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Teledyne 400E User Manual

Teledyne 400E
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INSTRUCTION MANUAL
MODEL 400E
OZONE ANALYZER
© TELEDYNE INSTRUMENTS
ADVANCED POLLUTION INSTRUMENTATION
(T-API)
6565 NANCY RIDGE DRIVE
SAN DIEGO, CA 92121-2251
TOLL-FREE:
800-324-5190
TEL:
858-657-9800
FAX:
858-657-9816
E-MAIL:
api-sales@teledyne.com
WEB SITE:
www.teledyne-api.com
04316
REV. B
Copyright 2001 T-API Inc. Dec 2003

Table of Contents

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Teledyne 400E Specifications

General IconGeneral
BrandTeledyne
Model400E
CategoryMeasuring Instruments
LanguageEnglish

Summary

MODEL 400E OZONE ANALYZER

SAFETY MESSAGES

Safety Alert Symbols

Defines the meaning of safety alert symbols used in the manual and on the instrument.

General Caution

Highlights the importance of using the analyzer only as described in the manual.

M400E DOCUMENTATION

Using This Manual

Explains the manual's structure, including Table of Contents, Specifications, Getting Started, FAQ, and Operations.

SPECIFICATIONS, AGENCY APPROVALS, AND WARRANTY

Specifications

Details the analyzer's technical specifications, including range, noise, drift, and environmental conditions.

EPA Equivalency Designation

Information on the analyzer's designation as an Equivalent Method Number by the EPA.

Warranty

Covers the warranty policy, coverage, non-API equipment, and general terms and conditions.

GETTING STARTED

Unpacking and Initial Set Up

Instructions for unpacking the analyzer, verifying for damage, and initial setup.

Electrical Connections

Guide for connecting the analyzer to power, including voltage and ground requirements.

Pneumatic Connections

Details on connecting sample, span, zero air, and dry air lines to the analyzer.

Initial Operation

Steps for starting the analyzer, including boot-up sequence and basic display.

Start Up

Procedure for powering on the instrument and initial boot sequence.

Warm Up

Information on the required warm-up time for internal components.

Warning Messages

Explanation of common warning messages displayed during startup and warm-up.

Functional Check

Verifying analyzer operation and setup of hardware options after warm-up.

Initial Calibration Procedure

Steps for performing the first calibration of the analyzer.

Zero Air and Span Gas

Defines Zero Air and Span Gas and their sources for calibration.

Basic Calibration Procedure

Step-by-step guide for performing a basic manual calibration.

FREQUENTLY ASKED QUESTIONS

Instrument Zero/Span Issues

Troubleshooting common issues with zero and span key display and functionality.

RS-232 Interface and iDAS Usage

Guidance on making the RS-232 interface work and using the iDAS.

OPTIONAL HARDWARE AND SOFTWARE

Zero/Span Valves (Option 50)

Description of the Zero/Span Valve Option for controlling calibration gas flow.

Internal Zero/Span (IZS) (Option 51)

Details the Internal Zero/Span Option with an integrated generator.

Ethernet Option

Information on connecting the analyzer to a local area network via Ethernet.

OPERATING INSTRUCTIONS

Operating Modes

Overview of the analyzer's operating modes: SAMPLE, SETUP, DIAG.

Sample Mode

Describes the standard operating mode for analyzing O3 concentration.

Warning Message Display

Lists common warning messages, their meanings, and potential causes.

Test Functions

Details Test Functions for viewing instrument status and diagnosing problems.

Calibration Functions

Explains how to access and use the calibration modes (CALZ, CALS).

Set-Up Mode

Procedures for configuring hardware and software features of the analyzer.

Password Enable / Security Mode (PASS)

Explains password protection for calibration and setup functions.

Communications Menu (COMM)

Details on configuring the analyzer's serial communication ports (COM1, COM2).

Configuring the Internal Zero/Span Option (IZS)

Steps for configuring the performance parameters of the IZS O3 Generator.

Analog Outputs – Range Configuration

Guide to configuring the four analog output channels' signal types and ranges.

Measurement Range Modes

Describes Single, Dual, and Auto range modes for analog outputs.

Analog Outputs - Electronic Configuration

Steps for setting electronic signal types and ranges for analog output channels.

Analog Output Calibration Mode

Explains automatic and manual calibration methods for analog outputs.

Diagnostic Mode (DIAG)

Overview of diagnostic and configuration tools available in the DIAG menu.

Signal I/O Diagnostic Functions

Accessing and controlling digital and analog I/O signals for troubleshooting.

