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T204 Nitrogen Oxides + 03 Analyzer

1. 175 9 2 6 Manual Calibration Checks with Valve Options 175 9 2 7 Manual Calibration Using Valve Options 176 07889A DCN6900 ix Table of Contents Teledyne API T204 Analyzer Manual 9 3 Automatic Zero Span Cal Check AutoCal sse eene nennen nnns 178 9 3 1 SETUP gt ACAL Programming and AUTO CAL 181 9 4 Calibration Quality Analysis iis bear er c ee EH dE eds 184 9 5 Gas Flow Calibration NO Only EE LEE EE AEEA EAE nnne 185 10 EPA PROTOCOL CALIBRATION nnns 187 10 1 References Relating to NO Monitoring nene 187 10 2 references relating to monitoring ssssessseseeeeeneene nennen menn enne nnne eis 188 PART III MAINTENANCE AND SERVICE eene memes 191 11 INSTRUMENT MAINTENANCE 193 11 1 Maintenance Schedule 2 5 rd e e RE Pon s a o DE RR ERR 193 13 2 Predictive DiagroStlCS os tes scape er ER EE eR TR ER YO EH trt ER ERR 195 13 3 Maintenance PFOCedUres ie PEE ERE Ez EUR TES EE Ihr tet ie Es 196 11 3 1 Replacing the Sample Particulate Filter 196 11 3 2 Changing the Generator Dryer Particulat
2. 159 8 2 Interactive Mode 5 n Ir ubt Ert degree I baee 160 8 2 1 Remote Control via a Terminal Emulation Program ssseeeenne 160 8 3 Remote Access by Modem esses ases nnne ea a nnne aa nns raten tnnt 162 8 4 Password Security for Serial Remote Communications sssssssseeeeene eee 165 9 CALIBRATION PROCEDURES nennen nnne nnns LOZ 9 1 Betore Galibration entro Pet ete ee oret re qe e ee Hte mer reed 167 9 1 1 Required Equipment Supplies and Expendables sss 167 9 1 2 Calibration Gases eicere tae EH EO RR P CA a e P EET Re 168 9 1 3 Data Recording Devices eni Re am e E EU aree rb c eee E He dE adt 169 9 1 4 NO Conversion Efficiency CE nennen nennen nnns 170 9 2 Manual Calibration Checks and Calibration of the T204 Analyzer in its Base Configuration 170 9 2 1 Setup for Basic Calibration Checks and Calibration of the T204 analyzer 171 9 2 2 Performing a Basic Manual Calibration Check 172 9 2 3 Performing a Basic Manual Calibration sss enne 173 9 2 4 Manual Calibration and Cal Checks with the Zero Span Valve Option Installed 175 9 2 5 Setup for Calibration Using Valve
3. sag 29 3 2 3 Internal Chassis Layouts 3 ie cie e co egets Pee te uo Se tee Re 31 3 3 Connectionis and Setup 1 nm Dee tola tet E aU RI oM t i 32 3 3 1 Electrical Connections cag edo pe ngo 32 3 3 2 Pneumatic Connections esses rnnt nennen aaa Eedi 46 3 4 Startup Functional Checks and Initial Calibration 58 3 4 1 Start eis p E 58 3 4 2 Functional Checks eredi toe nett tr rediit aereo s bn pereas Eds AE 60 3 4 3 Initial C allDratlon za e o tein eret eoe oni eaa deh o ep Eee Ed 61 3 4 3 1 lriterferents zen eo edere ue e E RR eed e e ded Anda ida Eddie ana 62 PART II OPERATING INSTRUCTIONS eren nnns OF 4 OVERVIEW OF OPERATING MODES 69 4 1 Sample MOode io o ee o e mte D lt aiia tonio 70 4 1 1 Test FUNCIONS 71 4 1 2 Warning Messages ede ido ripe bte bert bid 73 AD Calibration Mode rient bien eda dr ttti e odas br atur food eaae iode 74 AS SOUP A 75 4 3 1 Password Security ioes EE ed tm te Geb et e kia Lebe ie Gal ae a Mt 75 4 3 2 Primary Setup Menu npe tbe bites
4. 220 12 3 Using the Internal Electronic Status 220 12 3 1 CPU Status Indicator circiter dou tnde ed Dd dod ua ad 220 12 3 2 Relay PCA Status LEDS inet eee re tee dove nete dece ek he dede v ee d ida 220 12 4 Gas Flow Problems itii rine dna ke edd a pu daa cda 222 12 4 1 Zero or Low Flow Problems sse mener enne nnne 223 12 5 Calibration Problemis iei rii senda ceti ido keine diac inae edd a pu daa na 227 12 5 1 Negative nennen nennen ener nene 227 12 5 2 No RESPONSE 228 12 5 3 Unstable Zero and Span 229 12 5 4 Inability to Span No SPAN Button 229 12 5 5 Inability to Zero No ZERO Button 2 230 12 5 6 Non Linear ReSponse ridere hin e dd Re e odia ge edd a EE 230 12 5 7 Discrepancy Between Analog Output and Display 231 12 5 8 Discrepancy Between NO and NOx slopes 231 12 6 Other Performance Problems nce narn E a E 232 12 6 1 Excessive NOlsSQ
5. tie aim 302 13 6 2 PMT Cooling SyStem iere treten e eet epe e eee Eee e es 304 13 7 Pneumatic Sensor Board 305 13 8 Power Supply Circuit 306 13 8 1 AG Power ConflIgUratlOr eoe oci eec Ree ee esa RE DR Rr ERR RR een 307 13 9 Front Panel Touchscreen Display Interface ssssssssssseeeeeeneeen mener 311 13 9 1 LVDS Transmitter Board RH I e TERRE IRE EUH TH BARRE RT RR ae 312 13 9 2 Front Panel Touchscreen Display Interface PCA 312 13 10 Software Operation Ma sod uda o ee de ea sedeo te dava our na dd 312 13 10 1 Adaptive Filter iiic c adi et ee td Lodo cu Fa eL be d v ER e 313 13 10 2 Temperature Pressure Compensation TPC 313 13 10 3 Calibration Slope and Offset nennen ener 314 Index 315 APPENDIX A MENU 1 APPENDIX B SPARE PARTS LIST nnnm 1 APPENDIX C REPAIR QUESTIONNAIRE enne CL APPENDIX D ELECTRONIC nnns DL 07889A DCN6900 xi Table of Contents Teledyne API T204 Analyzer Manual FIGURES Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure
6. 94 5 8 SETUP gt VARS Variables Setup and Definition 95 5 9 SETUP gt Diag Diagnostics Functions eene nennen nennen enne nnns 96 5 9 1 Sigrial W O e ect re te Pat ete e deii bao tee aug 98 5 9 2 Analog Output DAG AOUT ied En de ee Ee E n t Cen 99 5 9 3 Analog I O Configuration DIAG AIO sssseeeeeeenm emm ener 99 5 9 4 Optic Test c om meet et ou imet mule Nt ae rad Cerere etim euis 114 5 9 5 Electrical Test Rer te e e t ecu be S gen i e He ads 114 5 9 6 Ozone Gen Override 114 5 9 7 Flow Calli Ration iiit t e cote tret 114 6 COMMUNICATIONS SETUP AND OPERATION 1 115 6 1 Data Terminal Communication Equipment DTE DCE sss eene nemen 115 6 2 Communication Modes Baud Rate and Port nnne nne 115 6 2 1 Commuriication MOdGS i iioc hatc bee e qe a RO EDO EA RO MR LECHE MARCI Mice Riu 116 6 2 2 Com Port Baud Rate bcne I e qo 118 6 2 3 Com Port Testlrigi icc ep abc eec pq a ROME ix SO Mb LEER M IR Mice Raine 118 6 3 DD 120 6 4 RS 4985 e beet ute 120 6 5 ECC ti deh ina
7. Only active when the optional internal span gas generator is installed Only active when the dual pressurized span option is installed Only active when one of the pressurized span gas options is installed Only active when one of the pressurized zero gas options is installed 296 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 4 4 2 WATCHDOG CIRCUITRY The most important of the status LED s on the relay board is the red bus watch dog LED It is controlled directly by analyzer s CPU over the bus Special circuitry on the relay PCA watches the status of D1 Should this LED ever stay ON or OFF for 30 seconds indicating that the CPU or I C bus has stopped functioning this Watchdog Circuit automatically shuts all valves and turns off all heaters 13 4 4 3 VALVE CONTROL The relay board also hosts two valve driver chips each of which can drive up to four valves The main valve assembly in the T204 is the NO NOx Auto zero solenoid valve component mounted right in front of the NO converter housing see Figure 11 4 e These two valves are actuated with 12 V supplied from the relay board and under the control of the CPU through the 2 bus Additional valve sets also controlled by the CPU via the bus and the relay PCA can be included in the T204 07889A DCN6900 297 Principles of Operation Teledyne API T204 Analyzer Manual
8. 13 4 4 4 HEATER CONTROL For a variety of reasons such as efficiency of certain chemical reactions stabilization of sample gas temperature and pressure etc various subcomponents of the T204 are heated cooled Two types of sensors are used to gather temperature data for the CPU THERMISTORS These are used in areas where the temperature control point is at or near ambient temperature e g the reaction cell temperature internal chassis temperate e Thermistors change resistance as they heat up and cool down A DC signal is sent from the Mother board of a sent voltage and current As the thermistor changes resistance the returning voltage rises and falls in direct relationship to the change in temperature e The output signal from the thermistors is received by the motherboard converted into digital data which is forwarded to the CPU THERMOCOUPLES These are used where the target temperature is high such as the NO NO converter e Thermocouples generate DC voltage that rises and falls as the thermocouple heats up and cools down e This DC signal interpreted conditioned and amplified by the Relay PCA then transmitted to the motherboard where it is also converted into digital data and forwarded to the CPU All of the heaters used in the T204 are AC powered which are turned ON OFF by AC Relays located on the relay PCA in response to commands issued by the CPU Reaction Cell Thermistor MOTHER BOARD The
9. CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU COMM VARS_ DIAG EXIT COMMUNICATIONS MENU ID COM1 COM2 COM1 MODE 0 lt SET SET gt EDIT COM1 INITIALIZE MODEM SET SET INIT INITIALIZING MODE MODEM INITIALIZED Test runs automatically PREV NEXT OFF EXIT If there is a problem initializing the modem the message MODEM NOT INITIALIZED will appear 164 07889A DCN6900 Teledyne API T204 Analyzer Manual Remote Operation 8 4 PASSWORD SECURITY FOR SERIAL REMOTE COMMUNICATIONS In order to provide security for remote access of the T204 a LOGON feature can be enabled to require a password before the instrument will accept commands This is done by turning on the SECURITY MODE refer to Section 5 5 Once the SECURITY MODE is enabled the following items apply A password is required before the port will respond or pass on commands If the port is inactive for one hour it will automatically logoff which can also be achieved with the LOGOFF command Three unsuccessful attempts to log on with an incorrect password will cause subsequent logins to be disabled for 1 hour even if the correct password is used If not logged on the only active command is the request for the help screen The following messages will be returned at logon LOGON SUCCESSFUL Correct password given LOGON FAILED Password not given or incorrect LOGOFF SUCCESSFUL Connection
10. Optional Dual Span Select Valve D12 Green Optional Pressurized Span Shutoff Valve D13 Green Optional Pressurized Zero Shutoff Valve c nal CE c3 D1 RED Watchdog Indicator Figure 13 15 Status LED Locations Relay PCA Table 13 3 Relay PCA Status LED s Status When Lit Status When Unlit LED Color Function Energized State Default State T Cycles ON OFF every 3 Seconds Red Watchdog Circuit under direct control of the analyzer s CPU D2 Yellow Reaction Cell Heater Heating Not Heating D3 Yellow NO gt NO Converter Heater Heating Not Heating D4 SPARE 1 Internal Span Gas Generator 7 05 Yellow Perm Tube Oven Heater Heating Not Heating D6 SPARE D7 Green Zero Span Valve Valve OPEN to span gas flow Valve OPEN to zero gas flow D8 Green Sample Cal Valve vane Valve OPEN to calibration gas flow sample gas flow Sample gas flow BYPASSES Sample gas flow is routed Auto Valve the reaction cell THROUGH the reaction cell Gas flow routed THROUGH Gas Flow BYPASSES DAQ NONO Valye NO2 gt NO converter NO2 gt NO converter D11 Green Bual Span Gas 10 ORAN Valve OPEN to SPAN inlet Select Valve gas inlet 3 Pressurized Span D12 Green Shutoff Valve Span gas flow SHUTOFF Span gas flow OPEN 4 Pressurized Zero D13 Green Shutoff Valve Zero gas flow SHUTOFF Zero gas flow OPEN 014 16 SPARE
11. olii edite siae 75 4 3 3 Secondary Setup Menu SETUP MORE sse 76 5 1 SETUP gt CFG Configuration Information eisern ena e eene eene nennen nennen nnns 77 5 2 SETUP gt ACAL Automatic Calibration 78 5 3 SETUP DAS Internal Data Acquisition System sss een eene 78 5 4 SETUP gt RNGE Analog Output Reporting Range Configuration sse 78 5 4 1 T204 Physical Ranges epe e er aE 78 5 4 2 T204 Analog Output Reporting Ranges sssssseeeeeenemeene eene 78 5 4 3 SEIUP gt RNGE 2 iMODE inem rere ette pe S eee P Te ERN 80 5 5 SETUP gt PASS Password Protection esses nennen ennemi ener nennen enn 88 5 6 SETUP gt CLK Setting the Internal Time of Day Clock ssseeen emen 91 5 6 1 Setting the Time Of Day ui enter dre ce e ette dig eq e o regents 91 5 6 2 Adjusting the Internal Clock s Speed sssssssssee enm emen 92 5 7 SETUP gt COMM Communications Ports asee a LEE EEE nene enne nennen nennen nnns 93 07889A DCN6900 viii Teledyne API T204 NO OS3 Analyzer Manual Table of Contents 5 7 1 ID Machine Identification E ENE inen 93 5 7 2 INET Etliernet scsi fete net eet ete HEC e e ete CE iid 94 5 7 3 COM1 COM2 Mode Baude Rate and Test Port
12. 216 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service WARNING FAULT CONDITION POSSIBLE CAUSES The CPU cannot communicate with the RELAY BOARD WARN Relay Board Bus failure Failed Relay Board Loose connectors wiring Sample flow rate is lt 350 cc min or gt SAMPLE FLOW WARN 600 cc min Failed Sample Pump Blocked Sample Inlet Gas Line Dirty Particulate Filter Leak downstream of RCELL Critical Flow Orifice Failed Sample Pressure Sensor Failed Vacuum Pressure Sensor SYSTEM RESET The computer has rebooted This message occurs at power on If itis confirmed that power has not been interrupted Failed 5 VDC power Fatal Error caused software to restart Loose connector wiring A failure of the analyzer s CPU motherboard or power supplies can result in any or ALL of the above messages Note 07889A DCN6900 217 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 1 2 FAULT DIAGNOSIS WITH TEST FUNCTIONS Note Note In addition to being useful as predictive diagnostic tools the test functions viewable from the analyzer s front panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzer s principles of operation see Section 13 The acceptable ranges for these test functions are listed in the Nominal Range col
13. 270 Pneumatic Flow During the Auto Zero Cycle enne 272 Vacuum Manifold Standard Configuration 275 Flow Control Assembly amp Critical Flow Orifice sseeeee mn 276 Location of Flow Control Assemblies amp Critical Flow Orifices 278 Ozone Generator Principle sess 280 Semi Permeable Membrane Drying Process essem enm ennemis 281 T204 Sample Gas Dryer uice eee det e ette ee D uda deere 282 T204 Electronic Block Diagram nennen nennen nnns 286 2 inet be OR deett in DO e eater eden 288 Relay PCA Layout P N 045230100 2222 emen nennen nennen nennen 294 Relay PCA P N 045230100 with AC Relay Retainer in Place 295 Status LED Locations Relay 296 Heater Control Loop Block Diagram ssesssseeeeenee nemen 298 Thermocouple Configuration Jumper JP5 300 T204 Sensor Module Assembly eese setenta nn tnnt tnmen nnns 301 Basic PMT BeSIUH irae ener alte T alten ibt be 302 PMT Prearip Block DIagram rte t ec 3
14. 4 7 e N Td m UE omc XS ee n soni EET mee lt aft 4 EPISC 3j ire AA 123456780 gauge A X ES DES As X NS CN G N J a Om MODEL 100 S N 51 o PS F RS232 RANGES STANDARD 4 2 c OPTIONS 50 47B f N FROM DRYER a OR Y y leica Wy EMM EMER MEME Y N O X X 3 N voir I EIL S N mm o ISI sos AC Power R5232 COM2 Model label with USB Port Connector DCE DTE COMM 1 port COMM 2 port Volt Freq Information option Switch RS232 only RS232orRS485 Caloshimlion Alarm Relay Figure 3 4 Rear Panel Layout Base Unit Table 3 2 provides a description of each component on the rear panel 07889A DCN6900 29 Getting Started Teledyne API T204 Analyzer Manual Table 3 2 Rear Panel Description Component Function cooling fan Pulls ambient air into chassis through side vents and exhausts through rear Connector for three prong cord to apply AC power to the analyzer CAUTION The cord s power specifications specs MUST comply with the power specs on the analyzer s rear panel Model number label AC power connector Model specs label Identifies the analyzer model number and provides power specs TO CONV not used FROM CONV not used
15. EXAMPLE This ENTER SETUP PASS 0 password enables the 8 ENTR EXIT SETUP mode The instrument still prompts for a password when entering the VARS and DIAG menus even if passwords are disabled but it displays the default password 818 upon entering these menus In this case the user only has to press ENTR to access the password protected menus Note In order to disable the PASSWORD feature after it has been turned ON the SETUP menu first requires a password once the password has been input and the ENTR button pressed the PRIMARY SETUP MENU appears and now the PASS menu can be accessed where pressing the ON button turns PASSWORD ENABLE back to OFF and pressing the ENTR button accepts the change Table 5 2 90 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 6 SETUP gt CLK SETTING THE INTERNAL TIME OF DAY CLOCK The T204 has an internal clock for setting the time and day it s speed can be adjusted to compensate for faster or slower CPU clocks Press SETUP gt CLK to access the clock 5 6 1 SETTING THE TIME OF DAY The time of day feature of the internal clock supports the DURATION step of the automatic calibration ACAL sequence feature has a built in clock for the AutoCal timer for the time TEST function and for time stamps on COM port messages and on DAS data entries To set the clock s time and date press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP C
16. Sra PREV NEXT NX10 Selects the data point to be viewed Cycles through parameters assigned to this DAS channel lt PRM PRM gt 1 Create edit the name of the channel I 1 EVENT i PARAMETERS NERA REPORT PERIOD NUMBER OF RECORD events Cycles through list of available trigger Cycl currently active parameters for this channel es through list of PREV NEXT Sets the time lapse between each 1 YES NO CAL MOD report Ez22222 2ez2cz2 ON PREV NEXT INS DEL EDIT PRNT OFF NO 1 oe a YES 1 1 MN Ato 2 1 YES NO i Sets the maximum number of records recorded by this channel lt SET SET gt EDIT PRNT PARAMETER SAMPLE MODE PRECISION 1 ACAL menu only appear if analyzer is equipped with Zero Span or IZS valve options Editing an existing DAS channel will erase any INST AVG MIN MAX data stored on the channel options Cycles through list of available amp currently active parameters for this channel PREV NEXT 3 Changing the event for an existing DAS channel rie iad DOES NOT erase the data stored on the channel Figure A 6 Internal Data Acquisition DAS Menu 07889A DCN6900 Teledyne T200 T204 and 200E Series 05295F DCN6900 APPENDIX A 2 Setup Variables APPENDIX A 2 Setup Variables Table A 1 Setup V
17. 5000 ppm NO gas to a final concentration of 500 ppb as this would operate at the very extreme dilution setting e 100 ppm NO gas in nitrogen is much more suitable to calibrate the T204 analyzer dilution ratio of 222 in the mid range of the system s capabilities 48 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started 3 3 2 2 BASIC CONNECTIONS FROM CALIBRATOR WITHOUT AND WITH SPAN GAS VENT here if input ENDE CAE ee e ence ee ee Pim E ae Removed during Q E is pressurized calibration T rn MODEL T700 EM Gas Dilution Calibrator w O3 E 2 Option 5 2 25 2 O O c LLI MODEL 701 Zero Gas T204 Generator T 0 E Chassis gt Figure 3 16 Gas Line Connections from Calibrator Basic T204 Configuration 07889A DCN6900 49 Getting Started Teledyne API T204 Analyzer Manual Source of E a OD VENT hEreIninput SAMPLE GAS is pressurized Removed during A calibration EU x l S 5 5 3 5 e MODEL 701 2 AOA Zero Gas BIO d Generator zi o 5 9 3 way Valve O e V E LL S uu m SAMPLE Control Valve EXHAUST T204 Chassis VENT 7 Figure 3 17 Gas Line Connections from Bottled Span Gas Basic T204 Configuration For basic configuration attach the following pneumatic lines SAMPLE GAS SOURCE Conn
