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INSTRUCTION MANUAL

MODEL 200E

NITROGEN OXIDES ANALYZER

ADVANCED POLLUTION INSTRUMENTATION DIVISION

(T-API)

6565 NANCY RIDGE DRIVE

SAN DIEGO, CA 92121-2251

USA

Toll-free Phone: 800-324-5190

Phone: 858-657-9800

Fax: 858-657-9816

Email: api-sales@teledyne.com

Website: http://www.teledyne-api.com/

044100102

Rev. A

Main Page

Table of Contents4
List of Figures10
M200E Documentation16
Available Documentation16
Manual Structure16
How to Use this Instruction Manual18
Specifications, Approvals and Warranty20
M200E Operating Specifications20
Table 2-1: Model 200E Basic Unit Specifications20
EPA Equivalency Designation21
CE Mark Compliance22
Warranty22
Getting Started24
Unpacking and Initial Setup24
Figure 3-1: Location of Shipping Screws and Power Configuration Plug25
M200E Layout26
Figure 3-2: M200E Layout26
Figure 3-3: M200E Rear Panel Layout27
Figure 3-4: M200E Front Panel Layout27
Pneumatic Connections28
Table 3-1: Inlet / Outlet Connector Nomenclature28
Span Gas Defined29
Figure 3-5: Basic Pneumatic Connections for Units Without Valve Options29
Zero Gas Defined30
Figure 3-6: Basic Pneumatic Connections for Units with Valve Options31
Electrical Connections32
Power Connection32
Analog Output Connections32
Figure 3-7: Analog Output Connector32
Figure 3-8: Status Output Connector33
Table 3-2: Analog Output Pin-Outs33
Table 3-3: Status Output Signals33
Figure 3-9: Control Input Connector34
Table 3-4: Control Input Signals34
Ethernet Connection and Configuration35
Initial Operation35
Startup35
Warm-Up36
Warning Messages36
Figure 3-10: Front Panel Display During Startup Sequence36
Table 3-5: Front Panel Display During System Warm-Up36
Table 3-6: Possible Warning Messages at Start-Up37
Functional Check38
Figure 3-11: M200E Pneumatic Diagram in Standard Configuration39
Figure 3-12: M200E Pneumatic Diagram with Options Installed40
First Calibration41
Basic Calibration Procedure41
Interferences for no Measurements42
Frequently Asked Questions & Glossary44
Frequently Asked Questions44
Glossary45
Optional Hardware and Software48
External Pumps (Option 10)48
Rack Mount Kits (Options 20-23)48
Current Loop Analog Outputs (Option 41)48
Particulate Filter Kit (Option 42A)49
Calibration Valve Options49
Zero/Span Valves (Option 50)49
Figure 5-1: Current Loop Option Installed on the Motherboard49
Internal Zero/Span (IZS) (Option 51)50
Table 5-1: IZS or Z/S Valve States50
IZS Permeation Tubes (Options 53 & 55)51
Table 5-2: Available Permeation Source Options51
Scrubbers and Expendables52
Charcoal Scrubber (Option 64A)52
Charcoal Refill Kit (Part# 00596)52
Zero Air Scrubber (Option 64B)52
Zero Air Scrubber Maintenance Kit (Option 43)52
Table 5-3: Contents of Zero Air Scrubber Maintenance Kit52
M200E Expendables Kit (Option 42)53
M200E Spare Parts Kit (Option 43)53
Communication Options53
RS232 Modem Cables (Options 60 and 60A)53
Multidrop (Option 62)53
Ethernet (Option 63)53
Sample Gas Conditioners (Options 86 & 88)54
Figure 5-2: M200E Ethernet Card and Rear Panel with Ethernet Installed54
Table 5-4: Dryer and NH54
Manual on CD (Part Number 044100200)55
Extended Warranty (Options 92 & 93)55
Operating Instructions56
Overview of Operating Modes56
Table 6-1: Analyzer Operating Modes56
Sample Mode57
Test Functions57
Table 6-2: Test Functions Defined58
Warning Messages59
Calibration Functions59
Table 6-3: List of Warning Messages Revision C.459
Calibration Mode60
Setup Mode60
Password (PASS)60
Table 6-4: Password Levels60
Configuration Information (CFG)62
Clock (CLK)62
Setup - Range Configuration (RNGE)63
Figure 6-1: Analog Output Connector Key63
Physical and Analog Output Ranges64
Reporting Range Modes64
Single Range Mode (SNGL)65
Independent Range Mode (IND)65
Auto Range Mode (AUTO)67
Range Units67
Dilution Ratio68
Setup - Internal Variables (VARS)70
Table 6-5: Variable Names (VARS) Revision C.470
Setup - Diagnostics (DIAG)72
