...................................................................................................................................289
12.6.1. Repairing Sample Flow Control Assembly ........................................................................................289
12.6.2. Removing/Replacing the GFC Wheel................................................................................................290
12.6.3. Checking and Adjusting the Sync/Demodulator, Circuit Gain (CO MEAS) ......................................292
12.6.3.1. Checking the Sync/Demodulator Circuit Gain............................................................................292
12.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain...........................................................................293
12.6.4. Disk-On-Module Replacement...........................................................................................................294
12.7. Frequently Asked Questions ...................................................................................................................295
12.8. Technical Assistance...............................................................................................................................296
13. THEORY OF OPERATION.............................................................................................. 297
13.1. Measurement Method..............................................................................................................................297
13.1.1. Beer’s Law .........................................................................................................................................297
13.2. Measurement Fundamentals...................................................................................................................298
13.2.1. Gas Filter Correlation.........................................................................................................................299
13.2.1.1. The GFC Wheel..........................................................................................................................299
13.2.1.2. The Measure Reference Ratio ...................................................................................................300
13.2.1.3. Summary Interference Rejection................................................................................................303
13.3. Flow Rate Control....................................................................................................................................304
13.3.1.1. Critical Flow Orifice.....................................................................................................................305
13.3.2. Particulate Filter.................................................................................................................................306
13.3.3. Pneumatic Sensors............................................................................................................................306
13.3.3.1. Sample Pressure Sensor ...........................................................................................................306
13.3.3.2. Sample Flow Sensor ..................................................................................................................306
13.4. Electronic Operation................................................................................................................................306
13.4.1. CPU....................................................................................................................................................309
13.4.1.1. Disk-On-Module (DOM)..............................................................................................................309
13.4.1.2. Flash Chip ..................................................................................................................................309
13.4.2. Optical Bench & GFC Wheel .............................................................................................................310
13.4.2.1. Temperature Control ..................................................................................................................310
13.4.2.2. IR Source....................................................................................................................................310
13.4.2.3. GFC Wheel.................................................................................................................................310
13.4.2.4. IR Photo-Detector.......................................................................................................................312
13.4.3. Synchronous Demodulator (Sync/Demod) Assembly .......................................................................312
13.4.3.1. Signal Synchronization and Demodulation ................................................................................313
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13.4.3.2. Sync/Demod Status LEDs..........................................................................................................314
13.4.3.3. Photo-Detector Temperature Control.........................................................................................315
13.4.3.4. Dark Calibration Switch..............................................................................................................315
13.4.3.5. Electric Test Switch....................................................................................................................315
13.4.4. Relay Board .......................................................................................................................................315
13.4.4.1. Heater Control............................................................................................................................315
13.4.4.2. GFC Wheel Motor Control..........................................................................................................315
13.4.4.3. Zero/Span Valve Options ...........................................................................................................316
13.4.4.4. IR Source....................................................................................................................................316
13.4.4.5. Status LEDs................................................................................................................................317
13.4.4.6. I2C Watch Dog Circuitry.............................................................................................................317
13.4.5. MotherBoard ......................................................................................................................................318
13.4.5.1. A to D Conversion ......................................................................................................................318
13.4.5.2. Sensor Inputs .............................................................................................................................318
13.4.5.3. Thermistor Interface ...................................................................................................................319
13.4.5.4. Analog Outputs...........................................................................................................................319
13.4.5.5. Internal Digital I/O.......................................................................................................................319
13.4.5.6. External Digital I/O......................................................................................................................319
13.4.6. I2C Data Bus ......................................................................................................................................320
13.4.7. Power Supply/ Circuit Breaker...........................................................................................................320
13.4.8. Front Panel Touchscreen/Display Interface.......................................................................................322
13.4.8.1. LVDS Transmitter Board ............................................................................................................322
13.4.8.2. Front Panel Touchscreen/Display Interface PCA.......................................................................322
13.5. Software Operation..................................................................................................................................323
13.5.1. Adaptive Filter....................................................................................................................................323
13.5.2. Calibration - Slope and Offset............................................................................................................324
13.5.3. Measurement Algorithm.....................................................................................................................324