18. Enter sign and number of seconds per day the clock gains or loses SETUP X X 8 CLOCK_ADJUST 0 Sec Day PREV NEXT JUMP EDIT ENTR EXIT EXIT discards the new r setting ENTR accepts the new setting J 92 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 7 SETUP gt COMM COMMUNICATIONS PORTS This section introduces the communications setup menu Section 6 provides the setup instructions and operation information Press SETUP gt MORE gt COMM to arrive at the communications menu SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X SECONDARY SETUP MENU COMM VARS DIAG COMMUNICATIONS MENU ID INET COM1 COM2 Figure 5 2 SETUP COMM Menu 5 7 1 ID MACHINE IDENTIFICATION In the SETUP gt MORE gt COMM menu press ID to display and or change the Machine ID which must be changed to a unique identifier number when more than one instrument of the same model is used e inan RS 232 multidrop configuration Sections 3 3 1 8 e onthe same Ethernet LAN Section 6 5 e when applying MODBUS protocol Section 6 7 1 e when applying Hessen protocol Section 6 7 2 The default ID is either 0 or the same as the model number 0204 Press any button s in the MACHINE ID menu Figure 5 3 until the Machine ID in the Parameter field
19. Teledyne API T204 Analyzer Manual Calibration Procedures Even though NO gas mixed into nitrogen gas N2 could be used as a span gas the matrix of the balance gas is different and may cause interference problems or yield incorrect calibrations e The same applies to gases that contain high concentrations of other compounds for example H20 The span gas should match all concentrations of all gases of the measured medium as closely as possible Cylinders of calibrated NO and NO gas traceable to NIST standards specifications also referred to as EPA protocol calibration gases or Standard Reference Materials are commercially available To measure with the T204 it is recommended that you use a span gas with concentration equal to 80 of the measurement range for your application O3 span gas can be generated using the Teledyne API s Model T700 calibrator with the photometer option 9 1 2 3 SPAN GAS FOR MULTIPOINT CALIBRATION NOx ONLY Some applications such as EPA monitoring require a multipoint calibration where span gases of different concentrations are needed We recommend using an NO gas of higher concentration combined with a gas dilution calibrator such as a Teledyne API s Model T700 For more information see Section 3 3 2 1 and Section 10 9 1 3 DATA RECORDING DEVICES A strip chart recorder data acquisition system or digital data acquisition system should be used to recor
20. U21 J1009 pins 1 12 bits 4 7 default I ST SYSTEM OK2 12 MB RELAY MB_RELAY_36 8 MB_RELAY_36 8 Ub ME CAL MODE ST CONC ALARM 1 ecd MB RELAY RELAY 3795 RELAY 3795 puru x SPAN CAL ST CONC ALARM 2 MB RELAY MB RELAY 38 MB RELAY 38 nee PROBE 1 3 ST HIGH RANGE2 Misc MN MB RELAY MB_RELAY_39 8 MB_RELAY_39 8 OUT PROBE 2 3 1 system OK 0 any alarm condition in dia Controlled by MODBUS coil regist 1 calibration mode 0 measure mode 1 conc limit 1 exceeded 0 conc OK Controlled by MODBUS coil regist 1 span calibration 0 zero calibration 1 conc limit 2 exceeded 0 conc OK Controlled by MODBUS coil regist select probe 1 1 not selected 1 high auto range in use mirrc ST HIGH RANGE status output 0 low auto range Controlled by MODBUS coil regist select probe 2 not selected A status outputs U24 J1017 pins 1 8 bits 0 7 default ST SPAN CAL ST DIAG MODE ST LOW SPAN CAL ST O2 CAL por 0 system OK any alarm condition conc valid conc filters contain no data high auto range in use low auto range in zero calibration not in zero in span calibration not in span in diagnostic mode not in diagnostic mode in low span calibration not in low span in O calibration mode in measure or other calibrati OF
21. 07889A DCN6900 211 Instrument Maintenance Teledyne API T204 Analyzer Manual 11 3 11 2 REPLACING THE UV LAMP Oy S6 mo 9 10 11 12 Disconnect power from the T204 Remove the top cover from the chassis Loosen the two UV lamp setscrews on the UV lamp housing Unplug the lamp power cord from the connector labeled P1 on the sensor module Loosen the four slotted captive screws attaching the sensor module to the chassis Carefully slide the lamp out of its housing The sensor module may need to be raised slightly to completely remove the lamp Install the new lamp seating it in the lamp housing until it stops Re attach the sensor module captive screws to the chassis Re tighten the two UV lamp setscrews Plug the lamp power cord into P1 on the sensor module Reconnect power to the instrument and turn on power switch Let instrument warm up for at least 20 minutes Perform UV lamp adjustment procedure in preceding section 11 3 11 3 REPLACING THE SENSOR VALVE 1 2 3 4 5 9 10 Disconnect power from the instrument Remove the chassis cover Locate sensor module assembly Figure 3 5 Unplug the two pin valve connector from the sensor PCA Figure 11 7 Remove the silver retainer clip from the top of the sensor valve A pair of pliers may be used to slide off the retainer clip The valve coil can now be removed by sliding upwards Remove the two 2 mounting screws us
22. 08156A DCN6900 Everywhereyoulook CUSTOMER PHONE CONTACT NAME FAX NO SITE ADDRESS MODEL SERIAL NO FIRMWARE REVISION 1 ARE THERE ANY FAILURE MESSAGES PLEASE COMPLETE THE FOLLOWING TABLE NOTE DEPENDING ON OPTIONS INSTALLED NOT ALL TEST PARAMETERS SHOWN BELOW WILL BE AVAILABLE IN YOUR INSTRUMENT F OPTION IS INSTALLED PARAMETER RECORDED VALUE ACCEPTABLE VALUE RANGE PPB PPM 50 PPB TO 20 PPM O3 S N N A READ PPB PPM 1 OF FULL SCALE RANGE WITH ZERO AIR O3 STAB PPB PPM lt 4 PPB WITH ZERO AIR SLOPE 1 03 0 15 03 OFFS PPB 20 PPB WITH ZERO AIR 03 RNG PPB 50 PPB TO 1000 PPB MEAS MV 250 to 1230 MV REF MV 250 to 1230 MV O3CEL PR PSIA 5 PSIA lt AMBIENT 147 PSIA O3SAMP TMP AMBIENT 5 O3LMP TMP 52 2 NOX STB PPB PPM lt 1 PPB WITH ZERO AIR SAMP FLW CM 500 50 O3GEN FL CM 80 15 PMT SIGNAL WITH ZERO MV 20 TO 150 AIR PMT SIGNAL AT SPAN GAS MV 0 5000MV CONC PPB 0 20 000 PPB NORM PMT SIGNAL AT MV 0 5000MV SPAN GAS CONC PPB 0 20000PPB AZERO MV 20 TO 150 HVPS V 400 900 RCELL TEMP 50 1 C BOX TEMP AMBIENT 5 C PMT TEMP 7 2 IZS 50 1 C MOLY TEMP 315 5 RCEL IN HG A lt 10 SAMP IN HG A I lt AMBIENT Teledyne API Technical Support EMAIL SDA_techsupport teledyne com PHONE 858 657 9800 TOLL FREE
23. 172 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Calibration Procedures 9 2 3 PERFORMING A BASIC MANUAL CALIBRATION The following section describes the basic method for manually calibrating the T204 If the analyzer s reporting range is set for the AUTO range mode a step will appear for selecting which range is to be calibrated LOW or HIGH Each of these two ranges MUST be calibrated separately 9 2 3 1 SETTING THE EXPECTED SPAN GAS CONCENTRATION The expected concentrations for both NOx and NO are usually set to the same value unless the conversion efficiency is not equal to 1 000 or not entered properly in the conversion efficiency setting Note When setting expected concentration values consider impurities in your span gas source e g NO often contains 1 3 and vice versa The span gas concentrations should be 80 of range of concentration values likely to be encountered in your application The default factory reporting range setting is 500 ppb and the default span gas concentration is 400 ppb To set the span gas concentration press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP SELECT CAL GAS To Calibrate press O3 SAMPLE RANGE TO CAL LOW l Only appears if the AUTO ENTR EXIT range mode is selected 7 Use these buttons to select the appropriate range Repeat entire procedure for M P CAL each range lt TST
24. APPENDIX 6 Terminal Command Designators Teledyne API T200 T204 and 200E Series 05295F DCN6900 APPENDIX A 6 Terminal Command Designators Table A 7 Terminal Command Designators Command Additional Command Syntax Description ID Display help screen and this list of commands LOGON ID password Establish connection to instrument LOGOFF ID Terminate connection to instrument SET ALL name hexmask Display test s LIST ALL name hexmask NAMES HEX Print test s to screen THD name Print single test CLEAR ALL name hexmask Disable test s SET ALL name hexmask Display warning s W ID LIST ALL name hexmask NAMES HEX Print warning s name Clear single warning CLEAR ALL name hexmask Clear warning s ZERO LOWSPAN SPAN 1 2 Enter calibration mode ASEQ number Execute automatic sequence C ID COMPUTE ZERO SPAN Compute new slope offset EXIT Exit calibration mode ABORT Abort calibration sequence LIST Print all I O signals name value Examine or set I O signal LIST NAMES Print names of all diagnostic tests ENTER name Execute diagnostic test EXIT Exit diagnostic test RESET DATA CONFIG exitcode Reset instrument D ID PRINT name SCRIPT Print DAS configuration RECORDS name Print number of DAS records REPORT name RECORDS number FROM lt start date gt TO lt end date
25. APPENDIX A 7 MODBUS Register Teledyne API T200 T204 and 200E Series 05295F DCN6900 MODBUS Register Description Address decimal 0 based 5 4 MODBUS Coil Registers single bit read write o to relay output signal 36 MB_RELAY_36 signal VO ls A 32 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version MODBUS Register Description Address decimal 0 based Triggers span calibration of NOx range 1 on enters cal off exits cal Triggers zero calibration of NOx range 2 on enters cal off exits cal Triggers span calibration of NOx range 2 on enters cal off exits cal Engineering firmware only Set DYN ZERO or DYN SPAN variables to ON to enable calculating new slope or offset Otherwise a calibration check is performed Triple range option Optional option CO option Concentration alarm option Low span option M200EUP All NOx references become NO for M200EU NO M200EU and M200EU NO External analog input option M200EU PHOTO option 32 bit integer value stored in high low word order i e not a floating point value 07889A DCN6900 A 33 APPENDIX A 7 MODBUS Register Map Teledyne API T200 T204 and 200E Series 05295F DCN6900 This page intentionally left blank A 34 07889A DCN6900 APP EN DIX B Spare Pa rts under
26. Outputs e 1 8 1 6 j 8 ORI TR 5 5 51 Optional gl Current al Loop Es N Outputs Touchscreen Display ao 0 2 Analog Outputs External Digital I O Circuit PC 104 CPU Card x Disk on AID Morera lt PC 104 Bus gt Module Converter x y Flash ane Chip Temperature CPU Status LED MOTHERBOARD Internal 2 Digital Bus Optical Test Control O3 Bench PCA X NO NOx Valve RELAY PCA PC Statu LED eo AutoZero Valve Gen Status K N Zero Span Reaction Cell DX Valve Optional ___ 2 1 NO to NO Converter Heater PMT Thermo NEM _ High Internal Span Gas PMT IAS Generator Perm Tube Power Oven Heater Supply vUL i Optional SENSOR MODULE internal Pump NO to NO Converter Thermocouple Sensor Figure 13 11 T204 Electronic Block Diagram 286 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation The core of the analyzer is a microcomputer central processing unit CPU that controls various internal processes interprets data makes calculations and reports results using specialized firmware developed by Teledyne API It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices via a separate printed circuit assembly ont
27. Report Period 000 01 00 No of Records 800 RS 232 Report OFF Channel Enabled ON Cal Hold OFF ON Name CALDAT Event SLPCHG lt Parameters 9 Report Period N A No of Records 200 RS 232 Report OFF Channel Enabled ON Cal Hold OFF OFF Name CALCHECK Event EXITMP Parameters 4 Report Period N A No of Records 200 RS 232 Report OFF Channel Enabled ON Cal Hold OFF OFF Name DIAG Event ATIMER Parameters 12 Report Period 001 00 00 No of Records 1100 RS 232 Report OFF Channel Enabled ON Cal Hold OFF OFF Name HIRES Event ATIMER Parameters 18 Report Period 000 00 01 No of Records 1500 RS 232 Report OFF Channel Enabled OFF Cal Hold OFF OFF Figure 7 1 PARAMETER NOXCNC1 PRECISION STORE NUM SAMPLES NOCNC1 NO2CNC1 O3CONC SL E STABIL AVG AVG 4 NOXZSC1 NOXSLP1 AVG AVG NOXOFS1 NOZSC1 NOSLP1 AVG AVG NOOFS1 AVG NO2ZSC1 AVG AVG N CNVEF1 f STABIL NOXCNC1 NOCNC1 AVG NO2CNC1 STABIL AVG 4 AVG SMPFLW O3FLOW RCPRES AVG 2 AVG 2 AVG SMPPRS RCTEMP 2 AVG 2 2 PMTTMP CNVTMP BOXTMP O3TEMP O3LAMP 2 2 AZERO HVPS NOXCNC1 2 2 AVG VG VG VG VG VG VG VG A A A A A A A NOCNC1 NO2CNC1 STABIL SMPFLW O3FLOW RCPRES SMPPRS RCTEMP PMTTMP CNVTMP MFTEMP BOXTMP O3TEMP
28. To initiate the test press the following button sequence SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID INET COM1 COM2 COM1 MODE 0 lt SET SET gt EDIT O Continue pressing lt SET or SET gt until COM1 TEST PORT lt SET SET gt TEST Test runs TRANSMITTING TO COM1 automatically COM1 TEST PORT PREV NEXT OFF Figure 6 3 COMM COM Test Port 07889A DCN6900 119 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 3 6 4 RS 232 The RS232 and COM2 communications COMM ports operate on the RS 232 protocol default configuration Possible configurations for these two COMM ports are summarized as follows e RS232 port can also be configured to operate in single or RS 232 Multidrop mode Option 62 refer to Section 3 3 1 8 e COM2 port can be left in its default configuration for standard RS 232 operation including multidrop or it can be reconfigured for half duplex RS 485 operation please contact the factory for this configuration Note that when the rear panel COM2 port is in use except for multidrop communication the rear panel USB port cannot be used Alternatively when the USB port is enabled COMZ port cannot be used except for mult
29. Toggle buttons to set DURATION 15 0MINUTES duration for each iteration of the sequence Set in Decimal minutes 0 ENTR EXIT from 0 1 60 0 SETUP DURATION 30 0 MINUTES SET SET EDIT EXIT SETUP CALIBRATE OFF SET SET EDIT EXIT SETUP CALIBRATE OFF Toggle button ENTR EXIT ion bu and amp ON SETUP X X CALIBRATE ON lt SET SET gt EDIT EXIT Display show SEQ 2 ZERO SPAN 2 00 30 SETUP SEQ 2 ZERO SPAN 2 00 30 EXIT returns Sequence Delta Time to the SETUP MORES ee PREV NEXT MODE SET EXIT 1 Menu Note If at any time an unallowable entry is selected Example Delta Days 367 the ENTR button will disappear from the display 07889A DCN6900 183 Calibration Procedures Teledyne API T204 Analyzer Manual CALIBRATION QUALITY ANALYSIS After completing one of the calibration procedures described above it is important to evaluate the analyzer s calibration SLOPE and OFFSET parameters These values describe the linear response curve of the analyzer separately for NO NOx The values for these terms both individually and relative to each other indicate the quality of the calibration To perform this quality evaluation you will need to record the values of the following test functions see Section 4 1 1 all of which are automatically stored in the DAS channel CALDAT for data analysis documentation
30. VERBOSE COMPACT HEX Print DAS Print DAS records records date format MM DD YYYY or YY HH MM SS CANCEL Halt printing DAS records LIST Print setup variables name value warn low warn high Modify variable V ID name value Modify enumerated variable CONFIG Print instrument configuration MAINT ON OFF Enter exit maintenance mode MODE Print current instrument mode B cer data channel definitions Upload DAS configuration CHANNELBEGIN propertylist CHANNELEND Upload single DAS channel CHANNELDELETE name Delete DAS channels A 26 07889A DCN6900 Teledyne T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version K3 The command syntax follows the command type separated by a space character Strings in brackets are optional designators The following key assignments also apply Terminal Key Assignments ESC Abort line CR ENTER Execute command Ctrl C Switch to computer mode Computer Mode Key Assignments LF line feed Execute command Ctrl T Switch to terminal mode 07889A DCN6900 A 27 Teledyne 200 T204 and 200E Series 05295F DCN6900 APPENDIX A 7 MODBUS Register Map APPENDIX 7 MODBUS Register Map MODBUS Register Description Address decimal 0 based MODBUS Floating Point Input Registers 32 bit IEEE 754 format read in high word low word order read only NOx concentrati
31. While these are the default setting for the T204 analyzer it is recommended that you verify them before proceeding with the calibration procedure by pressing the following menu button sequence 62 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started Verify that the MODE is set for SNGL If it is not press SINGL gt ENTR Verify that the RANGE is set for 500 0 If it is not toggle each numeric key until the proper range is set then press ENTR 7 Verify that the UNIT is set for PPB If it is not press PPB gt ENTR SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X RANGE CONTROL MENU MODE SET UNIT DIL SETUP X X RANGE MODE SINGL SNGL IND AUTO ENTR EXIT SETUP X X RANGE CONTROL MENU MODE SET UNIT DIL SETUP X X RANGE 500 0 Conc 0 0 5 0 0 0 ENTR EXIT SETUP X X RANGE CONTROL MENU Press EXIT until return to MODE SET UNIT DIL EXIT SAMPLE mode SETUP X X CONC UNITS PPB PPB PPM UGM MGM ENTR 07889A DCN6900 63 Getting Started Teledyne API T204 Analyzer Manual VERIFYING THE EXPECTED NOx NO AND O3SPAN GAS CONCENTRATION IMPACT ON READINGS OR DATA Verify the PRECISE Concentration Value of the SPAN gases independently IMPORTANT If you supply NO gas to the analyzer the values for expected NO and The NO and NO span co
32. on DIAG AUTO CALIBRATING CONC OUT 4 If any of the channels have not DIAG AIO AOUTS CALIBRATED NO been calibrated or if at least one channel has AUTO CAL turned SET gt CAL OFF this message will read NO 07889A DCN6900 103 Setup Menu Teledyne API T204 Analyzer Manual 5 9 3 5 AUTOMATIC INDIVIDUAL CALIBRATION OF THE ANALOG OUTPUTS To use the AUTO CAL feature to initiate an automatic calibration for an individual analog output select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED NO SET gt CAL DIAG AIO CONC OUT 2 5V CONC2 NOCAL SET SET EDIT EXIT DIAG AIO CONC OUT 2 RANGE 5V SET EDIT Continue pressing SET until DIAG AIO CONC OUT 2 CALIBRATED NO SET SET CAL EXIT DIAG AIO AUTO CALIBRATING CONC OUT 2 DIAG AIO CONC OUT 2 CALIBRATED YES SET SET CAL EXIT 104 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 9 3 6 MANUAL CALIBRATION OF THE ANALOG OUTPUTS CONFIGURED FOR VOLTAGE RANGES For highest accuracy the voltages of the analog outputs can be manually calibrated Note Calibration is performed with a voltmeter connected across the output terminals and by changing the actual output signal level using the front panel buttons in 100 10 or 1 count increments See Figure 3 7 for pin assi
