Teledyne 300E - Table 9-2: M300 E Test Function Record

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MAINTENANCE SCHEDULE & PROCEDURES Model 300E Carbon Monoxide Analyzer

Instruction Manual

P/N 04288 REV: A 147

Table 9–2: M300E Test Function Record

Date Recorded

Function

Operating

Mode*

STABILITY ZERO CAL

CO MEAS ZERO CAL

Zero CAL

MR RATIO

SPAN CAL

PRES SAMPLE

PHT DRIVE

SAMPLE

After

Warn-up

SLOPE SPAN CAL

OFFSET ZERO CAL

Main Page

Table of Contents3
M300E Documentation13
Using this Manual14
Specifications, Agency Approvals, and Warranty17
Specifications17
Table 2-1: Model 300E Specifications17
Epa Equivalency Designation18
Warranty19
Getting Started21
Unpacking and Initial Set up21
Figure 3-1: Removal of Shipping Screws22
Electrical Connections23
Pneumatic Connections27
Figure 3-2: Rear Panel Connectors27
Table 3-1: Inlet Outlet Nomenclature28
Figure 3-3: Basic Pneumatic Connections Flow Diagram29
Figure 3-4: Pneumatic Connections Flow Diagram W/ Valve Options30
Figure 3-5: Example Pneumatic Connections Flow Diagram through Gas Dilution31
Initial Operation32
Start up32
Warm up33
Warning Messages33
Functional Check34
Initial Calibration Procedure35
Figure 3-6: Assembly Layout39
Frequently Asked Questions41
Optional Hardware and Software43
Rack Mount Option43
Zero/Span/Shutoff Valve Options43
Zero/Span/Shutoff Valve Option 5044
Figure 5-1: Pneumatic Diagram - Zero/Span/Shutoff Valves & Internal Zero44
Zero/Span Valve Option 5145
Zero/Span Valve Option 5245
Figure 5-2: Pneumatic Diagram - Zero/Span/Shutoff Valves & Internal Zero with Zero45
Figure 5-3: Pneumatic Diagram - Zero/Span/ Valves & Internal Zero45
Zero/Span Valve Option 5346
Figure 5-4: Pneumatic Diagram - Zero/Span/ Valves & Internal Zero with Zero Air46
Table 5-1: Valve Option Operating States47
Current Loop Option48
Figure 5-5: Current Loop Option Installed48
Multidrop, RS-232 Option49
Ethernet Interface Option49
Dilution Ratio Option49
Operating Instructions51
Operating Modes51
Figure 6-1: Front Panel Display51
Sample Mode52
Table 6-1: Mode Field of the Display52
Warning Message Display53
Test Functions53
Table 6-2: Test Functions Defined54
Calibration Functions55
Set-Up Mode56
RNGE Menu56
Automatic Calibration (Autocal)56
Password Enable / Security Mode (PASS)56
Table 6-3: Password Levels57
Configuration Information (CFG)58
Time of Day Clock (CLK)59
Communications Menu (COMM)61
M300E Internal Variables61
Table 6-4: Variable Names (VARS)61
Analog Outputs - Range Configuration63
Physical Range Vs. Measurement Range63
A1 & A2 Measurement Range Modes64
A1 & A2 Single Range Mode65
A1 & A2 Dual Range Mode66
A1 & A2 Auto Range Mode68
Setting the Measurement Range Unit Type69
TEST Channel Output70
Using the Dilution Option71
Table 6-5: Test Functions Available to the TEST Analog Output Channel71
Analog Outputs - Electronic Configuration72
Table 6-6: Analog Output Voltage Range Min/Max73
Table 6-7: Analog Output Current Loop Min/Max73
Table 6-8: Analog Output Pin Assignments73
Voltage Output Range Selection and Offset Adjustment74
Figure 6-2: Analog Output Pin Assignments74
Current Loop Output Span and Offset Adjustment75
Figure 6-3: Setup for Checking Current Output Signal Levels75
Diagnostic Mode (Diag)77
Table 6-9: Current Loop Output Check77
Table 6-10: Diagnostic Mode (DIAG) Functions77
Signal I/O Diagnostic Functions79
Analog Output Step Test80
Analog I/O Configuration81