Table 6-6: M200E Diagnostic (DIAG) Functions72
Signal I/O73
Analog Output Step Test74
Analog I/O Configuration75
Table 6-7: DIAG - Analog I/O Functions75
Table 6-8: Analog Output Voltage Ranges75
Analog Output Signal Type and Range Selection76
Table 6-9: Analog Output Current Loop Range76
Table 6-10: Analog Output Pin Assignments76
Analog Output Calibration Mode77
Manual Analog Output Calibration79
Figure 6-2: Setup for Calibrating Analog Outputs79
Table 6-11: Voltage Tolerances for Analog Output Calibration79
Analog Output Offset Adjustment80
Current Loop Output Adjustment81
Figure 6-3: Setup for Calibrating Current Outputs82
AIN Calibration83
Test Channel Output83
Table 6-12: Current Loop Output Calibration with Resistor83
Table 6-13: Test Parameters Available for Analog Output A484
Optic Test85
Electrical Test85
Ozone Generator Override86
Flow Calibration87
Digital Inputs and Outputs87
Status Outputs87
Control Inputs88
Figure 6-4: Status Output Connector88
Table 6-14: Status Output Pin Assignments88
Setup - Communication Ports (COMM)89
Figure 6-5: Control Inputs with Local and External 5 V Power Supply89
Table 6-15: Control Input Pin Assignments89
Analyzer ID90
COM Port Default Settings90
COM Port Cable Connections91
COM2 Configuration91
DTE and DCE Communication92
COM Port Communication Modes92
Table 6-16: COM1 and COM2 DB-9 Pin Assignments92
Table 6-17: COM Port Communication Modes93
COM Port Baud Rate95
COM Port Testing95
Ethernet Port Configuration96
Table 6-18: Ethernet Status Indicators96
Hessen Mode Configuration99
Setup - Data Acquisition System (DAS)100
Table 6-19: Front Panel LED Status Indicators for Idas100
Idas Structure101
Idas Channels101
Idas Parameters102
Table 6-20: Idas Data Channel Properties102
Idas Triggering Events103
Table 6-21: Idas Data Parameter Functions103
Configuring the Idas104
Default M200E Idas Configuration104
Table 6-22: M200E Default Idas Configuration, Revision C.7105
Viewing Idas Data and Settings106
Editing Idas Data Channels107
Trigger Events108
Editing Idas Parameters109
Sample Period and Report Period110
Number of Records112
Report Function113
Compact Report114
Starting Date114
Disabling/Enabling Data Channels114
HOLDOFF Feature115
Remote Idas Configuration116
Figure 6-6: APICOM Graphical User Interface for Configuring the Idas116
Remote Operation of the Analyzer117
Basic Operation117
Terminal Operating Modes117
Figure 6-7: Idas Configuration through a Terminal Emulation Program117
Help Commands in Terminal Mode118
Command Syntax118
Table 6-23: Terminal Mode Software Commands118
Data Types119
Table 6-24: Command Types119
Status Reporting120
Remote Access by Modem120
COM Port Password Security121
APICOM Remote Control Program122
Figure 6-8: APICOM Remote Control Program Interface122
Additional Communications Documentation123
Table 6-25: Serial Interface Documents123
Calibration Procedures124
Calibration Preparations124
Required Equipment, Supplies, and Expendables124
Zero Air124
Span Gas Standards124
Permeation Tubes125
Calibration Gas Traceability125
Data Recording Devices125
Conversion Efficiency125
Figure 7-1: Gas Supply Setup for Determination of no126
Manual Calibration127
Connect Zero Air and Span Gases to the Analyzer128
Set Expected no and no128
Span Gas Concentrations128
Figure 7-2: Setup for Manual Calibration Without Z/S Valve or IZS Option128
Perform Zero/Span Calibration129
Calibration Checks130
Calibration with Zero/Span Valves130
Calibration with IZS Option132
Figure 7-3: Pneumatic Connections for Manual Calibration Checks with IZS132
Calibration Checks with IZS or Zero/Span Valves134
Figure 7-4: Setup for Manual Calibration Check with Z/S Valve or IZS Option134
Calibration with Independent or AUTO Ranges135
Calibration in AUTO Range Mode135
Independent Range Mode136
Calibration with Remote Contact Closures136
Automatic Calibration (Autocal)137
Table 7-2: Autocal Modes137