33. rain di aer e CR EI e 10 Turn off the instrument power and reconnect the PMT and then reassemble the sensor e f any faults are found in the test you must obtain new HVPS as there are no user serviceable parts inside the supply 12 7 14 PMT TEMPERATURE CONTROL The TEC control PCA is located on the sensor housing assembly under the slanted shroud next to the cooling fins and directly above the cooling fan If the red LED located on the top edge of this assembly is not glowing the control circuit is not receiving power Check the analyzers power supply the relay board s power distribution circuitry and the wiring connecting them to the PMT temperature control PCA TEC Control Test Points Four test points are also located at the top of this assembly they are numbered left to right start with the 1 point immediately to the right of the power status LED These test points provide information regarding the functioning of the control circuit e Todetermine the current running through the control circuit measure the voltage between T1 and T2 Multiply that voltage by 10 e To determine the drive voltage being supplied by the control circuit to the TEC measure the voltage between T2 and T3 e If this voltage is zero the TEC circuitry is most likely open Or e If the voltage between T2 and 0 VDC and the voltage measured between T1 and T2 0 VDC there is most likely an o
34. 0 114132 0 050724 For Help press F1 Example MODBUS Poll window Port 4 115200 8 N 1 07889A DCN6900 129 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 7 2 HESSEN 6 7 2 1 Note 6 7 2 2 The Hessen protocol is a multidrop protocol in which several remote instruments are connected via a common communications channel to a host computer The remote instruments are regarded as slaves of the host computer The remote instruments are unaware that they are connected to a multidrop bus and never initiate Hessen protocol messages They only respond to commands from the host computer and only when they receive a command containing their own unique ID number The Hessen protocol is designed to accomplish two things to obtain the status of remote instruments including the concentrations of all the gases measured and to place remote instruments into zero or span calibration or measure mode Teledyne API s implementation supports both of these principal features The Hessen protocol is not well defined therefore while Teledyne API s application is completely compatible with the protocol itself it may be different from implementations by other companies HESSEN COMM PORT CONFIGURATION Hessen protocol requires the communication parameters of the T204 s COMM ports to be set differently than the standard configuration as shown in the table below Table 6 4 RS 232 Co
35. 3 Check if the particle filter is clogged e Briefly remove the particle filter to see if this improves the flow e Bevery cautious when handling the sample gas dryer fittings see Section 11 3 2 on proper handling instructions e If the filter is clogged replace it with a new unit e f taking off this filter does not solve the problem continue to the next step e Donotleave the sample gas dryer without filter for more than a few seconds as you may draw in dust which will reduce the performance of the dryer 4 Aleak between the flow meter and the reaction cell where the flow determining critical orifice is located may cause a low flow the system draws in ambient air through a leak after the flow meter e Check for leaks as described in Section 11 3 10 e Repair the leaking fitting line or valve and re check 224 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 5 The most likely cause for zero or low ozone flow is a clogged critical flow orifice or sintered filter within the orifice assembly e The orifice that sets the ozone flow is located on the reaction cell e Check the actual ozone flow by disconnecting the tube from the reaction cell and measuring the flow going into the cell e If this flow is correct 80 cm min the orifice works properly e If this flow is low replace the sintered filter e The orifice holder assembly allows a quick and easy replacement of th
36. 32 49 52 169 170 173 182 Calibration Mode 76 CALS BUTTON 76 177 266 CALZ Button 76 177 CANNOT DYN SPAN 61 75 139 CANNOT DYN ZERO 61 75 139 chemiluminescence 19 64 234 269 270 272 273 278 279 289 302 Chemiluminescence 270 271 278 279 303 Circuit Breaker 308 CLOCK ADJ 94 97 CO2 50 64 171 COMM PORT Default Settings 44 COMM Ports 118 and DAS System 155 Baud Rate 120 45 134 COM2 45 118 134 Communication Modes 118 119 Machine ID 47 Parity 118 132 Testing 120 CONC 142 CONC Button 97 240 266 CONC PRECISION 97 Concentration Field 29 CONFIG INITIALIZED 61 75 Continuous Emission Monitoring CEM 89 Control Buttons Definition Field 29 Control Inputs 39 180 240 267 294 SPAN CAL 1 240 ZERO CAL 240 CONV TEMP WARNING 61 75 139 07889A DCN6900 315 INDEX Teledyne API T204 Analyzer Manual CPU 43 44 62 75 94 101 114 216 219 220 222 235 242 243 289 290 291 294 295 296 298 309 314 Analog to Digital Converter 61 75 101 239 291 294 STATUS LED S 222 Critical Flow Orifices 209 278 279 280 CriticalflowOrifices 281 CriticalFlowOrifices 267 279 Current Loop Outputs 35 37 81 109 111 Converting from Voltage Output 37 Manual Calibration 109 D DAS System 29 61 71 74 75 77 93 218 and APICOM 158 160 and Terminal Emulation Programs 160 Channel Names 147 Channels 142 144 CALCHEK
37. Connector for AC Relays K4 amp K5 Figure 13 13 Relay PCA Layout P N 045230100 CAUTION ELECTRICAL SHOCK HAZARD Only those relays actually required by the configuration of the T204 are populated A protective retainer plate is installed over the ac power relay to keep them securely seated in their sockets and prevent accidental contact with those sockets that are not populated see Figure 13 14 Never remove this retainer while the instrument is plugged in and turned on The contacts of the AC relay sockets beneath the shield carry high AC voltages even when no relays are present 294 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation Retainer Mounting Screws AC Relay Retainer Plate Figure 13 14 Relay PCA P N 045230100 with AC Relay Retainer in Place 13 4 4 1 STATUS LED S Sixteen LED s are located on the analyzer s relay PCA some are designated spare and are not used to show the current status on the various control functions performed by the relay PCA see Figure 13 15 The LED s are described in Table 13 3 07889A DCN6900 295 Principles of Operation Teledyne API T204 Analyzer Manual D10 Green NO NO Valve D9 Green AutoZero Valve D8 Green Optional Sample Cal Valve D7 Green Optional Zero Span Valve D3 Yellow NO NO Converter Heater D2 Yellow Reaction Cell Heater 7 D11 Green
38. MULTI not used TO DRYER not used FROM DRYER not used Connect a gas line from the source of sample gas here SAMPLE Calibration gases can also enter here on units without zero span shutoff valve options installed Connect an exhaust gas line of not more than 10 meters long here that leads outside the EXHAUST shelter or immediate area surrounding the instrument The line must be tubing or greater SPAN 1 On units with zero span valve option installed connect a gas line to the source of calibrated span gas here SPAN2 VENT not used ZERO AIR with zero span valve option installed attach a gas line to the source of zero air RX TX LEDs indicate receive RX and transmit TX activity on the when blinking COM 2 Serial communications port for RS 232 or RS 485 RS 232 Serial communications port for RS 232 only Switch to select either data terminal equipment or data communication equipment during DCE DTE din RS 232 communication STATUS For outputs to devices such as Programmable Logic Controllers PLCs ANALOG OUT For voltage or current loop outputs to a strip chart recorder and or a data logger CONTROL IN For remotely activating the zero and span calibration modes ALARM Option for concentration alarms and system warnings ETHERNET Connector for network or Internet remote communication using Ethernet cable ANALOG IN
39. Option for external voltage signals from other instrumentation and for logging these signals USB Connector for direct connection to laptop computer using USB cable Model Label Includes voltage and frequency specifications 30 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started 3 2 3 INTERNAL CHASSIS LAYOUT Motherboard DOM with Fan Assy ay bed O Power Entry CPU PCA Vacuum Ozone manifold Dryer Assy Sample Dryer 5V Power Supply Pressure Flow Sensor 12V Power Supply TEC Assy Molycon w TEC Driver PCA Cooler mm Sensor Assy Reaction Cell Assy Sample Filter Interface PCA Figure 3 5 Internal Chassis Configuration O3 Destruct AutoZero Valve NO NOx Valve O3 Sensor Assy UV Lamp Assy O3 Cleanser O3 Generator ON OFF Switch Touchscreen Control Module 07889A DCN6900 31 Getting Started Teledyne API T204 Analyzer Manual 3 3 CONNECTIONS AND SETUP This section presents the electrical Section 3 3 1 and pneumatic Section 3 3 2 connections for setup and preparing for instrument operation 3 3 1 ELECTRICAL CONNECTIONS This section presents the electrical connections for AC power and communications Mote length be no greater than 3 meters for all I O connections which include Analog In Analog Out Status Out Control In Etherne
40. PNEUMATIC LAYOUT FOR AMBIENT ZERO AMBIENT SPAN VALVES OPT 50A INSTRUMENT CHASSIS Measurement Cell MEASURE REFERENCE SAMPLE GAS INLET 5 REFERENCE CYCLE GAS PATH Particulate Filter O Destruct SPAN GAS INLET MEASURE CYCLE GAS PATH ZERO GAS INLET sorption Tube ZERO SPAN VALVE GAS PRESSURE SENSOR 2 NO NOx VALVE pM i FLOW PRESSURE Ar b e SENSORPCA SAMPLE VACUUM gt i PRESSURE PRESSURE SENSOR SENSOR f C FLOW EXHAUST Converter SENSOR GAS OUTLET AUTOZERO A 4 VALVE a CX N CNON Cleanser Flow 80 Orifice Dia 0 004 Flow 500 Orifice Dia 0 010 GENERATOR Flow 500 Orifice Dia 0 010 EXHAUST MANIFOLD Destruct Flow 80 cn min Orifice Dia Figure 3 21 Pneumatics with Zero Span Valves OPT 50A 56 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started Table 3 7 Zero Span Valves Operating States OPT 50A VALVE PORT VALVE CONDITION STATUS SAMPLE No COM NC COM ZERO CAL No COM NC COM SPAN CAL COM 07889 6900 57 Getting Started Teledyne API T204 Analyzer Manual 3 4 STARTUP FUNCTIO
41. Port Cooling Exhaust COMM port Status Analog Digital Control Ethernet Analog Inputs Fan Port LEDs Outputs Outputs Inputs Port Option pum m X X 1 lil T N TI 1 3 So S 3 Jo 1 PN 070110000 YEAR 2010 o E PWR 100 120 V 60Hz 3 0A RANGES STANDARD OPTIONS 50A 47B o oii E CS N ALL A EET LY m S tk E 7 VU j A V AN if AC Power Span 1 Zero Air RS232 COM2 Model label with USB Port Connector port port COMM 1 port COMM 2 port 1 Volt Freq Information RS232 only RS232 or RS485 DCE DTE Concentration Switch Alarm Relay Figure 3 19 Rear Panel Layout with Z S Valve Options OPT 50 07889A DCN6900 53 Getting Started Teledyne API T204 Analyzer Manual VENT here if input Source of is pressurized SAMPLE Gas 2019 MODEL 700 E Gas Dilution gt Calibrator em SAMPLE 55 EXHAUST z 2 BE I sPAN1 o EO em a Ic a azs MODEL 701 ZERO AIR Zero Gas ill Generator Figure 3 20 Gas Line Connections for T204 with Z S Valves Option 50 SAMPLE GAS SOURCE Attach a sample inlet line to the SAMPLE inlet fitting e Use PTFE tubing minimum 74 e Sample Gas pressure must equal ambi
42. SETUP X X 101 19 45 NXZSC1 401 0346 PV10 PREV NX10 NEXT lt PRM PRM gt EXIT SETUP XX 102 04 55 25 1 400 9868 SETUP 101 19 45 NXSLP1 0 9987 PPB PV10 PREN NX10 NEXT SPRM PRM EXT PV10 PREV NX10 NEXT PRM PRM gt EXIT Continue pressing NEXT to view remaining DAS channels 07889A DCN6900 143 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual 7 1 3 EDITING DAS DATA CHANNELS DAS configuration is most conveniently done through the APICOM remote control program The following list of button strokes shows how to edit using the front panel SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE Main DAS Menu SETUP X X DATA ACQUISITION DAS EDIT Touchscreen Button Functions FUNCTION PREV Selects the previous data channel in the list NEXT Selects the next data channel in the list VIEW EDIT SETUP X X ENTER PASSWORD 818 Inserts a new data channel into the list BEFORE the selected channel DEL Deletes the currently selected data channel EDIT Enters EDIT mode ENTR EXIT EDIT Channel Menu SETUP X X 0 CONC ATIMER 4 800 Exports the configuration of all data channels to the PRINT RS 232 interface Buttons only appear when applicable INS DEL EDIT PRNT EXIT PREV NEXT Enters EDIT mode for the selecte
43. Using the amplified PMT temperature signal from the PMT preamplifier board see Section 10 4 5 it sets the drive voltage for the thermoelectric cooler The warmer the PMT gets the more current is passed through the TEC causing it to pump more heat to the heat sink e Ared LED located on the top edge of this circuit board indicates that the control circuit is receiving power e Four test points are also located at the top of this assembly e For the definitions and acceptable signal levels of these test points see 12 7 14 13 7 PNEUMATIC SENSOR BOARD The flow and pressure sensors of the T204 are located on a printed circuit assembly just behind the PMT sensor Refer to Section 12 7 6 1 for a figure and on how to test this assembly The signals of this board are supplied to the motherboard for further signal processing All sensors are linearized in the firmware and can be span calibrated from the front panel 07889A DCN6900 305 Principles of Operation Teledyne API T204 NO OS3 Analyzer Manual 13 8 POWER SUPPLY CIRCUIT BREAKER The analyzer operates on 100 VAC 115 VAC or 230 VAC power at either 50 Hz or 60Hz Individual instruments are set up at the factory to accept any combination of these five attributes A 6 75 amp circuit breaker is built into the ON OFF switch In case of a wiring fault or incorrect supply power the circuit breaker will automatically turn off the analyzer e Under normal operation the T204 dr
44. Yellow Reaction Cell Heate dis Snake 011 Green Optional Dual Span Select Valve 012 Green Optional Pressurized Span Shutoff Valve D13 Green Optional Pressurized Zero Shutoff Valve Ia _ 7E D1 RED Watchdog Indicator Figure 12 3 Relay PCA Status LEDS Used for Troubleshooting 07889A DCN6900 221 Troubleshooting amp Service Teledyne API T204 Analyzer Manual Table 12 3 Relay PCA Status LED Failure Indications FAULT LED COLOR FUNCTION STATUS INDICATED FAILURE S LED ROW 1 2 Continuously D2 Yellow Reaction Cell heater ON or OFF Heater broken thermistor broken Continuously D3 Yellow converter heater ON or OFF Heater broken thermocouple broken D7 Green Zero Span valve status Valve broken or stuck valve driver chip broken D8 Green Sample Cal valve status patente Valve broken or stuck valve driver chip broken D9 Green Auto zero valve status Continuously Valve broken or stuck valve driver chip broken ON or OFF D10 Green NO NO valve status Continuously Valve broken or stuck valve driver chip broken ON or OFF LED ROW 2 Internal span gas generator Continuously 05 Yellow perm tube heater ON or OFF Heater broken thermistor broken D11 Green Dual span select valve pennas Valve broken or stuck valve driver chip broken ON or OFF D12 Green Pressurized Span shutoff valve Valve b
45. corresponding SIGNALI O function 284 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 3 4 4 O SUPPLY AIR FLOW SENSOR In contrast to the sample gas flow the ozone flow is measured with a mass flow sensor which is mounted on the flow pressure sensor PCA just behind the PMT sensor assembly Pneumatically it lies between the sample gas dryer and the This mass flow sensor has a full scale range of 0 1000 cm min and can be calibrated through software to its span point Section 9 5 Since the flow value displayed on the front panel is an actual measurement and not a calculated value short term variability in the measurement may be higher than that of the sample flow which is based on a calculation from more stable differential pressures On the other hand any sustained drift i e long term change in the ozone flow rate may usually indicate a flow problem This information is used to validate the gas flow rate e flow rate exceeds 15 of the nominal flow rate 80 cm min a warning message OZONE FLOW WARNING is displayed on the analyzer s front panel see Section 4 1 2 and the generator is turned off e Asecond warning OZONE GEN OFF is also displayed e This flow measurement is viewable through instrument s front panel display as the test function OZONE FL and the SIGNAL I O function OZONE FLOW As with all other test parameters we recommend to monito
46. exported via the analyzer s RS 232 port etc DAS CHANNELS The key to the flexibility of the DAS is its ability to store a large number of combinations of triggering events and data parameters in the form of data channels Users may create up to 20 data channels and each channel can contain one or more parameters For each channel the following are selected e one triggering event e upto 50 data parameters which can be the shared between channels e several other properties that define the structure of the channel and allow the user to make operational decisions regarding the channel The DAS Channel properties are described in the APICOM DAS manual PN 07463 DEFAULT DAS CHANNELS A set of default Data Channels has been included in the analyzer s software for logging NO NO O concentrations as well as certain predictive diagnostic data For the software revision being shipped with the T204 at the time of this writing these default channels are CONC Samples all concentrations at one minute intervals and stores an average every hour with a time and date stamp Readings during calibration and calibration hold off are not included in the data e default the last 800 hourly averages are stored 140 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM CALDAT Logs new slope and offset of NOx and NO measurements every time a zero or span calibr
47. gt NO Configuration Converter amp Jumpers Reaction Cell Solenoid PS 2 Drivers 12 VDC RELAY PCA M 4 AC MODEL SPECIFIC Fans POWER IN VALVES OPTIONAL Chassis Auto zero valves etc Zero Span e g NOx NO Valves VALVE Figure 13 23 Power Distribution Block Diagram 13 8 1 AC POWER CONFIGURATION The T204 analyzer s digital components will operate with any of the specified power regimes As long as instrument is connected to 100 120 VAC or 220 240 VAC at either 50 or 60 Hz Internally the status LEDs located on the Relay PCA Motherboard and CPU should turn on as soon as the power is supplied However some of the analyzer s non digital components such as the various internal pump options or the AC powered heaters for the gt NO converter the reaction cell and some of the T204 s must be properly configured for the type of power being supplied to the instrument Configuration of the power circuits is set using several jumper sets located on the instruments relay PCA 07889A DCN6900 307 Principles of Operation Teledyne API T204 Analyzer Manual ps RELAY PCA JP6 Configuration Jumpers for Optional AC Heaters O2 Sensor Internal Perm Tube Oven Heater JP2 Configuration Jumpers for AC Heaters NO2 gt NO converter Reaction Cell JP7 Pump Configuration Internal Pump Options Only Figure 1