Table 6-11: DIAG - Analog I/O Functions81
Electric Test84
Dark Calibration Test85
Flow Calibration86
External Digital I/O86
Status Outputs86
Figure 6-4: Status Output Connector86
Control Inputs87
Table 6-12: Status Output Pin Assignments87
Figure 6-5: Control Inputs88
Table 6-13: Control Input Pin Assignments88
Serial Interfaces89
Serial I/O Default Settings89
Serial I/O Physical Connections90
COM-B RS-232/485 Configuration90
DTE Versus DCE Communication91
Table 6-14: COM-A and COM-B Default Pin Assignments91
Setting the Serial I/O Communication Mode92
Table 6-15: COMM Port Communication Modes92
Setting the Serial I/O Baud Rate94
Testing the Serial I/O95
Operating the Analyzer from a Terminal or Computer96
Table 6-16: Basic Terminal Mode Software Commands96
Obtaining Help97
Command Line Interface97
Table 6-17: Terminal Mode Help Commands97
Table 6-18: Serial I/O Command Designations97
Data Types98
Asynchronous Status Reporting99
Connecting the Analyzer to a Modem100
Serial Port Password Security Feature102
Apicom103
Serial I/O Reference Documents103
Table 6-19: Serial Interface Documents103
The Internal Data Acquisition System (Idas)104
When the Idas Is Operating104
Disabling the Idas105
Idas Record Structure105
Table 6-20: Idas Data Channel Properties106
Table 6-21: Idas Data Parameter Functions107
Default Idas Channels108
Figure 6-6: Default Idas Channels Setup109
Viewing Existing Data Channels110
Configuring the Idas111
Editing the List of Data Channels111
Editing the Data Channel Name112
Editing the Data Channel Trigger Event113
Adding or Deleting Data Parameters114
Configuring the Data Parameter Functions115
Editing the Data Channel Report Period116
Selecting the Data Channel Number of Records117
Turning the RS-232 Report Function On/Off118
Disabling/Enabling the Data Channel119
Turning the HOLDOFF Feature On/Off120
Maximum Number of Channels, Parameters, and Records121
Interface to the Idas121
Calibration Procedures123
Before Calibration123
Zero Air and Span Gas124
Table 7-1: NIST - Standard Reference Materials (SRM) for Carbon Monoxide124
Manual Calibration Without Zero/Span Valves125
Figure 7-1: Pneumatic Connections for Manual Calibration W/O Z/S Valves125
Manual Calibration with Zero/Span Valves128
Figure 7-2: Pneumatic Connections for Manual Calibration with Z/S Valves128
Zero/Span Calibration on Auto Range or Dual Ranges131
Use of Zero/Span Valves with Remote Contact Closure131
Automatic Zero/Span Cal/Check (Autocal)132
Table 7-2: AUTOCAL Modes132
Table 7-3: Autocal ATTRIBUTE Setup Parameters132
Epa Protocol Calibration137
M300E Calibration - General Guidelines137
Calibration Equipment, Supplies, and Expendables138
Level 1 Calibrations Versus Level 2 Checks138
Performing EPA Calibrations and Checks140
Precision Check141
Auditing Procedure141
Calibration Frequency142
Summary of Quality Assurance Checks143
Dynamic Multipoint Calibration Procedure143
References144
Maintenance Schedule & Procedures145
Maintenance Schedule145
Table 9-1: M300E Maintenance Schedule146
Table 9-2: M300E Test Function Record147
Predicting Failures Using the Test Functions148
Table 9-3: Predictive Uses for Test Functions148
Maintenance Procedures149
Replacing the Sample Particulate Filter149
Figure 9-1: Replacing the Particulate Filter149
Rebuilding the Sample Pump150
Performing Leak Checks150
Performing a Sample Flow Check152
Flow Calibration153