Table 7-3: Autocal Attribute Setup Parameters137
Table 7-4: Example Auto-Cal Sequence138
Calibration Quality Analysis139
Table 7-5: Calibration Data Quality Evaluation140
Epa Protocol Calibration142
Calibration of Equipment142
Table 8-1: Activity Matrix for EPA Calibration Equipment and Supplies143
Table 8-2: Activity Matrix for Calibration Procedure143
Gas Phase Titration (GPT)144
GPT Principle of Operation144
GPT Calibrator Check Procedure144
Example GPT Calculation146
Multipoint Calibration Procedure147
Zero Calibration148
Span Calibration148
Figure 8-1: GPT Calibration System148
Calibration149
Calibration Frequency150
Other Quality Assurance Procedures150
Table 8-3: Definition of Level 1 and Level 2 Zero and Span Checks151
Summary of Quality Assurance Checks152
Short Calibration Checks152
Table 8-4: Activity Matrix for Data Quality152
Zero/Span Check Procedures153
Precision Check153
Precision Check Procedure153
Certification of Working Standards153
Certification Procedures of Working Standards154
Other Methods of Establishing Traceability154
References154
Instrument Maintenance156
Maintenance Schedule156
Table 9-1: M200E Preventive Maintenance Schedule156
Predictive Diagnostics158
Maintenance Procedures158
Table 9-2: Predictive Uses for Test Functions158
Changing the Sample Particulate Filter159
Figure 9-1: Sample Particulate Filter Assembly159
Changing the O Dryer Particulate Filter160
Figure 9-2: Particle Filter on O Supply Air Dryer160
Changing the Ozone Filter Chemical161
Figure 9-3: 04419 Ozone Filter Unit161
Rebuilding the External Sample Pump162
Changing the Pump and IZS Dust Filters163
Changing the IZS Permeation Tube163
Changing the External Zero Air Scrubber164
Changing the no Converter165
Figure 9-4: Zero Air Scrubber Assembly165
Cleaning the Reaction Cell166
Figure 9-5: no 2 Converter Assembly166
Figure 9-6: Reaction Cell Assembly167
Cleaning or Changing Critical Flow Orifices168
Figure 9-7: Critical Flow Orifice Assembly168
Checking for Light Leaks169
Theory of Operation170
Measurement Principle170
Chemiluminescence170
Nox171
Figure 10-1: M200E Sensitivity Spectrum171
Chemiluminescence Detection172
The Photo Multiplier Tube172
Figure 10-2: no 2 Conversion Principle172
Optical Filter173
Auto Zero173
Figure 10-3: Reaction Cell with PMT Tube173
Measurement Interferences174
Direct Interference174
Third Body Quenching174
Figure 10-4: Reaction Cell During the Autozero Cycle174
Table 10-1: List of Interferents175
Light Leaks176
Pneumatic Operation176
Pump and Exhaust Manifold176
Sample Gas Flow177
Figure 10-5: External Pump Pack177
Sample Particulate Filter178
Table 10-2: M200E Valve Cycle Phases178
Ozone Gas Air Flow179
Figure 10-6: Ozone Generator Principle179
Perma Pure Dryer180
Figure 10-7: Semi-Permeable Membrane Drying Process180
Ozone Supply Air Filter181
Figure 10-8: M200E Perma Pure181
Ozone Scrubber182
Flow Rate Control - Critical Flow Orifices182
Figure 10-9: Location of Flow Control Assemblies183
Figure 10-10: Flow Control Assembly & Critical Flow Orifice183
Table 10-3: M200E Gas Flow Rates184
Pneumatic Sensors185
Sample Pressure Sensor185
Vacuum Pressure Sensor185
O 3 Supply Air Flow Sensor185
Electronic Operation186
Figure 10-11: M200E Electronic Block Diagram186
Cpu187
Figure 10-12: M200E CPU Board Annotated187
Disk on Chip188
Flash Chip188
Sensor Module, Reaction Cell & PMT188
Reaction Cell Heating Circuit188
Photo Multiplier Tube (PMT)189
PMT Cooling System189
Figure 10-13: Schematic of Basic PMT Design and Functionality189
TEC Control Board190
PMT Preamplifier190
Pneumatic Sensor Board191
Figure 10-14: PMT Preamp Block Diagram191
Relay Board192
Heater Control192
Valve Control192
Status Leds192
Motherboard193
A to D Conversion193
Sensor Inputs193
Thermistor Interface194
Analog Outputs194
External Digital I/O195
C Data Bus195
Power-Up Circuit195
Power Supply/ Circuit Breaker195
Communications Interface196
Figure 10-15: Power Distribution Block Diagram196