48. ignore the sign at 315 C and about 0 mV at room temperature e Measure the continuity with an Ohm meter e t should read close to zero If the thermo couple does not have continuity it is broken e lfitreads zero voltage at elevated temperatures it is broken To test the thermocouple at room temperature heat up the converter can e g with a heat gun and see if the voltage across the thermocouple leads changes e f the thermocouple is working properly the electronic circuit is broken ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY If the thermocouple is broken do NOT replace the thermocouple without first consulting the factory using the wrong Type could cause permanent damage to the instrument The Type K thermocouple has a red and a yellow wire If in doubt consult the factory 07889A DCN6900 243 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 10 2 CONVERSION EFFICIENCY The efficiency at which the NO gt NO converter changes NO into NO directly effects the accuracy of the T204 s NO NO and NO measurements The T204 firmware includes a Converter Efficiency CE gain factor that is multiplied by the NO and NOx measurements to calculate the final concentrations for each This gain factor is stored in the analyzer s memory The default setting for the NO converter efficiency is 1 0000 Over time the molybdenum in the NO gt NO converter oxidizes and it
49. lt TST TST gt ZERO CONC EXIT point measurement Press EXIT to leave the x a calibration unchanged and M P CAL NOX STB XXXX PPB NOX XXXX return to the previous lt TST TST gt ENTR CONC EXIT Allow span gas to enter the sample port at the rear of the analyzer M P CAL NOX STB XXXX PPB NOX XXXX Wait until STABIL falls below 1 0 PPB This may take several minutes lt TST TST gt CAL SETUP The SPAN button now appears during the transition from zero to span Press ENTR to change M P CAL NOX STB XXXX PPB NOX XXXX the OFFSET amp SLOPE values based on the zero point measurement You may see both buttons If either the ZERO or SPAN lt TST TST gt ZERO SPAN CONC EXIT buttons fail to appear refer to the Troubleshooting section Press EXIT to leave the of this manual calibration unchanged and M P CAL NOX STB XXXX PPB NOX XXXX return to the previous lt TST TST gt ENTR CONC EXIT M P CAL NOX STB XXXX PPB NOX XXXX EXIT at this point lt TST TST ENTR CONC EXIT returns to the SAMPLE menu If the ZERO or SPAN buttons are not displayed the measurement made during is out of the allowable range allowed for a reliable calibration See Section 12 for troubleshooting tips Note 174 07889A DCN6900 Teledyne API T204 Analyzer Manual Calibration Procedures 9 2 4 MANUAL CALIBRATION AND CAL CHECKS WITH THE ZERO SPAN VALVE OPTION INSTALLED Generally performing calibration checks and
50. 050610700 07889A DCN6900 B 3 T204 Spare Parts List PN 07887A DCN6919 06 17 2014 2 of 3 page s 050610900 CONFIGURATION PLUGS 220 240V M200E 050611100 CONFIGURATION PLUGS 100V M200E 050700200 KIT RELAY BD NOX CONFIGURATION 051210000 051990000 052820000 052930200 076510000 76510100 58021100 58230000 59940000 62390000 62420200 64540000 64540100 64540200 66970000 67240000 67300000 67300100 67300200 67900000 81090000 78890000 68810000 69500000 72150000 CN0000073 CN0000458 CN0000520 L0000001 L0000003 M0000004 T0000010 KIT000051 KIT000095 KIT000207 KIT000218 KIT000219 KIT000231 KIT000253 KIT000254 OR0000001 OR0000002 OR0000025 PCA E SERIES MOTHERBD GEN 5 ICOP ACCEPTS ACROSSER OR ICOP CPU PCA SER INTRFACE ICOP CPU E OPTION USE WITH ICOP CPU 062870000 POWER ENTRY 120 60 KB FILTER FLOW CONTROL FILTER DFU KB FLOWMETER KB OR0000027 ORING COLD BLOCK PMT HOUSING amp HEATSINK B 4 07889A DCN6900 T204 Spare Parts List PN 07887A DCN6919 06 17 2014 3 of 3 page s 46320000 RETAINER WINDOW M460L M465L 46690000 LAMP BLOCK M460L M465L KB ELBOW VITON SS 1 8 TUBE TO 10 32 loOPo000031 WINDOW QUARTZ 1 2 DIA 063 THICK KB 07889A DCN6900 B 5 B 6 This page intentionally left blank 07889A DCN6900 Appendix C 29 TELEDYNE Warranty Repair Questionnaire ADVANCED POLLUTION INSTRUMENTATION T204
51. 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 3 3 EDITING DAS PARAMETERS Data parameters are types of data that may be measured and stored by the DAS For each Teledyne API s analyzer model the list of available data parameters is different fully defined and not customizable Appendix A lists firmware specific data parameters for the T204 DAS parameters include data such as NO NO and NO concentration measurements temperatures of the various heaters placed around the analyzer pressures and flows of the pneumatic subsystem and other diagnostic measurements as well as calibration data such as stability slope and offset Most data parameters have associated measurement units such as mV ppb cm min etc although some parameters have no units e g SLOPE With the exception of concentration readings none of these units of measure can be changed To change the units of measure for concentration readings see Section 5 4 3 4 Note concentration value Therefore DAS data files may contain concentration data recorded in more than one type of unit if the units of measure were Each data parameter has user configurable functions that define how the data are recorded which are listed in Table 7 2 Table 7 2 DAS Data Parameter Functions FUNCTION EFFECT PARAMETER Instrument specific parameter name SAMPLE MODE INST Records instantaneous reading AVG Records average
52. 12 7 13 1 HIGH VOLTAGE POWER SUPPLY The HVPS is located in the interior of the sensor module and is plugged into the PMT tube It requires 2 voltage inputs The first is 15 V which powers the supply The second is the programming voltage which is generated on the preamplifier board Adjustment of the HVPS is covered in the factory calibration procedure in Section 12 8 4 This power supply has 10 independent power supply steps one to each pin of the PMT The following test procedure below allows you to test each step 1 2 Turn off the instrument Remove the cover and disconnect the 2 connectors at the front of the NOx sensor module Remove the end cap from the sensor 4 screws Remove the HVPS PMT assembly from the cold block inside the sensor 2 plastic Screws Disconnect the PMT from the HVPS Re connect the 7 pin connector to the sensor end cap and power up the instrument Scroll the front panel display to the HVPS test parameter Divide the displayed HVPS voltage by 10 and test the pairs of connector points as shown in the figure below Check the overall voltage should be equal to the HVPS value displayed on the front panel and the voltages between each pair of pins of the supply EXAMPLE If the HVPS signal is 700 V the pin to pin voltages should be 70 V 252 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service HVPS PINS VOLTAGE e
53. 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 4 1 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 Figure 5 8 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 8 1 Figure 9 1 Figure 9 2 Figure 11 1 Figure 11 2 Figure 11 3 Figure 11 4 Figure 11 5 Figure 11 6 Figure 11 7 Figure 12 1 Figure 12 2 Figure 12 3 Figure 12 4 Front Paniel ha yOut ss moa ext ge e ee eR td 25 Display Screen and Touch Control E RE NEEE EEEE ARAR 26 Display Touch Control Screen Mapped to Menu Charts 28 Rear Panel Layout Base Umt 29 Internal Chassis Configuration eene 31 Analog ki oit eia ie ie nte bat n 33 Analog Output Connector eene nennen nennen nennen nennen nennen nnns 34 Current Loop Option Installed on the Motherboard 35 Status Output Connector ut Tert ert er te ise er ie Io Te e dee re eges ecd 36 Energ
54. 64 Mounting Screws 210 NO NOx valve 277 Optical Filter 271 Ozone 73 281 Scrubber 285 PMT 302 303 Pneumatice Leaks 226 Principles of Operation 270 RCELL PRESS WARN 61 RCELL TEMP 315 RCELL TEMP WARN 61 SAMP 315 SAMP FLOW 73 Sample Pressure Sensor 285 Temperature 300 Temperature Sensor 293 Theory of Operation 270 271 273 Troubleshooting 231 234 Vacuum Pressure Sensor 286 Reaction Cell Temperature 73 REAR BOARD NOT DET 62 75 Rear Panel Ambient Zero Span Valve Options 55 Analog Outputs 81 REF_4096 MV 239 REF_GND 239 RELAY BOARD WARN 62 75 139 relay PCA 62 75 216 235 265 289 296 297 299 300 301 308 309 Relay PCA 295 302 DC Power Test Points 236 Status LED s 222 223 297 298 309 Troubleshooting 222 223 235 236 237 Reporting Range 64 77 80 82 Configuration 77 Dilution Feature 89 HIGH 86 LOW 86 Modes 89 AUTO 86 IND 83 SNGL 82 Upper Span Limit 73 80 82 84 85 89 RS 232 19 45 46 47 71 78 122 142 155 157 161 291 Activity Indicators 44 Troubleshooting 243 RS 485 71 118 122 291 S SAFETY MESSAGES ELECTRIC SHOCK 34 195 210 235 258 296 General 34 48 109 281 SAMP 74 SAMP FLW 73 Sample Flow Sensor 218 SAMPLE FLOW WARNING 62 75 139 Sample Gas Line 52 56 Sample Inlet 32 Sample Mode 29 SAMPLE mode 71 72 97 180 Sample Pressure Sensor 218 Sample Temperature Sensor 218 Scubber Zero Air 170 Sensors Sample
55. C D E amp F 07889A DCN6900 37 Getting Started Teledyne API T204 Analyzer Manual 3 3 1 7 CONCENTRATION ALARM RELAY OPTION 61 The analyzer has an option for four 4 dry contact relays on the rear panel of the instrument This relay option is different from and in addition to the Contact Closures that come standard on all TAPI instruments The relays have 3 pins that have connections on the rear panel they are a Common C a Normally Open NO amp a Normally Closed NC pin see Figure 3 11 ALARM 1 ALARM 2 ALARM 3 ALARM 4 NO C NC NO C NC NO C NC NO C NC Figure 3 11 Concentration Alarm Relay Alarm 1 System OK 2 Alarm 2 Conc 1 Alarm 3 Conc 2 Alarm 4 Range Bit ALARM 1 RELAY Alarm 1 which is System OK 2 system OK 1 is the status bit is in the energized state when the instrument is OK amp there are no warnings If there is a warning active or if the instrument is put into the DIAG mode Alarm 1 will change states This alarm has reverse logic meaning that if you put a meter across the Common amp Normally Closed pins on the connector you will find that it is OPEN when the instrument is OK This is so that if the instrument should turn off or lose power it will change states amp you can record this with a data logger or other recording device ALARM 2 RELAY amp ALARM 3 RELAY The Alarm 2 Relay on the rear
56. Check m ben De t RENE t ies abs etek cece RU ERR bia 109 Table 6 1 COMM Port Communication Modes ssssssesseeeeen eene eene nemen nnn nnne 116 Table 6 2 Ethernet Status ege pense th e e sabi CT eee EPOR ERE 121 Table 6 4 RS 232 Communication Parameters for Hessen 130 Table 6 5 Teledyne API s Hessen Protocol Response Modes 133 Table 6 6 Default Hessen Status Flag Assignments ssssssssseeeeneeneeeenen ene 137 Table 7 1 Front Panel LED Status Indicators for DAS ssssssssseee eene 139 Table 7 2 DAS Data Parameter Functions ssssssesssseeeeenenee ennemi 147 Table 8 1 Terminal Mode Software Commands sse ennemis 160 Table 8 2 Teledyne API s Serial Command Types sssssssseeee nennen nennen enn 161 Table 9 1 AUT OGAL MOd6GS ee tet uela tL el 178 Table 9 2 AutoCal Attribute Setup Parameeters sssssssssssssssssseeneenen emeret nnne 179 Table 9 3 Example AutoCal 180 Table 9 4 Calibration Data Quality Evaluation sse emm emen 184 Table 11 1 T204 Maintenance Schedule 194 Table 11 2 Predictive
57. DAS Configuration Through a Terminal Emulation Program See Section 8 2 1 for configuration commands and their strict syntax Commands can be pasted in from of an existing text file which was first edited offline and then uploaded through a specific transfer procedure IMPACT ON READINGS OR DATA Whereas the editing adding and deleting of DAS channels and parameters of one channel through the front panel control buttons can be done without affecting the other channels uploading a DAS configuration script to the analyzer through its communication ports will erase all data parameters and channels by replacing them with the new DAS configuration Backup of data and the original DAS configuration is advised before attempting any DAS changes 158 07889A DCN6900 8 REMOTE OPERATION This section provides information needed when using external digital and serial I O for remote operation It assumes that the electrical connections have been made as described in Section 3 3 1 The T204 can be remotely configured calibrated or queried for stored data through the serial ports via either Computer mode using a personal computer or Interactive mode using a terminal emulation program 8 1 COMPUTER MODE Computer Mode is used when the analyzer is connected to a computer with a dedicated interface program such as APICOM 8 1 1 REMOTE CONTROL VIA APICOM APICOM is an easy to use yet powerful interface program that allows the user to a
58. DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service Step 2 Input the starting NO concentration value into the T204 by pressing SAMPLE RANGE 500 0 PPB NO XXXX lt TST TST gt CAL SETUP SELECT CAL GAS This step only appears if the analyzer s reporting range is set for AUTO range mode Select LOW and press ENTR Repeat entire procedure for HIGH range Use these buttons to select the appropriate range Repeat entire procedure SAMPLE RANGE 500 0 PPB NO XXXX for each range lt TST TST gt CAL SETUP SAMPLE RANGE 500 0 PPB NO XXXX TEST ZERO SPAN CONC EXIT M P CAL CONCENTRATON MENU NOX NO CONV EXIT M P CAL CONVERTER EFICIENCY MENU NO2 CAL SET EXIT The expected NO span M P CAL NO2 CE CONC 500 0 Conc concentration value defaults to 400 0 Conc 0 4 0 0 0 0 ENTR EXIT Toggle these buttons Make sure that you specify to change this value to the actual concentration value of the NO gas the concentration of the NO gas being used 07889A DCN6900 245 Troubleshooting amp Service Teledyne API T204 Analyzer Manual STEP 3 To cause the analyzer to calculate and record the gt NO converter efficiency press Toggle these buttons to initialize the converter efficiency at 1 0000 The analyzer calculates the converter s efficiency Check the calculated converter efficiency gain factor If the gain factor
59. ELECTRICAL TEST The ELECTRICAL TEST function creates a current which substitutes the PMT signal and feeds it into the preamplifier board This signal is generated by circuitry on the pre amplifier board itself and tests the filtering and amplification functions of that assembly along with the A D converter on the motherboard It does not test the PMT itself The electrical test should produce a PMT signal of about 2000 1000 mV Section 12 7 12 2 presents instructions for use in troubleshooting and service 5 9 6 OZONE GEN OVERRIDE This feature is used to manually turn the ozone generator off and on Read Section 13 3 3 to understand the ozone generator and refer to Section 12 7 15 1 for instructions on using the override feature in troubleshooting and service 5 9 7 FLOW CALIBRATION This function is used to calibrate the gas flow output signals of sample gas and ozone generator supply Section 9 5 presents instructions for flow calibration 114 07889A DCN6900 6 COMMUNICATIONS SETUP AND OPERATION This instrument s rear panel connections include an Ethernet port a USB port option and two serial communications ports labeled RS232 which is the COMI port and COM2 refer to Figure 3 4 These ports give the user the ability to communicate with issue commands to and receive data from the analyzer through an external computer system or terminal Connection instructions were provided in Section 3 3 1 8 This section provide
60. Figure 3 5 can be checked with a Voltmeter Test Point 1 Ground Test Point 2 10V reference voltage Test Point 3 3 ozone flow Test Point 4 1 sample pressure Test Point 5 2 vacuum pressure S3 flow sensor ozone SW26 1 pressure sensor reaction cell vacuum SW26 52 pressure sensor sample 04002 PCB CN59 Power and signal connector mounting bracket Captive fastener Figure 12 6 Pressure Flow Sensor Assembly The following procedure assumes that the wiring is intact and that the motherboard and power supplies are operating properly 12 7 7 1 BASIC PCA OPERATION CHECK e Measure the voltage between TP2 and TP1 C1 it should be 10 VDC 0 25 VDC If not then the board is bad Replace the PCA 12 7 7 2 SAMPLE PRESSURE SENSOR CHECK 1 Measure the pressure on the inlet side of S1 with an external pressure meter 2 Measure the voltage across TP4 and TP1 e The expected value for this signal should be P Expected mVDC T X 4660 250moc 10 rdg 30 EXAMPLE If the measured pressure is 20 Hg in A the expected voltage level between TP4 and TP1 would be between 2870 mVDC and 3510 mVDC 240 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service EXAMPLE If the measured pressure is 25 Hg in A the expected voltage level between TP4 and would be between 3533 mVDC and 4318 mVDC e If this vol
61. Gas Generator and Valve Options 255 12 7 17 Temperature Sensor x one umet ee edt ede t dig er eet 256 12 8 5 tee em en e gene ME NEHME NE Pe eie ME dete a nae andes abd 257 12 8 1 Disk On Module Replacement Procedure nenne ent 257 12 8 2 Generator eene ener nnne nennen 258 12 8 3 Sample and Ozone Dryer s 258 12 8 4 PMT Sensor Hardware Calibration sssssssssseseseemee eene 259 12 8 5 Replacing the PMT HVPS or TEC cccccceeeeeeecceceeeeeeeeeceeaeeeeeeeseseceaeaeeeeeeesesennaeaeeeeeess 261 12 8 6 Removing Replacing the Relay PCA from the 264 12 9 Frequently Asked Questions enasini eai a ar eee nennen enne eren nemen 265 12 19 Technical ASSISEtanca iuo ie TU eri a ee aeter eL epe be pe PL ded eo a reae gerade 266 13 PRINCIPLES OF OPERATION 207 13 1 Nitrogen Oxides Measurement Principle sess enn 267 13 1 1 Chemiluminescence Creation in the T204 Reaction 267 13 1 2 Chemil
62. It also supplies the drive voltage and gain adjustment for the PMT s High Voltage Power Supply HVPS The Thermo Electric Cooler TEC controls the temperature of the PMT to ensure the accuracy and stability of the measurements 300 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation PMT Housing End Plate This is the entry to the PMT Exchange PMT Output Connector PMT Preamp PCA PMT Power Suppe amp Aux Signal Connector High voltage Power Supply HVPS O Test LED ws PMT Cold Block P d Connector to PMT Pre Amp PCA 12V Power Connector Insulation Gasket Light from Reaction PMT Temperature chamber shines Sensor through hole in side of Cold Block 7 Thermo Electric Cooler TEC PMT Heat Exchange Fins TEC Driver PCA Cooling Fan Housing Figure 13 18 T204 Sensor Module Assembly 13 6 PHOTO MULTIPLIER TUBE PMT The T204 uses a photo multiplier tube PMT to detect the amount of chemiluminescence created in the Reaction Cell A typical PMT is a vacuum tube containing a variety of specially designed electrodes Photons from the reaction are filtered by an optical high pass filter enter the PMT and strike a negatively charged photo cathode causing it to emit electrons A high voltage potential across these focusing electrodes directs the electrons toward an array of high voltage dynodes The dynodes in this electron multiplier arr