13.5.4. Temperature and Pressure Compensation........................................................................................324
13.5.5. Internal Data Acquisition System (DAS)............................................................................................324
14. A PRIMER ON ELECTRO-STATIC DISCHARGE .......................................................... 325
14.1. How Static Charges are Created.............................................................................................................325
14.2. How Electro-Static Charges Cause Damage ..........................................................................................326
14.3. Common Myths About ESD Damage......................................................................................................327
14.4. Basic Principles of Static Control.............................................................................................................328
14.4.1. General Rules....................................................................................................................................328
14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance...................................................329
14.4.2.1. Working at the Instrument Rack.................................................................................................329
14.4.2.2. Working at an Anti-ESD Work Bench.........................................................................................330
14.4.2.3. Transferring Components from Rack to Bench and Back..........................................................330
14.4.2.4. Opening Shipments from Teledyne API’s Customer Service ....................................................331
14.4.2.5. Packing Components for Return to Teledyne API’s Customer Service.....................................331
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
APPENDIX B - T300/T300M SPARE PARTS LIST
APPENDIX C - REPAIR QUESTIONNAIRE - T300
APPENDIX D - SCHEMATICS
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LIST OF FIGURES
Figure 3-1: Front Panel Layout.......................................................................................................................37
Figure 3-2: Display Screen and Touch Control..............................................................................................38
Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts .............................................................40
Figure 3-4: Rear Panel Layout .......................................................................................................................41
Figure 3-5: Internal Layout – T300.................................................................................................................43
Figure 3-6: Internal Layout – T300M..............................................................................................................44
Figure 3-7: Optical Bench Layout (shorter bench, T300M, shown) ...............................................................45
Figure 3-8: Analog In Connector ....................................................................................................................47
Figure 3-9: Analog Output Connector ............................................................................................................48
Figure 3-10: Current Loop Option Installed on Motherboard ...........................................................................49
Figure 3-11: Status Output Connector .............................................................................................................50
Figure 3-12: Control Input Connector...............................................................................................................52
Figure 3-13: Concentration Alarm Relay..........................................................................................................53
Figure 3-14: Rear Panel Connector Pin-Outs for RS-232 Mode......................................................................56
Figure 3-15: Default Pin Assignments for CPU COM Port connector (RS-232)..............................................57
Figure 3-16: Jumper and Cables for Multidrop Mode.......................................................................................59
Figure 3-17: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram.....................................................60
Figure 3-18: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas.....................................63
Figure 3-19: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator.............................63
Figure 3-20: T300/T300M Internal Gas Flow (Basic Configuration) ................................................................65
Figure 3-21: Pneumatic Connections – Option 50A: Zero/Span Calibration Valves........................................66
Figure 3-22: Internal Pneumatic Flow OPT 50A – Zero/Span Valves..............................................................67
Figure 3-23: Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves .....68
Figure 3-24: Internal Pneumatic Flow OPT 50B – Zero/Span/Shutoff Valves.................................................69
Figure 3-25: Pneumatic Connections – Zero Scrubber/Pressurized Span Calibration Valves (Opt 50E) .......70
Figure 3-26: Internal Pneumatic Flow OPT 50E – Zero Scrubber/Pressurized Span......................................71
Figure 3-27: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .......................................72
Figure 3-28: Internal Pneumatic Flow OPT 50H – Zero Scrubber/Ambient Span ...........................................74
Figure 3-29: Zero/Span Calibration Procedure ................................................................................................84
Figure 4-1: Front Panel Display......................................................................................................................89
Figure 4-2: Viewing T300/T300M Test Functions..........................................................................................91
Figure 4-3: Viewing and Clearing T300/T300M WARNING Messages .........................................................94
Figure 5-1: Analog Output Connector Pin Out ...............................................................................................99
Figure 5-2: COMM– Machine ID ..................................................................................................................113
Figure 5-3: Accessing the Analog I/O Configuration Submenus..................................................................121
Figure 5-4: Setup for Checking / Calibrating DCV Analog Output Signal Levels.........................................128
Figure 5-5: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter..................130
Figure 5-6: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ................132
Figure 5-7. DIAG – Analog Inputs (Option) Configuration Menu .................................................................136
Figure 6-1: COM1[2] – Communication Modes Setup .................................................................................145
Figure 6-2: COMM Port Baud Rate..............................................................................................................146
Figure 6-3: COMM – COM1 Test Port..........................................................................................................147
Figure 6-4: COMM – LAN / Internet Manual Configuration..........................................................................150
Figure 6-5 : COMM – LAN / Internet Automatic Configuration (DHCP)........................................................151
Figure 7-1: Default DAS Channel Setup ......................................................................................................171
Figure 7-2: APICOM Remote Control Program Interface.............................................................................186
Figure 7-3: APICOM User Interface for Configuring the DAS......................................................................187
Figure 7-4: DAS Configuration Through a Terminal Emulation Program.....................................................188
Figure 9-1: Pneumatic Connections – Basic Configuration – Using Bottled Span Gas...............................200
Figure 9-2: Pneumatic Connections – Basic Configuration – Using Gas Dilution Calibrator.......................200
Figure 9-3: Pneumatic Connections – Option 50A: Ambient Zero/Ambient Span Calibration Valves.........205
Figure 9-4: Pneumatic Connections – Option 50B: Ambient Zero/Pressurized Span Calibration Valves ...206
Figure 9-5: Pneumatic Connections – Option 50H: Zero/Span Calibration Valves .....................................206
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