Cleaning the Optical Bench154
Cleaning Exterior Surfaces of the M300E154
Theory of Operation155
Measurement Method156
Beer's Law156
Measurement Fundamentals156
Gas Filter Correlation157
Figure 10-1: Measurement Fundamentals157
Figure 10-2: GFC Wheel157
Figure 10-3: Measurement Fundamentals with GFC Wheel158
Figure 10-4: Affect of CO in the Sample on CO MEAS & CO REF159
Figure 10-5: Effects of Interfering Gas on CO MEAS & CO REF160
Figure 10-6: Chopped IR Signal160
Pneumatic Operation161
Sample Gas Flow161
Figure 10-7: Model 300E Pneumatic Operation161
Critical Flow Orifice162
Sample Pressure Sensor162
Sample Flow Sensor163
Particulate Filter163
Valve Options163
Electronic Operation164
Overview164
Figure 10-8: 300E Electronic Block Diagram164
Cpu166
Optical Bench & GFC Wheel166
Figure 10-9: GFC Light Mask168
Figure 10-10: Segment Sensor and M/R Sensor Output168
Synchronous Demodulator (Sync/Demod) Assembly169
Figure 10-11: 300E Sync / Demod Block Diagram170
Figure 10-12: Sample & Hold Timing171
Relay Board173
Figure 10-13: Location of Relay Board Status Led's174
Table 10-1: Relay Board Status Led's174
Mother Board175
Power Supply/ Circuit Breaker178
Interface179
Figure 10-14: Power Distribution Block Diagram179
Figure 10-15: Interface Block Diagram180
Figure 10-16: Front Panel181
Software Operation182
Table 10-2: Front Panel Status Led's182
Adaptive Filter183
Figure 10-17: Basic Software Operation183
Calibration - Slope and Offset184
Measurement Algorithm184
Internal Data Acquisition System (Idas)185
Troubleshooting & Repair Procedures187
General Troubleshooting Hints187
Interpreting WARNING Messages188
Figure 11-1: Viewing and Clearing Warning Messages189
Table 11-1 Warning Messages189
Fault Diagnosis with TEST Functions191
Table 11-2: Test Functions - Indicated Failures192
Using the Diagnostic Signal I/O Function193
Figure 11-2: Example of Signal I/O Function194
Internal Electronic Status Led's195
Figure 11-3: CPU Status Indicator195
Figure 11-4: Sync/Demod Board Status LED Locations196
Table 11-3: Sync/Demod Board Status Failure Indications196
Figure 11-5: Relay Board Status Leds197
Gas Flow Problems199
Typical Flow Problems199
Calibration Problems201
Miss-Calibrated201
Non-Repeatable Zero and Span202
Inability to Span - no SPAN Key202
Inability to Zero - no ZERO Key203
Other Performance Problems203
Temperature Problems203
Excessive Noise205
Subsystem Checkout206
AC Mains Configuration206
DC Power Supply207
Table 11-4: DC Power Test Point and Wiring Color Codes207
Table 11-5: DC Power Supply Acceptable Levels207
I 2 C Bus208
Keyboard/Display Interface208
Relay Board208
Sensor Assembly209
Table 11-6: Relay Board Control Devices209
Table 11-7: Opto Pickup Board Nominal Output Frequencies210
Motherboard212
Table 11-8: Analog Output Test Function - Nominal Values Voltage Outputs212
Table 11-9: Analog Output Test Function - Nominal Values Current Outputs213
Cpu214
Table 11-10: Status Outputs Check214
Communications215
Repair Procedures216
Repairing Sample Flow Control Assembly217
Removing/Replacing the GFC Wheel218
Figure 11-6: Critical Flow Restrictor Assembly Disassembly218
Figure 11-7: Removing the GFC Sensor Heater Cover219
Figure 11-8: Removing the Opto-Pickup Assembly220
Figure 11-9: Removing the GFC Wheel Housing220
Disk-On-Chip Replacement Procedure221
Figure 11-10: Removing the GFC Wheel221

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