63. M P CAL NOX STB XXX X PPB ENTR The SPAN button now appears during the transition from zero to span TST gt T CONC You may see both buttons If either the ZERO or SPAN buttons fail to appear see Section 11 for troubleshooting tips M P CAL NOX STB XXX X PPB NOX X XXX EXIT at this point T returns to the SAMPLE menu lt TST TST gt ENTR CONC Note If the ZERO or SPAN buttons are not displayed the measurement made during is out of the allowable range allowed for a reliable calibration See Section 12 for troubleshooting tips 07889A DCN6900 177 Calibration Procedures Teledyne API T204 Analyzer Manual 9 2 7 3 USE OF ZERO SPAN VALVE WITH REMOTE CONTACT CLOSURE Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN connector Instructions for setup and use of these contacts are found in Section 3 3 1 6 When the contacts are closed for at least 5 seconds the instrument switches into zero low span or high span mode and the internal zero span valves will be automatically switched to the appropriate configuration e The remote calibration contact closures may be activated in any order e tis recommended that contact closures remain closed for at least 10 minutes to establish a reliable reading e The instrument will stay in the selected m
64. Manual Instrument Maintenance 11 3 4 MAINTAINING THE EXTERNAL SAMPLE PUMP PUMP PACK 11 3 4 1 REBUILDING THE PUMP The sample pump head periodically wears out and must be replaced when the RCEL pressure exceeds 10 in Hg A at sea level adjust this value accordingly for elevated locations A pump rebuild kit is available from the factory Refer to the label on the pump for the part number Instructions and diagrams are included in the kit A flow and leak check after rebuilding the sample pump is recommended A span check and re calibration after this procedure is necessary as the response of the analyzer changes with the RCEL pressure 11 3 4 2 REPLACING THE SCRUBBER Do NOT attempt to change the contents of the inline exhaust scrubber cartridge change the entire cartridge CAUTION oO ONO aA ON Through the SETUP gt MORE gt DIAG menu turn OFF the OZONE GEN OVERRIDE Wait 10 minutes to allow pump to pull room air through scrubber before proceeding to step 2 Disconnect exhaust line from analyzer Turn off unplug analyzer sample pump Disconnect tubing from NOx or charcoal scrubber cartridge Remove scrubber from system Dispose of according to local laws Install new scrubber into system Reconnect tubing to scrubber and analyzer Turn on pump Through the SETUP menu per Step 1 above turn ON the OZONE GEN OVERRIDE 11 3 5 CHANGING THE PUMP DFU FILTER The exhaus
65. NEXT buttons to between the available modes Continue pressing NEXT until COM1 HESSEN PROTOCOL OFF Activate Deactivate PREV NEXT OFF EXIT the HESSEN mode by toggling the ON OFF button COM1 HESSEN PROTOCOL OFF PREV NEXT ON ENTR EXIT EAT MISES setting ENTR accepts the COM1 MODE 16 new setting 7 lt SET SET gt EDIT EXIT COMMUNICATIONS MENU ID HESN COM COM2 EXIT 07889A DCN6900 131 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 7 2 3 SELECTING A HESSEN PROTOCOL Currently there are two versions of Hessen Protocol in use The original implementation referred to as TYPE 1 and a more recently released version TYPE 2 that has more flexibility when operating with instruments that can measure more than one type of gas For more specific information about the difference between TYPE 1 and TYPE 2 download the Manual Addendum for Hessen Protocol from the Teledyne API s web site http www teledyne api com manuals To select a Hessen Protocol Type press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID HESN COM1 COM2 EXIT HESSEN VARIATION TYPE1 lt SET SET gt EDIT HESSEN VARIATION TYPE1 TYP1 TYP2 ENTR EXIT EXIT discards th
66. NO concentration calculations The FLOW CALIBRATION submenu located under the DIAG menu allows the calibration adjustment of these calculations To calibrate the flow of gas calculations made by the press SETUP gt MORE gt DIAG gt default password ENTR press NEXT until the FLOW CALIBRATION menu appears DRG SIGNALO EXIT returns you to PREV NEXT ENTR EXIT the Secondary Setup E Menu Continue pressing NEXT until FLOW CALIBRATION PREV NEXT ENTR FLOW SENSOR TO CAL Use these buttons to select which flow SAMP OZONE ENTR calculation to adjust SAMP Calibrates the sample gas flow calculation derived from the pressure measurements before and after the sample gas enters the reaction cell OZONE Calibrates the gas flow calculation derived from the direct measurements of WAITING FOR FLOW gas flow into the O3 Generator PREV NEXT ENTR ACTUAL FLOW 1 000 LPM 1 0 0 0 0 ENTR EXIT EXIT discards the new Toggle these keys to E setting match the actual flow as measured by the external flow meter ENTR accepts the new setting 07889A DCN6900 185 Calibration Procedures Teledyne API T204 Analyzer Manual This page intentionally left blank 186 07889A DCN6900 10 EPA PROTOCOL CALIBRATION To ensure high quality accurate measurements at all times the T204 analyzer must be calibrated prior to use A quality assurance program centered on this
67. O A 12 07889A DCN6900 Teledyne T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version Table A 3 Test Measurements NONOXCONC NO 396 5 NOX 396 5 Simultaneously displays NO and NOX concentrations RANGE 6 RANGE 500 0 PPB D A range in single or auto range modes RANGE1 9 RANGE1 500 0 PPB D A 1 range in independent range mode RANGE2 t6 RANGE2 500 0 PPB D A 2 range in independent range mode RANGE3 6 RANGE3 500 0 PPB D A 3 range in independent range mode STABILITY NOX STB 0 0 PPB Concentration stability standard O2 STB 0 0 PCT deviation based on setting of CO2 STB 0 0 PCT STABIL FREQ and STABIL SAMPLES Select gas with STABIL GAS variable RESPONSE RSP 8 81 1 30 SEC Instrument response Length of each signal processing loop Time in parenthesis is standard deviation SAMPFLOW SAMP FLW 460 CC M Sample flow rate PMT PMT 800 0 MV Raw PMT reading NORMPMT NORM PMT 793 0 MV PMT reading normalized for temperature pressure auto zero offset but not range MANIFOLDTEMP MF TEMP 50 8 C Bypass or dilution manifold temperature 07889A DCN6900 A 13 APPENDIX 3 Wamings and Test Measurements Teledyne API T200 T204 and 200E Series 05295F DCN6900 is MOLY CONV or O3KL SAMPRESTTEMP 1 SMP RST TMP 49 8 C Sample restrictor temperature RCELLPRESS RCEL 7 0 IN HG A Reaction cell pressure SAMPP
68. O ports and circuitry to specific values until the CPU boots and the instrument software can establish control 07889A DCN6900 293 Principles of Operation Teledyne API T204 NO OS3 Analyzer Manual 13 4 4 RELAY PCA The CPU issues commands via a series of relays and switches located on a separate printed circuit assembly called the relay PCA Figure 13 13 to control the function of key electromechanical devices such as heaters and valves The relay PCA receives instructions in the form of digital signals over the bus interprets these digital instructions and activates its various switches and relays appropriately The relay PCA is located in the right rear quadrant of the analyzer and is mounted vertically on the backside of the same bracket as the instrument s DC power supplies Thermocouple Status LED s Signal Output D2 through D16 Watchdog DC Power Supply m JP5 Status LED D1 Test Points ermocouple Configuration 2 dumpers _ X IC Connector aaa ale UEELELEI JL O gt NO Converter 1 Temp Sensor le O Power 9 Connection 9 55 BENE Configuration E Valve Control Jumper Te Drivers O 05 ZO 0 b Output e RETE Valve Control IN AC Relay K2 Connector for NO gt NO Converter Heater AC Relays AC Relay K1 K1 amp K2 A Reaction Cell Heater a DC Power Distribution Connectors
69. OS3LAMP AZERO HVPS REFGND REF4096 Default DAS Channels Setup 142 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 1 2 DAS CONFIGURATION LIMITS The number of DAS objects are limited by the instrument s finite storage capacity For information regarding the maximum number of channels parameters and records and how to calculate the file size for each data channel refer to the DAS manual downloadable from the TAPI website at http www teledyne api com manuals under Special Manuals 7 1 2 VIEWING DAS DATA AND SETTINGS DAS data and settings can be viewed on the front panel through the following menu sequence SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP DAS VIEW Touchscreen Functions Concentration field FUNCTION displays all gases PV10 Moves the VIEW backward 10 record SETUP X X PRIMARY SETUP MENU PREV Moves the VIEW backward 1 records or channel CFG DAS RNGE PASS CLK MORE EXIT SETUP X X DATA ACQUISITION VIEW EDIT EXIT Buttons only appear when applicable SETUP X X CONC DATA AVAILABLE NEXT VIEW EXIT SETUP 101 21 00 NXCNC1 59 0346 PPB PV10 PREV NX10 NEXT lt PRM PRM gt EXIT SETUP X X 101 22 00 NXCNC1 000 0000 PPB SETUP X X 101 21 00 NOCNC1 22 0934 PPB PV10 PREV NX10 NEXT lt PRM PRM gt EXIT PV10 PREV NX10 NEXT lt PRM PRM gt EXIT SETUP X X CALDAT DATA AVAILABLE NEXT VIEW EXIT
70. PCA to J12 on the motherboard e J1 onthe Multidrop LVDS PCS to the front panel LCD JP2 has a shunt on Pins 21 22 Remove this shunt from all analyzers except the last analyzer in the chain leave the shunt installed on Pins 21 22 on Disk on Module last analyzer DOM Adjust accordingly if new instrument s added later Serial multi drop and LVDS board seated on CPU Cable PN 04671 J4 to J12 on motherboard a o o a o o o ogo ooo i ar oga 000 iO oou ogo ogo ogo i ai ogo iO oo ogo ogo ogo ogo iD Or ogo ogo video cable to front panel LCD a m m m a a a a a a a a m m a a a m m a a a CPU COM1 CPU CON is not 011 connector used in Multidrop Figure 3 14 Jumper and Cables for Multidrop Mode Note If you are adding an instrument to the end of a previously configured chain remove the shunt between Pins 21 22 of JP2 on the Multidrop LVDS PCA in the instrument that was previously the last instrument in the chain Close the instrument 5 Referring to Figure 3 15 use straight through DB9 male gt DB9 female cables to interconnect the host RS232 port to the first analyzer s RS232 port then from the first analyzer s COM2 port to the second analyzer s RS232 port from the second analyzer s 2 port to the third analyzer s RS232 port etc connecting in this fashion up to eight analyze
71. TEMP WARNING Converter temperature outside of warning limits WPMTTEMP PMT TEMP WARNING PMT temperature outside of warning limits WAUTOZERO AZERO WRN XXX X MV Auto zero reading above limit Value WPREREACT 12 PRACT WRN XXX X MV shown in message indicates auto zero reading at time warning was displayed WHVPS HVPS WARNING High voltage power supply output outside of warning limits WDYNZERO CANNOT DYN ZERO Contact closure zero calibration failed while DYN ZERO was set to ON WDYNSPAN CANNOT DYN SPAN Contact closure span calibration failed while DYN SPAN was set to ON WREARBOARD REAR BOARD NOT DET Rear board was not detected during power up WRELAYBOARD RELAY BOARD WARN Firmware is unable to communicate with the relay board WFRONTPANEL FRONT PANEL WARN Firmware is unable to communicate with the front panel WANALOGCAL ANALOG CAL WARNING The A D or at least one D A channel has not been calibrated 07889A DCN6900 A 11 APPENDIX 3 Wamings and Test Measurements Teledyne API T200 T204 and 200E Series 05295F DCN6900 Warning Name The name is used to request a message via the RS 232 interface as in T BOXTEMP Engineering firmware only Current instrument units Factory option option User configurable D A output option Optional m CO option Concentration alarm option M200EUP M200EU and M200EU NO External analog input option Os option oO ON BP WN e RB H N e
72. Technical Information Service NTIS Phone 703 487 4650 part number PB 273 518 or the USEPA Center for Environmental Research Information 513 569 7562 part number EPA 600 4 77 027A 07889A DCN6900 189 EPA Protocol Calibration Teledyne API T204 Analyzer Manual This page intentionally left blank 190 07889A DCN6900 PART Ill MAINTENANCE AND SERVICE 07889A DCN6900 191 192 07889A DCN6900 11 INSTRUMENT MAINTENANCE For the most part the T204 analyzer is maintenance free However it is recommended that a minimal number of simple procedures be performed regularly to ensure that the T204 continues to operate accurately and reliably over its lifetime In general the exterior can be wiped down with a lightly damp cloth avoid spraying anything directly onto any part of the analyzer Service and troubleshooting are covered in Section 12 11 1 MAINTENANCE SCHEDULE Table 11 1 shows a typical maintenance schedule for the T204 Please note that in certain environments i e dusty very high ambient pollutant levels some maintenance procedures may need to be performed more often than shown IMPORTANT IMPACT ON READINGS OR DATA A span and zero calibration check see CAL CHECK REQ D Column of Table 11 1 T204 Maintenance Schedule must be performed following some of the maintenance procedures listed herein To perform a CHECK of the instrument s Zero or Span Calibration follow the same steps as
73. This warning message clears itself when the ozone generator is turned on i i 1 HVPS WARNING High voltage power supply output outside of warning limits 07889A DCN6900 73 Overview of Operating Modes Teledyne API T204 Analyzer Manual 4 2 CALIBRATION MODE Note IMPORTANT Pressing the CAL button switches the analyzer into calibration mode In this mode the user can in conjunction with introducing zero or span gases of known concentrations into the analyzer cause it to adjust and recalculate the slope gain and offset of the its measurement range This mode is also used to check the current calibration status of the instrument If the instrument includes one of the available zero span valve options the SAMPLE mode display will also include CALZ and CALS buttons Pressing either of these buttons also puts the instrument into calibration mode e The CALZ button is used to initiate a calibration of the analyzer s zero point using internally generated zero air e The CALS button is used to calibrate the span point of the analyzer s current reporting range using span gas It is recommended that this span calibration be performed at 80 of full scale of the analyzer s currently selected reporting range EXAMPLES If the reporting range is set for 0 to 500 ppb an appropriate span point would be 400 ppb If the of the reporting range is set for 0 to 1000 ppb an appropriate span point would be 800 pp
74. X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID HESN COM 1 2 EXIT HESSEN VARIATION TYPE1 SET SET EDIT EXIT Continue pressing SET until HESSEN STATUS FLAGS SET SET EDIT EXIT SETUP X X TEMP WARNING 0008 Or continue pressing NEXT until desired PREVNEXT EDIT PRINT EXIT flag message is displayed SETUP X X TEMP WARNING 0 008 The lt CH and CH gt CH CH DEL 0 ENTR EXIT EXIT discards the buttons move the LL new setting cursor brackets left and right along the bit string ENTR accepts the new setting 7 Press the button repeatedly to cycle through the available character set 0 9 INS Inserts a the character at the NOTE Values of A F can also be set but are meaningless current location of the cursor brackets 6 7 2 7 INSTRUMENT ID Each instrument on a Hessen Protocol network must have a unique identifier ID number Refer to Section 5 7 1 for information and to customize the ID of each 138 07889A DCN6900 7 DATA ACQUISITION SYSTEM DAS AND APICOM The internal data acquisition system DAS enables the analyzer to store concentration and calibration data as well as a host of diagnostic parameters The principal use of the DAS is logging data for trend analysis and predictive diagnostics which can assist in identifying possible problems before they affect the f
75. a Disk on Module DOM and an embedded flash chip 13 4 2 1 DISK ON MODULE The DOM is a 44 pin IDE flash drive with storage capacity to 128 MB It is used to store the computer s operating system the Teledyne API firmware and most of the operational data generated by the analyzer s internal data acquisition system DAS 13 4 2 2 FLASH CHIP This non volatile embedded flash chip includes 2MB of storage for calibration data as well as a backup of the analyzer configuration Storing these key data on a less heavily accessed chip significantly decreases the chance of data corruption In the unlikely event that the flash chip should fail the analyzer will continue to operate with just the DOM However all configuration information will be lost requiring that the unit be recalibrated 288 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation 13 4 3 MOTHERBOARD This PCA provides a multitude of functions including A D conversion digital input output PC 104 to translation temperature sensor signal processing and is a pass through for the RS 232 and RS 485 signals 13 4 3 1 A TO D CONVERSION Analog signals such as the voltages received from the analyzers various sensors are converted into digital signals that the CPU can understand and manipulate by the analog to digital converter A D Under the control of the CPU this functional block selects a particular signal input and t
76. alarm limit 2 exceeded WSAMPFLOW SAMPLE FLOW WARN Sample flow outside of warning limits WOZONEFLOW OZONE FLOW WARNING Ozone flow outside of warning limits WOZONEGEN OZONE GEN OFF Ozone generator is off This is the only warning message that automatically clears itself It clears itself when the ozone generator is turned on WRCELLPRESS RCELL PRESS WARN Reaction cell pressure outside of warning limits WBOXTEMP BOX TEMP WARNING Chassis temperature outside of warning limits WRCELLTEMP RCELL TEMP WARNING Reaction cell temperature outside of warning limits WMANIFOLDTEMP MANIFOLD TEMP WARN Bypass or dilution manifold A 10 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version Warning Name temperature outside of warning limits WCO2CELLTEMP CO2 CELL TEMP WARN CO sensor cell temperature outside of warning limits WO2CELLTEMP O2 CELL TEMP WARN sensor cell temperature outside of warning limits WO3CELLTEMP 3 O3 CELL TEMP WARN O3 sensor sample temperature outside of warning limits WO3PHOTOREF O3 CELL PHOTOREF WARN O3 sensor photometer reference signal warning WO3LAMPTEMP P O3 CELL LAMP WARN cell lamp temperature warning WO3PRESSURE P O3 CELL PRESS WARN cell pressure warning WIZSTEMP IZS TEMP WARNING IZS temperature outside of warning limits specified by IZS SET variable WCONVTEMP CONV