Front Panel197
Display197
Figure 10-16: M200E Electronic Interface Block Diagram197
Keypad198
Front Panel States Led's198
Display / Keyboard Interface Electronics198
Table 10-4: Front Panel Status Led's198
Software Operation199
Adaptive Filter199
Figure 10-17: Keyboard and Display Interface Block Diagram199
Calibration - Slope and Offset200
Figure 10-18: Schematic of Basic Software Operation200
Temperature/Pressure Compensation (TPC)201
Converter Efficiency Compensation202
Internal Data Acquisition System (Idas)202
Troubleshooting & Repair204
General Troubleshooting204
Warning Messages205
Fault Diagnosis with Test Functions205
Figure 11-1: Viewing and Clearing Warning Messages205
Using the Diagnostic Signal I/O Function206
Table 11-1: Test Functions - Possible Causes for Out-Of-Range Values206
Status Led's207
Motherboard Status Indicator (Watchdog)207
Figure 11-2: Switching Signal I/O Functions207
CPU Status Indicator208
Relay Board and Status Leds208
Figure 11-3: Motherboard Watchdog Status Indicator208
Figure 11-4: Relay Board PCA209
Gas Flow Problems210
Table 11-2: Relay Board Status Leds210
Zero or Low Flow Problems211
Sample Flow Is Zero or Low211
Ozone Flow Is Zero or Low212
High Flow213
Sample Flow Is Zero or Low but Analyzer Reports Correct Flow213
Calibration Problems213
Negative Concentrations213
No Response214
Unstable Zero and Span215
Inability to Span - no SPAN Key215
Inability to Zero - no ZERO Key216
Non-Linear Response216
Discrepancy between Analog Output and Display217
Other Performance Problems217
Discrepancy between no and no Slopes217
Excessive Noise218
Slow Response218
Auto-Zero Warnings218
Subsystem Checkout219
Simple Vacuum Leak and Pump Check219
Detailed Pressure Leak Check219
Performing a Sample Flow Check220
AC Power Configuration221
DC Power Supply221
Table 11-3: DC Power Test Point and Wiring Color Code221
C Bus222
Keyboard / Display Interface222
Table 11-4: DC Power Supply Acceptable Levels222
Relay Board223
Motherboard223
A/D Functions223
Analog Output Voltages223
Table 11-5: Relay Board Control Devices223
Status Outputs224
Control Inputs224
Table 11-6: Analog Output Test Function - Nominal Values224
Table 11-7: Status Outputs Check224
Cpu225
Communication225
General RS-232 Troubleshooting225
Modem or Terminal Operation226
PMT Sensor226
PMT Preamplifier Board226
High Voltage Power Supply227
Pneumatic Sensor Assembly227
Reaction Cell Pressure228
Sample Pressure228
Ozone Flow229
Converter229
Figure 11-5: Pressure / Flow Sensor Assembly229
Generator231
IZS Option231
Box Temperature231
PMT Temperature232
Repair Procedures232
Disk-On-Chip Replacement232
Flash Chip Replacement or Upgrade233
O 3 Generator Replacement233
Sample and Ozone Dryer Replacement234
PMT Sensor Hardware Calibration234
Figure 11-6: Pre-Amplifier Board Layout235
Replacing the PMT, HVPS or TEC236
Figure 11-7: M200E Sensor Assembly237
Technical Assistance238
Appendix A: Software Documentation240
Figure A-1: Basic Sample Display Menu241
Appendix241
Figure A-2: Sample Display Menu - Units with Z/S Valve or IZS Option Installed242
Figure A-3: Primary Setup Menu (Except Idas)243
Figure A-4: Secondary Setup Menu (COMM & VARS)244
Figure A-5: Secondary Setup Menu (DIAG)245
Figure A-6: Internal Data Acquisition (Idas) Menu246
Appendix247
Setup Variables for Serial I/O, Revision C.8247
APPENDIX A-2: Setup Variables for Serial I/O, Revision247
Warnings and Test Measurements, Revision C.8256
M200E Signal I/O Definitions, Revision C.8258
APPENDIX A-4: M200E Signal I/O Definitions, Revision258
APPENDIX A-5: M200E Trigger Events and Idas Functions, Revision261
Terminal Command Designators, Revision C.8263
APPENDIX A-6: Terminal Command Designators, Revision263
Appendix B: Spare Parts and Expendables266
Appendix C: Repair Questionnaire - M200E272
Appendix D: Diagrams and Schematics274

Teledyne 200E - Page 2

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