Analog Output (Step Test)

Test to verify analog output calibration and functionality.

Analog I/O Configuration

Details functions for configuring Analog I/O parameters.

Serial Interfaces

Information on the analyzer's two serial communication ports (COM-A, COM-B).

COM Port Default Settings

Default configuration settings for the COM ports.

COM Port Physical Connections

Instructions for physically connecting serial ports to computers or modems.

COM-B RS-232/485 Configuration

Configuring COM2 for RS-232 or RS-485 operation.

Setting the COM Port Communication Mode

Configuring the serial port's communication modes (e.g., QUIET, COMPUTER).

Setting the COM Port Baud Rate

Procedure for selecting the baud rate for COM ports.

Ethernet Configuration (Optional Hardware)

Steps for configuring the Ethernet interface for network connectivity.

Manually Configuring the Network IP Addresses

Procedure for manually setting network IP addresses, gateway, and subnet mask.

Changing the Analyzer’s HOSTNAME

Instructions for changing the analyzer's network identification name.

Operating the Analyzer from a Terminal or Computer

Methods for controlling the analyzer remotely via RS-232 ports.

Command Line Interface

Details the syntax and structure of commands for remote operation.

Asynchronous Status Reporting

Information on receiving status messages and audit trails via RS-232.

COM Port Password Security Feature

Enables password protection for remote access to COM ports.

The Internal Data Acquisition System (iDAS)

Overview of the iDAS for storing concentration and diagnostic data.

Editing the List of Data Channels

Procedure for editing, adding, or deleting data channels in the iDAS.

Default iDAS Channels

Description of the predefined data channels for logging O3 and diagnostic data.

Viewing Existing Data Channels

Steps to view logged data from the default iDAS channels.

CALIBRATION PROCEDURES

Before Calibration

General information required before performing analyzer calibration.

Required Equipment, Supplies, and Expendables

List of necessary equipment and supplies for calibration.

Zero Air and Span Gas

Details on obtaining and using Zero Air and Span Gas for calibration.

Manual Calibration & Calibration without Zero/Span Valve or IZS Options

Basic method for manual calibration without valve options.

Manual Calibration with Zero/Span Valve Option Installed

Procedure for manual calibration when Zero/Span Valve option is installed.

Manual Calibration Check with IZS or Zero/Span Valve Options Installed

Procedure for checking calibration with IZS or Zero/Span Valve options.

Automatic Zero/Span Cal/Check (AutoCal)

System for unattended periodic operation of ZERO/SPAN valve options.

EPA PROTOCOL CALIBRATION

M400E Calibration – General Guidelines

General principles for calibrating the M400A analyzer for accurate measurements.

Calibration Equipment, Supplies, and Expendables

List of essential equipment, supplies, and expendables for O3 measurement.

Recommended Standards for Establishing Traceability

Guidelines for verifying calibration gas standards against EPA/NIST traceability.

Calibration Frequency

Recommendations for frequency of Level 1 and Level 2 calibration checks.

Level 1 Calibrations versus Level 2 Checks

Distinguishes between Level 1 (official) and Level 2 (quick) calibration checks.

Multipoint Calibration

Procedures for multipoint calibration using UV photometry or transfer standards.

Multipoint Calibration Procedure

Steps for performing multipoint calibration including zero and span points.

Dynamic Multipoint Calibration Check

EPA-prescribed calibration based on photometric assays in a dynamic system.

Linearity Test

Procedure to check photometer linearity and accuracy.

Auditing Procedures

Methods for independent assessment of data accuracy and system quality.

Multipoint Calibration Audit

A performance audit challenging the analyzer with known O3 concentrations.

Data Processing Audit

Audit to verify data reduction accuracy and transcription processes.

Summary of Quality Assurance Checks

Overview of scheduled checks for verifying monitoring system operational status.

MAINTENANCE SCHEDULE & PROCEDURES

Maintenance Schedule

A typical schedule for preventative maintenance procedures.

Predicting Failures Using the Test Functions

Using Test Functions to predict potential failures by monitoring value changes.

Maintenance Procedures

Detailed procedures for performing periodic maintenance tasks.

Replacing the Sample Particulate Filter

Instructions for inspecting and replacing the sample particulate filter.

Rebuilding the Sample Pump

Procedure for replacing the sample pump diaphragm.

Performing Leak Checks

Procedures for performing vacuum and pressure leak checks.

Flow Calibration

Adjusting the analyzer's internal flow sensors to match an independent flow meter.