77. allowable operating parameters e Appendix C includes a list of test functions viewable from the analyzer s front panel as well as their expected values e These functions are also useful tools for diagnosing problems with your analyzer e The enclosed Final Test and Validation Data sheet P N 04409 lists these values before the instrument left the factory To view the current values of these parameters press the following button sequence on the analyzer s front panel Remember until the unit has completed its warm up these parameters may not have stabilized 60 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started lt TST TST gt CAL Toggle lt TST TST gt buttons to scroll through list of functions This will match the currently selected units of measure for the range being displayed gt RANGE Va uePPB RANGE1 Va uePPB gt RANGE2 Va uePPB S N Value OS READ Va uePPB OS STAB Va uePPB SLOPE Value O3 OFFS ValuePPB OS RNG Va uePPB O3 MEAS ValueMV OS REF Va ueMV O3CEL PR ValuePSIA O3AMP TMP ValuePC gt O3LMP TMP ValuePC NOX STB Va uePPB SAMP FLW ValueJCCIM OZGEN FL ValuefCC M PMTz Value MV NORM PMT Value MV AZERO Value MV HVPS Value V RCELL TEMP Va uePC BOX TEMP Va uePC gt TEMP Va uePC MOLY TEMP ValuePC RCEL ValueAN HG A
78. and archival NO OFFS NO SLOPE NOx OFFS NOx SLOPE OFFS SLOPE Ensure that these parameters are within the limits listed in Table 9 4 and frequently compare them to those values on the Final Test and Validation Data Sheet P N 04490 that came attached to your manual which should not be significantly different If they are refer to the troubleshooting Section 12 Table 9 4 Calibration Data Quality Evaluation Function Minimum Value Optimum Value Maximum Value NOx SLOPE 0 700 1 000 1 300 NO SLOPE 0 700 1 000 1 300 NOx OFFS 20 0 mV 0 0 mV 150 0 mV NO OFFS 20 0 mV 0 0 mV 150 0 mV SLOPE 0 5 1 0 2 0 OFFS 10 ppb 0 0 ppb 10 ppb The default DAS configuration records all calibration values in channel CALDAT as well as all calibration check zero and span values in its internal memory e Review these data to see if the zero and span responses change over time e These channels also store the STB figure standard deviation of gas concentration to evaluate if the analyzer response has properly leveled off during the calibration procedure e Finally the CALDAT channel also stores the converter efficiency for review and documentation 07889A DCN6900 Teledyne API T204 Analyzer Manual Calibration Procedures 9 5 GAS FLOW CALIBRATION NOx ONLY Note Rate of sample gas and generator flow through the T204 is a key part of the NO NO and
79. assembly and the black plastic reaction cell with window gasket stainless steel reaction cell sleeve optical filter and O rings The reaction cell both plastic part and stainless steel sleeve and optical filter should be cleaned with Distilled Water DI Water and a clean tissue and dried thereafter Usually it is not necessary to clean the sample and ozone flow orifices since they are protected by sintered filters e f tests show that cleaning is necessary refer to Section 11 3 8 on how to clean the critical flow orifice Do not remove the sample and ozone nozzles They are Teflon threaded and require a special tool for reassembly If necessary the manifold with nozzles attached can be cleaned in an ultrasonic bath Reassemble in proper order and re attach the reaction cell to the sensor housing Reconnect pneumatics and heater connections then re attach the pneumatic sensor assembly and the cleaning procedure is complete After cleaning the reaction cell it is also recommended to exchange the ozone supply air filter chemical as described in Section 11 3 3 After cleaning the analyzer span response may drop 10 15 in the first 10 days as the reaction cell window conditions This is normal and does not require another cleaning 206 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 11 3 8 REPLACING CRITICAL FLOW ORIFICES There are several critical flow orifices installed
80. behind the sensor assembly The measurements made by these sensors are used for a variety of important calculations and diagnostics 13 3 4 1 SAMPLE PRESSURE SENSOR An absolute pressure transducer connected to the input of the NO NOx valve is used to measure the pressure of the sample gas before it enters the analyzer s reaction cell e In conjunction with the measurement made by the vacuum pressure sensor this upstream measurement is used to compute the sample gas sample flow rate and to validate the critical flow condition 2 1 pressure ratio through the sample gas critical flow orifice Section 13 3 2 e If the Temperature Pressure Compensation TPC feature is turned on Section 13 10 2 the output of this sensor is also used to supply pressure data for that calculation e The actual pressure value is viewable through the analyzer s front panel display as the test function SAMP e flow rate of the sample gas is displayed as SAMP FLW and the SIGNAL I O function SAMPLE_PRESSURE 07889A DCN6900 283 Principles of Operation Teledyne API T204 Analyzer Manual 13 3 4 2 13 3 4 3 VACUUM PRESSURE SENSOR An absolute pressure transducer connected to the exhaust manifold is used to measure the pressure downstream from and inside the instrument s reaction cell The output of the sensor is used by the CPU to calculate the pressure differential between the gas upstream of the reaction cell and
81. chemical reaction that gives off light hv e The instrument measures the amount of chemiluminescence to determine the amount of NO in the sample gas e Acatalytic reactive converter converts NO in the sample gas to NO which along with the NO present in the sample is reported as NOx NO is calculated as the difference between NOx and NO Calibration of the instrument is performed in software and usually does not require physical adjustments to the instrument During calibration the microprocessor measures the sensor output signal when gases with known amounts of NO or are supplied and stores these results in memory The microprocessor uses these calibration values along with the signal from the sample gas and data of the current temperature and pressure of the gas to calculate a final NOx concentration The concentration values and the original information from which it was calculated are stored in the unit s internal data acquisition system DAS Section 0 and are reported to the user through the front panel display or several output ports 13 1 NITROGEN OXIDES MEASUREMENT PRINCIPLE 13 1 1 CHEMILUMINESCENCE CREATION IN THE T204 REACTION CELL The T204 s measures the amount of NO present in a gas by detecting the chemiluminescence that occurs when nitrogen oxide NO is exposed to ozone This reaction is a two step process e Inthe first step one molecule of NO and one molecule of collide and chemically react to
82. connection to the LAN is valid green activity Flickers during any activity on the LAN The analyzer is shipped with DHCP enabled by default This allows the instrument to be connected to a network or router with a DHCP server The instrument will automatically be assigned an IP address by the DHCP server Section 6 5 2 This configuration is useful for quickly getting an instrument up and running on a network However for permanent Ethernet connections a static IP address should be used Section 6 5 1 below details how to configure the instrument with a static IP address 6 5 1 CONFIGURING ETHERNET COMMUNICATION MANUALLY STATIC IP ADDRESS To configure Ethernet communication manually 1 Connect a cable from the analyzer s Ethernet port to a Local Area Network LAN or Internet port 2 From the analyzer s front panel touchscreen access the Communications Menu SETUP gt MORE gt COM M see Figure 5 2 3 Enter the INET menu shown in Figure 6 4 turning DHCP mode to OFF and editing the Instrument and Gateway IP addresses and Subnet Mask to the desired settings default settings showin in Table 6 3 Alternatively from the computer enter the same information through an application such as HyperTerminal 07889A DCN6900 121 Communications Setup and Operation Teledyne API T204 Analyzer Manual SETUP XX COMMUNICATIONS MENU Internet Configuration Button Functions FUNCTION Location of cursor Pre
83. e transparent Notice any discoloration of the contents which is usually white and slightly The amount of discolored chemical usually with yellow tint may give you an indication of the lifetime of the chemical in your application The maintenance cycle of this item is dependent on ambient moisture sub micron particle load and other factors and may differ from that shown in Table 11 1 7 Discard the used silica gel desiccant without touching it It may contain nitric acid which is a corrosive and highly irritating substance 07889A DCN6900 199 Instrument Maintenance Teledyne API T204 NO 03 Analyzer Manual CAUTION GENERAL SAFETY HAZARD Immediately wash your hands after contact with the silica gel disiccant IMPORTANT 8 Using a small powder funnel fill the cartridge with about 10 g new silica gel desiccant Teledyne API P N CH43 so that it is level on both legs of the cartridge e Slight vibration is required to settle the chemical into the cartridge and achieve tightest packing which increases performance and lifetime of the filter e Ensure that the level of the chemical does not protrude farther than the first two threads of the NPT fitting IMPACT ON READINGS OR DATA Use only genuine pre conditioned Teledyne API s refill kits for this procedure Teledyne API s refill kits have been properly conditioned to prevent a significant increase of the T204 s Auto Zero value which can ca
84. enough LS WARNING ELECTRICAL SHOCK HAZARD Should the AC power circuit breaker trip investigate and correct the condition causing this situation before turning the analyzer back on 12 7 2 DC POWER SUPPLY If you have determined that the analyzer s AC mains power is working but the unit is still not operating properly there may be a problem with one of the instrument s switching power supplies The supplies can have two faults namely no DC output and noisy output To assist tracing DC Power Supply problems the wiring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the relay PCA follow a standard color coding scheme as defined in the following table Table 12 4 DC Power Test Point and Wiring Color Codes NAME TEST POINT COLOR DEFINITION DGND 1 Black Digital ground 5V 2 Red AGND 3 Green Analog ground 15V 4 Blue 15V 5 Yellow 12R 6 Purple 12 V return ground line 12V 7 Orange 234 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service eje Figure 12 4 Location of DC Power Test Points on Relay PCA 12 7 3 BUS A voltmeter should be used to verify that the DC voltages are correct per the values in the table below and an oscilloscope in AC mode with band limiting turned on can be used to evaluate if the supplies are produ
85. gain factor for NOx gas Default 1 e g 11 EXIT discards the new setting ENTR accepts the new setting 77 07889A DCN6900 87 Setup Menu Teledyne API T204 Analyzer Manual 4 Calibrate the analyzer e Ensure that the calibration span gas is either supplied through the same dilution system as the sample gas or has an appropriately lower actual concentration EXAMPLE If the reporting range limit is set for 100 ppm and the dilution ratio of the sample gas is 20 gain either e aspan gas with the concentration of 100 ppm can be used if the span gas passes through the same dilution steps as the sample gas or e abppm span gas must be used if the span gas IS NOT routed through the dilution system 5 5 SETUP PASS PASSWORD PROTECTION The T204 provides password protection of the calibration and setup functions to prevent unauthorized adjustments When the passwords have been enabled in the PASS menu item the system will prompt the user for a password anytime a password protected function e g SETUP is selected This allows normal operation of the instrument but requires the password 101 to access to the menus under SETUP When PASSWORD is disabled SETUP gt OFF any operator can enter the Primary Setup SETUP and Secondary Setup SETUP gt MORE menus Whether PASSWORD is enabled or disabled a password default 818 is required to enter the VARS or DIAG menus in the SETUP gt MORE menu T
86. green LEDs should be on e Ifthe lights are not lit locate the small switch on the rear panel to switch it between DTE and DCE modes e If both LEDs are still not illuminated ensure that the cable is properly constructed 42 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started Note ATTENTION Received from the factory the analyzer is set up to emulate an RS 232 DCE device RS 232 COM1 RS 232 fixed DB 9 male connector e Baud rate 115200 bits per second baud e Data Bits 8 data bits with 1 stop bit e Parity None COM2 RS 232 configurable to RS 485 DB 9 female connector e Baud rate 19200 bits per second baud e Data Bits 8 data bits with 1 stop bit e Parity None RS 232 MULTIDROP OPTION 62 CONNECTION When the RS 232 Multidrop option is installed connection adjustments and configuration through the menu system are required This section provides instructions for the internal connection adjustments then for external connections and ends with instructions for menu driven configuration Because the RS 232 Multidrop option uses both the RS232 and COM2 DB9 connectors on the analyzer s rear panel to connect the chain of instruments COM2 port is no longer available for separate RS 232 or RS 485 operation COULD DAMAGE INSTRUMENT AND VOID WARRANTY Printed Circuit Assemblies PCAs are sensitive to electro static discharges too small to be felt by the human nervous syst
87. in the T204 see Figure 13 7 for a pneumatic location of each orifice Despite the fact that these flow restrictors are protected by sintered stainless steel filters they can on occasion clog up particularly if the instrument is operated without sample filter or in an environment with very fine sub micron particle size dust INLET FITTING Loser P N FT10 O RING P N OR34 SPRING SINTERED P N HW20 FILTER P N FL1 O RING S lt P N CRITICAL FLOW gt ORIFICE SPECIFY DASH Ri FOR FLOW RATE O RING P N 00094 P N OR86 ORIFICE ae ee HOLDER a P N 04090 P N 04550D Figure 11 6 Critical Flow Orifice Assembly To clean or replace a critical flow orifice 1 Turn off power to the instrument and vacuum pump 2 Remove the analyzer cover and locate the reaction cell Figure 11 4 and Figure 11 5 3 Unscrew the 1 8 sample and ozone air tubes from the reaction cell For orifices on the reaction cell Figure 11 5 Unscrew the orifice holder with a 9 16 wrench e This part holds all components of the critical flow assembly as shown in Figure 11 6 e Appendix B contains a list of spare part numbers 5 Fororifices in the vacuum manifold the assembly is similar to the one shown in Figure 11 6 except e Without the orifice holder P N 04090 and bottom O ring P N OR34 and e With an NPT fitting in place of the FT 10 fitting 6 After taking off the connecting tube un
88. internal external gas lines damaged seals punctured gas lines a damaged malfunctioning pumps etc 5 Follow the procedures defined in Section 3 4 2 to confirm that the analyzer s vital functions are working power supplies CPU relay PCA touchscreen PMT cooler etc e See Figure 3 5 for the general layout of components and sub assemblies in the analyzer e See the wiring interconnect diagram and interconnect list in Appendix D FAULT DIAGNOSIS WITH WARNING MESSAGES The most common and or serious instrument failures will result in a warning message being displayed on the front panel Table 12 1 lists warning messages along with their meaning and recommended corrective action It should be noted that if more than two or three warning messages occur at the same time it is often an indication that some fundamental sub system power supply relay PCA motherboard has failed rather than an indication of the specific failures referenced by the warnings The analyzer will alert the user that a Warning Message is active by flashing the FAULT LED and displaying the Warning message in the Param field along with the CLR button press to clear Warning message The MSG button displays if there is more than one warning in queue or if you are in the TEST menu and have not yet cleared the message 214 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service The following display touch scree
89. is NOT greater than 0 9600 the NO converter needs to be replaced Starting from CONVERTER EFFICIENCY MENU see preceding steps CAL CONVERTER EFFICIENCY MENU NO2 CAL SET ENTR EXIT M P CAL CONVERTER EFFICIENCY MENU NO2 CAL SET SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt ENTR SETUP Toggle TST gt button until Set the Display to show the NOX STB test function E This function calculates SAMPLE NO2 PPB the stability of the NO NO lt TST TST gt measurement Allow NO gas of the proper concetration to enter the sample port at the rear of the analyzer SAMPLE NO2 STB XX X PPB Wait until NOX STB falls below 0 5 ppb This may take several minutes lt TST TST gt ENTR M P CAL CONVERTER EFICIENCY MENU NO2 CAL SET EXIT CE FACTOR 0 9852 Gain 8 5 2 ENTR EXIT 246 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 7 10 4 EVALUATING gt NO CONVERTER PERFORMANCE If the converter appears to have performance problems conversion efficiency is less than 96 check the following Recalculate the converter efficiency see previous section Accuracy of NO2 source GPT or gas tank standard e NO gas standards are typically certified to only 2 and often change in concentrations over time You should get the standard re certified every year e f you use the GPT calibration check the accuracy
90. is substituted for the PMT signal and feeds it into the preamplifier board e This signal is generated by circuitry on the pre amplifier board itself and tests the filtering and amplification functions of that assembly along with the A D converter on the motherboard e It does not test the PMT itself e The electrical test should produce a PMT signal of about 2000 1000 mV To activate the electrical test press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration display continuously cycles through all gasses Continue pressing lt TST or TST gt until SAMPLE PMT 2750 MV NOX XXXX lt TST TST gt CAL SETUP SETUP X X PRIMARY SETUP MENU ENTER PASSWORD CFG DAS RNGE PASS CLK MORE EXIT 8 1 8 SETUP SECONDARY SETUP MENU SIGNAL COMM VARS DIAG EXIT PREV NEXT Continue pressing NEXT until ELECTRICAL TEST PREV NEXT ENTR While the ETEST is active PMT should 2000 mv 1000mv DIAG ELEC PMT 2750 MV NOX XXXX lt TST TST CAL EXIT 07889A DCN6900 251 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 13 PMT PREAMPLIFIER BOARD To check the correct operation of the preamplifier board perform an the optics test OTEST and an electrical test ETEST described in Sections 12 7 12 1 and 12 7 12 2 above If the instrument passes the OTEST but fails the ETEST the preamplifier board may be faulty or need a hardware calibration
91. m 80 Sample restrictor temperature Diagnostic test input TEST INPUT 11 62 64 70 72 74 76 78 m Nosoefrrmesa O O O calibration just before computing new slope and offset HE calibration just before computing new slope and offset calibration just before computing new slope and offset 07889A DCN6900 A 29 APPENDIX A 7 MODBUS Register Map Teledyne API T200 T204 and 200E Series 05295F DCN6900 MODBUS Register Description Address decimal 0 based External analog input 4 slope eng unit V External analog input 5 slope eng unit V External analog input 6 slope eng unit V 16 16 16 19 19 Converter efficiency factor offset for range 3 202 concentration during zero span calibration just before computing new slope and offset Converter efficiency factor slope for range 3 fe as ANN ec oo OMNE p c i computing new slope and offset ma cse Eco sensor cell temperature 0 computing new slope and offset A 30 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version MODBUS Register Description Address decimal 0 based 41214 414 4 416 4 418 14 15 420 lt photometer measurement potential cell pressure O3 lamp temperature O3 bench serial number bench firmware revision MODBUS Floating Point Holding R
92. may be changing in concentrations as the linearity test is performed e Check for leaks as described in Section 11 3 10 The calibration device is in error e Check flow rates and concentrations particularly when using low concentrations e lfamass flow calibrator is used and the flow is less than 10 of the full scale flow on either flow controller you may need to purchase lower concentration standards The standard gases may be mislabeled as to type or concentration e Labeled concentrations may be outside the certified tolerance The sample delivery system may be contaminated e Check for dirt in the sample lines or reaction cell Calibration gas source may be contaminated NO in NO gas is common Dilution air contains sample or span gas Ozone concentration too low because of wet air in the generator e Generator system needs to be cleaned and dried with dry supply air e Check the sample gas dryer for leaks e This mostly affects linearity at the low end Ozone stream may be contaminated with impurities e exhausted ozone cleanser chemical will let compounds such as HNO ammonia derivatives break through to the reaction cell e Check the contents of the ozone cleanser and replace as necessary Section 11 3 3 e This also will affect linearity mostly at the low level Sample inlet may be contaminated with NOx exhaust from this or other analyzers e Verify proper venting of the pump exhaust 230 078
93. measurements viewable as TEST FUNCTIONS through the instrument s front panel display see Section 4 1 1 e The preset gain parameters are set at the factory and may vary from analyzer to analyzer The TPC feature is enabled or disabled by setting the value of the variable TPC ENABLE see Section 5 8 07889A DCN6900 313 Principles of Operation Teledyne API T204 Analyzer Manual 13 10 3 CALIBRATION SLOPE AND OFFSET Calibration of the analyzer is performed exclusively in software During instrument calibration see Sections 9 and 10 the user enters expected values for zero and span via the front panel touchscreen control and commands the instrument to make readings of calibrated sample gases for both levels e The readings taken are adjusted linearized and compared to the expected values e With this information the software computes values for instrument slope and offset and stores these values in memory for use in calculating the NO NO and NO concentrations of the sample gas The instrument slope and offset values recorded during the last calibration can be viewed via the instrument s front panel see Section 4 1 1 314 07889A DCN6900 INDEX A AC Power 21 309 311 115 VAC 311 50 HZ 311 60 Hz 21 235 309 311 AIN 114 AMBIENT ZERO SPAN VALVE OPTION 55 AMBIENT ZERO SPAN VALVE OPTION Flow Diagram 58 INTERNAL PNEUMATICS 58 Valve States 59 Ambient Zero Span Valve Options R
94. menu Table 5 3 lists all variables that are available within the 818 password protected level See Appendix A2 for a detailed listing of all of the T204 variables that are accessible through the remote interface Table 5 3 Variable Names VARS VARS VARIABLE DESCRIPTION DEFAULT VALUES Changes the Internal Data Acquisition System DAS May be set for HOLDOFF timer intervals DAS HOLD OFF No data is stored in the DAS channels during situations when the between software considers the data to be questionable such as during warm 9 5 20 min up of just after the instrument returns from one of its calibration mode to SAMPLE Mode Selects the gas measurement mode in which the instrument NO MEASURE MODE isto operate NOx only NO only or and NO NO NO simultaneously NO NO Selects which gas measurement is displayed when the NO ES STABIL GAS STABIL test function is selected NO NO Enables or disables the Temperature and Pressure ENABEE Compensation TPC feature Section 13 10 2 Dynamic zero automatically adjusts offset and slope of the DYN ZERO NO and NOx response when performing a zero point ON OFF calibration during an AutoCal see Section 9 3 Dynamic span automatically adjusts the offsets and slopes of DYN SPAN the NO and NO response when performing a span point ON OFF calibration during an AutoCal see Section 9 3 Sets the number of significant digits to the right
95. meter to measure the actual flow If there is proper flow of around 450 550 cm min contact customer service e is no flow or low flow continue with the next step 2 Check pressures e Check that the sample pressure is at or around 28 in Hg A at sea level adjust as necessary when in elevated location the pressure should be about 1 below ambient atmospheric pressure and that the RCEL pressure is below 10 in Hg A e The T204 will calculate a sample flow up to about 14 in Hg A RCEL pressure but a good pump should always provide less than 10 in e f both pressures are the same and around atmospheric pressure the pump does not operate properly or is not connected properly The instrument does not get any vacuum e f both pressures are about the same and low probably under 10 in Hg A or 20 on sample and 15 on vacuum there is a cross leak between sample flow 07889A DCN6900 223 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 3 path and vacuum most likely through the sample gas dryer flow paths See troubleshooting the sample gas dryer later in this chapter e Ifthe sample and vacuum pressures are around their nominal values 28 and lt 10 in Hg A respectively and the flow still displays XXXX carry out a leak check as described in Section 11 3 10 e f gas flows through the instrument during the above tests but goes to zero or is low when it is connected to zero air or spa
96. of the converter 5 Perform a straight dilution with 445 ppb NO gas amp air as a diluent gas 6 Input the NO gas into the analyzer T Allow the machine to stabilize amp write down the NOx value on line 2 of GPT data sheet Section 12 7 11 1 8 Remove the converter bypass so that the NO gas is flowing through the NO2 gt NO converter 9 Allow the machine to stabilize 10 Write down your NOx value on your data sheet on lines 3 AND line 5 of the GPT data sheet 11 Subtract line 2 from line 3 amp write that number down on line 4 Also write the NO value on line 8 of the data sheet e The specification shown on the data sheet is the value that is used by Teledyne API when performing the procedure on new NO NO converters e Older NO gt NO converters might outgas a bit more NO therefore a slightly wider specification might be in order e If this value is a constant or changes only slightly over time this is not a problem the machine will calibrate this out PART3 PERFORM THE SIMPLIFIED GPT CALCULATION 12 Generate the same 450 ppb NO gas amp input 400 ppb of O3 or generate 450 ppb NO amp 400 ppb NO2 if that s what your calibrator says 13 Allow the instrument to stabilize for 10 minutes 14 Write down the NOx value on line 6 amp the NO value on line 9 15 Subtract line 6 from line 6 amp put that onto line 7 16 Subtract line 8 from line 7 amp put that onto line 10 17 Write the number from
97. of the ozone source Age of the converter e The NO converter has a limited operating life and may need to be replaced every 3 years or when necessary e g earlier if used with continuously high NO concentrations e We estimate a lifetime of about 10000 ppm hours a cumulative product of the NO concentration times the exposure time to that concentration e This lifetime heavily depends on many factors such as e Absolute concentration temporary or permanent poisoning of the converter is possible e Sample flow rate and pressure inside the converter e Converter temperature e Duty cycle e This lifetime is only an estimated reference and not a guaranteed lifetime In some cases with excessive sample moisture the oxidized molybdenum metal chips inside the converter cartridge may bake together over time and restrict air flow through the converter in which case it needs to be replaced e Section 11 3 6 describes how to replace the NO converter cartridge With no NO in the sample gas and a properly calibrated analyzer the NO reading is negative while the NO reading remains around zero The converter is destroying NO and needs to be replaced With no NO in the sample gas and a properly calibrated analyzer the NOx reading is significantly higher than the actual gas standard NO concentration The converter is producing NO and needs to be replaced 12 7 11 DETERMINING CE BY SIMPLIFIED GPT CALIBRATION This s
98. panel is associated with the Concentration Alarm 1 set point in the software amp the Alarm 3 Relay on the rear panel is associated with the Concentration Alarm 2 set point in the software Alarm 2 Relay NO Alarm 1 xxx PPM Alarm 3 Relay Alarm 2 xxx PPM Alarm 2 Relay NOx Alarm 1 xxx PPM Alarm 3 Relay NOx Alarm 2 xxx PPM The Alarm 2 Relay will be turned on any time the concentration set point is exceeded amp will return to its normal state when the concentration value goes back below the concentration set point Even though the relay on the rear panel is a NON Latching alarm amp resets when the concentration goes back below the alarm set point the warning on the front panel of the instrument will remain latched until it is cleared You can clear the warning on the front panel by either pushing the CLR button on the front panel or through the serial port 38 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started In instruments that sample more than one gas type there could be more than one gas type triggering the Concentration 1 Alarm Alarm 2 Relay For example the T204 instrument can monitor both NO amp gas The software for this instrument is flexible enough to allow you to configure the alarms so that you can have 2 alarm levels for each gas NO Alarm 1 20 PPM NO Alarm 2 100 PPM Alarm 1 20 PPM Alarm 2 100 PPM In this example NO Ala
99. predictive diagnostics and maintenance of the T204 e The last 1100 daily averages are stored to cover more than four years of analyzer performance HIRES Records one minute instantaneous data of all active parameters in the T204 Short term trends as well as signal noise levels can be detected and documented e Readings during calibration and the calibration hold off period are included in the averages e The last 1500 data points are stored which covers a little more than one day of continuous data acquisition These default data channels can be used as they are or they can be customized from the front panel to fit a specific application They can also be deleted to make room for custom user programmed Data Channels Appendix A lists the firmware specific DAS configuration in plain text format This text file can either be loaded into APICOM and then modified and uploaded to the instrument or can be copied and pasted into a terminal program to be sent to the analyzer IMPORTANT IMPACT ON READINGS OR DATA Sending a DAS configuration to the analyzer through its COM ports will replace the existing configuration and will delete all stored data Back up any existing data and the DAS configuration before uploading new 07889A DCN6900 141 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual List of Channels List of Parameters Name CONC Event ATIMER lt Parameters 5
100. produce one molecule of oxygen O2 one molecule of nitrogen dioxide NO2 Some of the NO molecules created by this reaction retain excess energy from the collision and exist in an excited state where one of the electrons of the 07889A DCN6900 267 Principles of Operation Teledyne API T204 Analyzer Manual NO molecule resides in a higher energy state than normal denoted by an asterisk in the following equation Equation 13 1 NO 0 gt 0 e The second step occurs because the laws of thermodynamics require that systems seek the lowest stable energy state available therefore the excited molecule quickly returns to its ground state releasing the excess energy This release takes the form of a quantum of light hv The distribution of wavelengths for these quanta range between 600 and 3000 nm with a peak at about 1200 nm Equation 13 2 NO NO nm All things being constant temperature pressure amount of ozone present etc the relationship between the amount of NO present in the reaction cell and the amount of light emitted from the reaction is very linear If more NO is present more IR light is produced By measuring the amount of IR light produced with a sensor sensitive in the near infrared spectrum see Figure 13 2 the amount of NO present can be determined In addition sometimes the excited NO collides with other gaseous molecules in the reaction cell chamber or e
101. reading during reporting interval SDEV Records the standard deviation of the data points recorded during the reporting interval MIN Records minimum instantaneous reading during reporting interval MAX Records maximum instantaneous reading during reporting interval PRECISION 0 to 4 Sets the number of digits to the right decimal point for each record Example Setting 4 399 9865 PPB Setting 0 400 PPB STORE NUM OFF Stores only the average default SAMPLES ON Stores the average and the number of samples in used to compute the value of the parameter This property is only useful when the AVG sample mode is used Note that the number of samples is the same for all parameters in one channel and needs to be specified only for one of the parameters in that channel Users can specify up to 50 parameters per data channel the T204 provides about 40 parameters However the number of parameters and channels is ultimately limited by available memory Data channels can be edited individually from the front panel without affecting other data channels However when editing a data channel such as during adding deleting or editing parameters all data for that particular channel will be lost because the DAS can store only data of one format number of parameter columns etc for any given channel In addition a DAS configuration can only be uploaded remotely as an entire set of channels Hence remote update of the DAS will a
102. standard deviation of concentration readings of the selected gas NOx STB Data points are recorded every ten seconds The calculation uses the last 25 data points SAMP FLW CC M Gas flow rate of the sample gas into the reaction cell OZONE FL CC M Gas flow rate of Ozone Generator O gas into the reaction cell The raw signal output of the PMT The signal output of the PMT after is has been normalized for temperature pressure auto zero offset but not range The PMT signal with zero NOx which is usually slightly different from V This offset is subtracted from the PMT signal and adjusts for variations in the zero signal The output power level of the high voltage power supply The temperature of the gas inside the reaction cell temperature HVPS MOLY TEMP Tre temperature ortne analyzers NO2 NO A PB PB A PB PB v V C C PB V V V C C C C 07889A DCN6900 71 Overview of Operating Modes Teledyne API T204 Analyzer Manual DISPLAY UNITS DESCRIPTION IN HG A The current pressure of the sample gas in the reaction cell as measured at ln the vacuum manifold IN HG A The current pressure of the sample gas as it enters the reaction cell iind measured between the NO NO and Auto Zero valves NOx SLOPE The slope calculated during the most recent NO zero span calibration NOx OFFS The offset calculated during the most recent NO zero span calibration NO OFFS The offset calculat
103. string Some commands allow you to access variables messages and other items When using these commands you must type the entire name of the item you cannot abbreviate any names 07889A DCN6900 161 Remote Operation Teledyne API T204 Analyzer Manual 8 2 1 4 STATUS REPORTING Reporting of status messages as an audit trail is one of the three principal uses for the RS 232 interface the other two being the command line interface for controlling the instrument and the download of data in electronic format You can effectively disable the reporting feature by setting the interface to quiet mode Section 6 2 1 Table 6 1 Status reports include warning messages calibration and diagnostic status messages Refer to Appendix A for a list of the possible messages and this for information on controlling the instrument through the RS 232 interface 8 2 1 5 GENERAL MESSAGE FORMAT All messages from the instrument including those in response to a command line request are in the format X DDD HH MM MESSAGE lt CRLF gt Where X is a command type designator a single character indicating the message type as shown in the Table 8 2 DDD HH MM is the time stamp the date and time when the message was issued It consists of the Day of year DDD as a number from 1 to 366 the hour of the day HH as a number from 00 to 23 and the minute MM as a number from 00 to 59 ID is the analyzer ID a number with 1
104. switches the COMM port settings from a No parity 8 data bits 1 stop bit to Even parity 8 data bits 1 stop bit E 7 1 2048 When turned on this mode switches the COMM port settings from aid No parity 8 data bits 1 stop bit to Even parity 7 data bits 1 stop bit Configures the COM2 Port for RS 485 communication RS 485 mode has precedence RS 485 1024 over multidrop mode if both are enabled Also configuring for RS 485 disables the rear panel USB port SECURITY 4 When enabled the serial port requires a password before it will respond see Section 5 5 The only command that is active is the help screen CR MULTIDROP 32 Multidrop protocol allows a multi instrument configuration on a single communications PROTOCOL channel Multidrop requires the use of instrument IDs ENABLE 64 Enables to send a modem initialization string at power up Asserts certain lines in the MODEM RS 232 port to enable the modem to communicate ERROR 128 Fixes certain types of parity errors at certain Hessen protocol installations CHECKING XON XOFF 256 Disables XON XOFF data flow control also known as software handshaking HANDSHAKE Enables CTS RTS style hardwired transmission handshaking This style of data HARDWARE nO s HANDSHAKE 8 transmission handshaking is commonly used with modems or terminal emulation protocols as well as by Teledyne Instrument s APICOM software HARDWARE 512 Disables the HARDWARE FIFO First In First Out When FIFO is enabled it FI