THEORY OF OPERATION

Measurement Method

Explains the Beer-Lambert equation principle for O3 concentration measurement.

Calculating O3 Concentration

Details the mathematical relationship for calculating O3 concentration using Beer's Law.

The Reference / Measurement Cycle

Describes the alternating measurement of O3 presence and absence.

Interferent Rejection

Explains how the analyzer rejects interference from other gases.

Pneumatic Operation

Overview of the analyzer's gas flow system and leak-tight requirements.

Electronic Operation

Block diagram and description of major electronic components.

CPU

Details the central processing unit and its storage capabilities.

Optical Bench

Describes the assembly that emits UV light and detects O3 presence.

Mother Board

Explains the functions of the motherboard, including A/D conversion and sensor inputs.

Interface

Describes the analyzer's communication methods with the outside world.

Front Panel

Details the components and information displayed on the analyzer's front panel.

Display

Explains the organization of information on the Vacuum Florescent Display.

Keypad

Describes the main method for user interaction with the analyzer.

Front Panel Status LED’s

Lists and defines the status indicators on the front panel.

Software Operation

Overview of the analyzer's internal software and its functions.

Adaptive Filter

Explains the software's adaptive filter for processing measurement data.

Calibration - Slope and Offset

Describes how slope and offset values are computed and stored.

Internal Data Acquisition System (iDAS)

Details the iDAS for storing historical trending and diagnostic data.

Editing the List of Data Channels

Procedure for editing, adding, or deleting data channels within the iDAS.

Default iDAS Channels

Description of predefined data channels for logging O3 and diagnostic data.

Viewing Existing Data Channels

Steps to view logged data from the default iDAS channels.

TROUBLESHOOTING & REPAIR PROCEDURES

General Troubleshooting Hints

Provides a systematic approach to diagnosing and repairing performance problems.

Interpreting Warning Messages

Guide to understanding warning messages and recommended corrective actions.

Fault Diagnosis With Test Functions

Using Test Functions to isolate and identify operational problems.

Gas Flow Problems

Troubleshooting common issues related to gas flow.

Calibration Problems

Addresses issues like mis-calibration and non-repeatable zero/span readings.

Temperature Problems

Troubleshooting issues related to UV Lamp, IZS Generator, and Box temperatures.

Subsystem Checkout

Methods to individually determine if a component or subsystem is causing a problem.

DC Power Supply

Procedure for verifying DC power supply voltages and noise levels.

Relay Board

Checking the relay board's status LEDs and output control.

Motherboard

Methods for checking the motherboard's A/D functions and analog outputs.

CPU

Troubleshooting procedures for CPU board failures.

RS-232 Communications

Troubleshooting common problems with RS-232 connections.

Repair Procedures

Procedures for repairing or replacing major analyzer components.

Replacing the IZS O3 Scrubber

Instructions for replacing the IZS Zero Air Scrubber.

APPENDIX A – Software Version-Specific Documentation

Model 400E Software Menu Trees

Diagrams illustrating the software menu structure for navigation.

Model 400E Setup Variables Available Via Serial I/O

List of setup variables configurable via serial interface.

Model 400E Signal I/O Definitions

Definitions for signal inputs, outputs, and control signals.

Model 400E iDAS Functions

Description of iDAS trigger events and data parameters.

APPENDIX B – M400E Spare Parts List

APPENDIX D – ELECTRONIC SCHEMATICS

Schematic for E Series Motherboard PCA #040690000

Detailed schematic of the motherboard PCA.

Interconnect List, M400E

List of cable connections and pin assignments between assemblies.

Schematic for PCA 03631, Isolated 0-20ma, E Series

Schematic for the isolated 0-20mA analog output board.

Schematic for PCA #04258 and PCB #04257, Keyboard/Display Interface for E series

Schematic for the keyboard and display interface circuitry.

PCA SCH, PRESS/FLOW

Schematic for the pressure and flow sensor PCA.

PCA, UV DETECTOR PREAMP

Schematic for the UV detector preamp circuitry.

SCH, UV LAMP DRIVER, M450

Schematic for the UV lamp driver module.

SCH, DC HEATER/THERMISTOR

Schematic for the DC heater and thermistor circuits.

Schematic for E Series Motherboard PCA #040690000

Detailed schematic of the motherboard PCA circuitry.

Schematic for E Series Motherboard PCA #040690000

Detailed schematic of the motherboard PCA circuitry.

Schematic for PCA 04420, UV Detector Preamp

Schematic for the UV detector preamp circuitry.

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