105. that measures the temperature of the PMT and various components of the PMT cooling system including the TEC 13 6 1 PMT PREAMPLIFIER The PMT preamplifier board provides a variety of functions e t amplifies the PMT signal into a useable analog voltage PMTDET that can be processed by the motherboard into a digital signal to be used by the CPU to calculate the NO NO and NO concentrations of the gas in the sample chamber e It supplies the drive voltage for the HVPS e It includes the circuitry for switching between the two physical ranges e It amplifies the signal output by PMT temperature sensor and feeds it back to the thermoelectric cooler driver PCA This amplified signal is also sent to the Motherboard to be digitized and forwarded to the CPU It is viewable via the front panel as the test function PMT TEMP e t provides means for adjusting the electronic signal output from the PMT by e Adjusting this voltage directly the sensitivity of the PMT s dynode array and therefore the strength of the signal output by the PMT through the use of two hexadecimal switches e Directly adjusting the gain of the output signal 302 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation These adjustments should only be performed when encountering problems with the software calibration that cannot be rectified otherwise See Section 12 8 4 for more information about this hardware calibrati
106. the DATA CHANNEL to be SETUP CONC edited lt SET SET gt EDIT EXIT Continue pressing lt SET or SET gt until SETUP X X CAL HOLD OFF OFF lt SET SET gt EDIT SETUP X X CAL HOLD OFF OFF OFF ENTR EXIT EXIT discards the new setting Toggle these buttons to turn the HOLDOFF feature ON OFF ENTR accepts the new setting J HOLDOFF also prevents DAS measurements from being made at certain times when the quality of the analyzer s measurements may be suspect e g while the instrument is warming up In this case the length of time that the HOLDOFF feature is active is determined by the value of the internal variable VARS DAS_HOLDOFF To set the length of the DAS HOLDOFF period go to the SETUP gt MORE gt VARS menu and at the DAS_HOLDOFF parameter see Table 5 3 press the Edit button 154 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 3 9 THE COMPACT REPORT FEATURE When enabled this option avoids unnecessary line breaks on all RS 232 reports Instead of reporting each parameter in one channel on a separate line up to five parameters are reported in one line The COMPACT DATA REPORT generally cannot be accessed from the standard DAS front panel menu but is available via the instrument s communication ports by using APICOM or the analyzer s standard serial data protocol 7 1 3 10 THE STARTING DATE FEAT
107. the chamber is completely dark the T204 records the output of the PMT and keeps a running average of these AZERO values This average offset value is subtracted from the raw PMT readings while the instrument is measuring NO and NOx to arrive at an Auto Zero corrected reading 07889A DCN6900 271 Principles of Operation Teledyne API T204 Analyzer Manual INSTRUMENT CHASSIS Measurement Cell MEASURE REFERENCE VALVE REFERENCE CYCLE GAS PATH c SAMPLE Particulate GAS INLET Filter MEASURE CYCLE GAS PATH sorption Tube GAS PRESSURE SENSOR 2 NO NOx VALVE ee a eee FLOW PRESSURE D x SENSORPCA O H EN SAMPLE VACUUM lt gt PRESSURE PRESSURE 1 SENSOR SENSOR i NO e Os FLOW e EXHAUST Converter SENSOR i GAS OUTLET AUTOZERO com VALVE US S 4 2 S GEN Flow 500 em min Flow 80 Orifice Dia Orifice Dia 0 010 0 004 EXHAUST MANIFOLD Destruct PERMAPURE DRYER Flow 80 cm min Orifice Dia Figure 13 4 Pneumatic Flow During the Auto Zero Cycle 272 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 2 OZONE MEASUREMENT PRINCIPLE The detection of ozone molecules is based on absorption of 254 nm UV light due to an internal electronic resona
108. the gas downstream from it and is also used as the main diagnostic for proper pump operation If the ratio between the upstream pressure and the downstream pressure falls below 2 1 a warning message SAMPLE FLOW WARN is displayed on the analyzer s front panel see Section 4 1 2 and the sample flow rate will display XXXX instead of an actual value If this pressure exceeds 10 in Hg A an RCEL PRESS WARN is issued even though the analyzer will continue to calculate a sample flow up to 14 in Hg If the Temperature Pressure Compensation TPC feature is turned on see Section 13 10 2 the output of this sensor is also used to supply pressure data for that calculation This measurement is viewable through the analyzer s front panel as the test function RCEL and the SIGNAL I O function RCELL PRESSURE SAMPLE GAS FLOW CALCULATION Sample gas flow in the T204 analyzer is not a directly measured value but is rather calculated based on the measured pressure differential across the sample gas critical flow orifice Specifically the upstream reading of the sample pressure sensor is compared to the downstream pressure reading of the vacuum pressure sensor and this differential is used by the analyzer s CPU to derive the gas flow rate through the reaction cell The results of this calculation are viewable from the instruments front panel via the test function SAMP FLW Since this is a calculated value and not a measured reading there is no
109. to 4 digits MESSAGE is the message content that may contain warning messages test measurements variable values etc lt CRLF gt is a carriage return line feed pair which terminates the message The uniform nature of the output messages makes it easy for a host computer to parse them into an easy structure Keep in mind that the front panel display does not give any information on the time a message was issued hence it is useful to log such messages for troubleshooting and reference purposes Terminal emulation programs such as HyperTerminal can capture these messages to text files for later review 8 3 REMOTE ACCESS BY MODEM The T204 can be connected to a modem for remote access This requires a cable between the analyzer s COMM port and the modem typically a DB 9F to DB 25M cable available from Teledyne API with P N WRO000024 Once the cable has been connected check to ensure that e The DTE DCE is in the DCE position e The T204 COMM port is set for a baud rate that is compatible with the modem e The Modem is designed to operate with an 8 bit word length with one stop bit e The MODEM ENABLE communication mode is turned ON Mode 64 see Section 6 2 1 162 07889A DCN6900 Teledyne API T204 Analyzer Manual Remote Operation Once this is completed the appropriate setup command line for your modem can be entered into the analyzer The default setting for this feature is AT YO DO HO 10 SO 0 Th
110. to a specific analog output channel select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO SET gt CAL EXIT Continue pressing SET gt until you reach the output to be configured DIAG CONC OUT 2 5V OVR NOCAL SET SET EDIT DIAG AIO CONC OUT 2 RANGE 5V SET gt EDIT Continue pressing SET gt until DIAG AIO CONC OUT 2 REC OFS 0 mV SET SET EDIT Toggle these DIAG AIO CONC OUT 2 REC OFS 0 mV buttons to set 0 0 0 0 ENTR EXIT the desired offset value DIAG AIO CONC_OUT_2 REC OFS 10 mV 0 0 1 DIAG AIO CONC_OUT_2 REC OFS 10 mV ENTR EXIT 0 lt SET SET gt EDIT 07889A DCN6900 111 Setup Menu Teledyne API T204 Analyzer Manual 5 9 3 10 AIN CALIBRATION DIAG AIO Perform Troubleshooting or call Teledyne APIs Customer Service This is the submenu to conduct a calibration of the T204 analyzer s analog inputs This calibration should only be necessary after major repair such as a replacement of CPU motherboard or power supplies To perform an analog input calibration select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED NO lt SET SET gt CAL Continue
111. to review all test data once per week and to do an exhaustive data analysis for test and concentration values once per month paying particular attention to sudden or gradual changes in all parameters that are supposed to remain constant such as the flow rates 226 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 5 CALIBRATION PROBLEMS This section describes possible causes of calibration problems 12 5 1 NEGATIVE CONCENTRATIONS Negative concentrations can have a variety of causes as described below 12 5 1 1 NEGATIVE NOx CONCENTRATIONS For NOx measurements negative concentration values can be caused for several reasons e Asslight negative signal is normal when the analyzer is operating under zero gas and the signal is drifting around the zero calibration point e This is caused by the analyzer s zero noise and may cause reported concentrations to be negative for a few seconds at a time down to 20 ppb but should randomly alternate with similarly high positive values e The T204 has a built in Auto Zero function which should take care of most of these deviations from zero but may yield a small residual negative value e If larger negative values persist continuously check if the Auto Zero function was accidentally turned off using the remote variables in Appendix A e In this case the sensitivity of the analyzer may be drifting negative e Acorruption of the Au
112. tools creates a risk of causing a significant leak 4 Take off the old filter element and replace it with a suitable equivalent Teledyne API P N FL 3 FITTING BODY DO NOT LOOSEN THESE FITTINGS HEX NUT HOWEVER IF IT BECOMES NECESSARY DO NOT TO RE TIGHTEN THESE FITTINGS MAIN DRYER ENSURE THAT THEY ARE TIGHTENED OVER FITTING LOOSEN THE PLASTIC INSERT AND THE O RING OF NUT DO NOT NUT THE INNER TUBING TIGHTEN BY HAND LOOSEN DO NOT AS MUCHAS POSSIBLE AND THEN DFU PARTICLE TIGHTEN 1 2 TURN WITH A WRENCH FILTER P N FL3 0 P N 04543A Figure 11 2 Particle Filter on O4 Generator Supply Air Dryer 07889A DCN6900 197 Instrument Maintenance Teledyne API T204 Analyzer Manual Holding the main dryer fitting steady with a 5 8 wrench and tighten the nut with your hands e f necessary use a second wrench but do not over tighten the nut Replace the cover plug in the power cord and restart the analyzer Check the O3 flow rate it should be around 80 cm min 15 Check the RCEL pressure e It should be the same value as recorded in Step 1 of this procedure Refer to Section Checking for Light Leaks to leak check after installing the new DFU particle filter 11 3 3 CHANGING THE OZONE GENERATOR CLEANSER CHEMICAL The ozone cleanser located next to the generator see Figure 3 5 cleans the stream from solid and liquid contaminants that are crea
113. when the analyzer is monitoring sample gas can be the most difficult and time consuming to isolate and resolve The following section provides an itemized list of the most common dynamic problems with recommended troubleshooting checks and corrective actions 12 6 1 EXCESSIVE NOISE Excessive noise levels under normal operation usually indicate leaks in the sample supply or the analyzer itself Ensure that the sample or span gas supply is leak free and carry out a detailed leak check as described earlier in this chapter Another possibility of excessive signal noise may be the preamplifier board the high voltage power supply and or the PMT detector itself e Contact the factory on troubleshooting these components 12 6 2 SLOW RESPONSE If the analyzer starts responding too slow to any changes in sample zero or span gas check for the following e Dirty or plugged sample filter or sample lines e Sample inlet line is too long e Leaking NO NOx valve Carry out a leak check e Dirty or plugged critical flow orifices Check flows pressures and if necessary change orifices Section 11 3 8 e Wrong materials in contact with sample use glass stainless steel or Teflon materials only Porous materials in particular will cause memory effects and slow changes in response e Dirty reaction cell Clean the reaction cell e Insufficient time allowed for purging of lines upstream of the analyzer Wait until stability is low e
114. you adjust the setting to an allowable value the ENTR button will re appear The T204 analyzer software has a variety of operating modes The most common mode that the analyzer will be operating in is the SAMPLE mode In this mode a continuous read out of the sample gas concentrations can be viewed on the front panel and output as an analog voltage from rear panel terminals The second most important operating mode is SETUP mode This mode is used for configuring the various sub systems of the analyzer such as for the DAS system the reporting ranges or the serial RS 232 RS 485 Ethernet communication channels The SETUP mode is also used for performing various diagnostic tests during troubleshooting 394 8 PPB 0 0 PPB 394 8 PPB 123 0 PPB O O O Figure 4 1 Front Panel Display 07889A DCN6900 69 Overview of Operating Modes Teledyne API T204 Analyzer Manual The mode field of the front panel display indicates to the user which operating mode the unit is currently running In addition to SAMPLE and SETUP other modes the analyzer can be operated in are described in Table 4 1 below Table 4 1 Analyzer Operating Modes DAG O One of the analyzer s diagnostic modes is active LO CAL A Unit is performing LOW SPAN midpoint calibration initiated automatically by the analyzer s AUTOCAL feature Unit is performing LOW SPAN midpoint calibration initiated remotely through the COM port
115. 03 Typical Thermo Electric Cooler E TE 304 PMT Cooling System Block 1 ERES 305 Power Distribution Block Diagram eicere ican EA RES 307 Location of AC power Configuration Jumpers 308 Pump AC Power Jumpers JP 7 ftii 309 Typical Set Up of AC Heater Jumper Set JP2 sssssssss 310 Front Panel and Display Interface Block Diagram 311 Basic Software Operation ssssssssssssssssssssseeseeen 312 T204 Basic Unit Specifications enne ener ennemis 19 Display Screen and Touch Control Description 27 Rear Panel Description 30 Analog Input Pin Assignments seieren EEA AERE 33 Analog Output Pin Assignments sesssssssssse eene nennen nennen nennen nennen erre nnns 34 Status Output Pin Assignments ssssssssssseen eene nennen nnne nennen nnn 36 Control Input Pin Assignments 0 00 eter e etter er
116. 04 ANALYZER IN ITS BASE CONFIGURATION IMPORTANT IMPACT ON READINGS OR DATA ZERO SPAN CALIBRATION CHECKS VS ZERO SPAN CALIBRATION Pressing the ENTR button during the following procedure resets the stored values for OFFSET and SLOPE and alters the instrument s Calibration This should ONLY BE DONE during an actual calibration of the T204 170 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Calibration Procedures 9 2 1 SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION OF THE T204 ANALYZER Connect the sources of zero air and span gas as shown below in one of the following ways Source of VENT here if input a a a a SAMPLE GAS is pressurized Removed during calibration MODEL 700E Gas Dilution T i Calibrator 2 o MODEL 701 Zero Gas Generator is not already vented Calibrated NOx at HIGH Span Concentration 8 Figure 9 1 Set up for Manual Calibrations Checks of T204 s in Base Configuration w a Gas Dilution Calibrator E Source of DR ES aay SN NEU MENT Hered input gt tn SAMPLE GAS Removed during calibration MODEL 701 Zero Gas Generator Calibrated NOx at HIGH Span Concentration Enclosur Wall Figure 9 2 Set up for Manual Calibrations Checks of T204 s in Base Configuration w Bottled Gas 07889A DCN6900 171 Calibration Procedures Teledyne API T204 Analyzer
117. 096_MV and REF_GND e f both are within 3 mV of nominal 4096 and 0 and are stable 0 2 mV then the basic A D is functioning properly If not then the motherboard is bad 2 Choose a parameter in the Signal I O function list see Section 12 1 3 such as OZONE FLOW e Compare this voltages at its origin see the interconnect drawing and interconnect list in Appendix D with the voltage displayed through the signal I O function If the wiring is intact but there is a large difference between the measured and displayed voltage 10 mV then the motherboard is bad STATUS OUTPUTS SYSTEM OK 1000 Q Figure 12 5 Typical Set Up of Status Output Test To test the status output electronics 1 Connect a jumper between the D and the V pin on the status output connector Connect a 1000 ohm resistor between the pin and the pin for the status output that is being tested Connect a voltmeter between the V pin and the pin of the output being tested 238 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service Under the DIAG Signal I O menu see Section 12 1 3 scroll through the inputs and outputs until you get to the output in question Alternately turn on and off the output noting the voltage on the voltmeter e It should vary between 0 volts for ON and 5
118. 1 4 exhaust tube and the 1 8 sample and ozone air tubes from the reaction cell Disconnect the heater thermistor cable 3 Remove two screws Teledyne API P N SN144 and two washers holding the reaction cell to the PMT housing and lift the cell and manifold out SENSOR HOUSING REFER TO FIGURE 12 20 CONNECTOR BRACKET P N 01831 SCREW INTEGRATED ORIFICE P N SN232 ASSEMBLY SAMPLE P N 04450 HEATER REFER TO CONNECTOR FIGURE 13 7 a ORIFICE S SA ASSEMBLY O x O RING THERMISTOR LA P N 04450 P N OR44 P N 00329 i REFER TO HEATER L FIGURE 13 7 REACTION CELL PIN HE17 MANIFOLD SM P N 00884 WINDOW GASKET P N 00227 OPTICAL FILTER P N 00273 SCREW DNE gt P N SN150 S VACUUM FITTING REACTION CELL INNER SLEEVE SCREW NOZZLE UNPLATED P N SN144 SAMPLE P N 00133 SCREW P N 00134 O RING P N SN150 P N OR2 TEATER NOZZLE 03 P N HE17 03 UNPLATED SCREW P N 00135 PIN SN144 WHER SWITCH P N SN22 PIN SW6 4 PLACES ina SCREW INTEGRATED P N Sos P N 0114205 Figure 11 5 Reaction Cell Assembly 07889A DCN6900 205 Instrument Maintenance Teledyne API T204 Analyzer Manual 10 11 Remove two screws Teledyne API P N SN150 and two washers The reaction cell will separate into two halves the stainless steel manifold
119. 12 B ski 06802 _0426801 _ a 7 Int Pump 05676 PRINTED DOCUMENTS ARE UNCONTROLLED CONTRACT TELEDYNE NA Advanced Pollution Instrumentation A Teledyne Technologies Company mz INTERCONNECT DRAWING T200X a P 11 7F4 06911 C peus 1 31 OSs 1a 4 oF 4 D 3
120. 143 CALDAT 143 CONC 142 Defaults 142 DIAG 143 HIRES 143 Compact Data Report 157 Default Settings 142 HOLD OFF 97 156 Number of Records 154 Parameters 142 149 AZERO 143 HVPS 143 NXCNC1 146 STABIL 143 Precision 149 Report Period 152 157 Sample Mode AVG 149 150 151 153 INST 149 150 151 153 MAX 149 MIN 149 150 151 153 SDEV 149 150 151 153 Sample Period 152 Starting Date 157 Store Number of Samples 149 150 151 153 Triggerning Events 142 148 ATIMER 146 148 EXITZR 148 SLPCHG 143 148 DAS HOLD OFF 97 data acquisition See DAS DATA INITIALIZED 61 75 DC Power 38 39 235 236 308 DC Power Test Points 235 236 Default Settings COMM PORT 44 DAS 142 Hessen Protocol 135 139 VARS 97 DHCP 125 DIAG DAS Channel 143 DIAG AIO 98 DIAG AOUT 98 DIAG ELEC 98 DIAG FCAL 98 DIAG I O 98 DIAG OPTIC 98 DIAGNOSTIC MENU DIAG 78 90 91 92 237 Accesing 99 AIN Calibrated 101 AIN CALIBRATED 114 Analog I O AOUT CALIBRATED Configuration 101 105 CONC_OUT_1 101 CONC_OUT_2 101 CONC_OUT_3 101 Analog I O Configuration 98 102 103 104 105 106 108 110 112 113 114 Analog Output Step Test 98 238 Electrical Test 98 Flow Calibration 98 Optic Test 98 OZONE GEN OVERRIDE 98 Signal I O 98 SIGNAL I O 220 221 223 237 239 240 295 Diagnostics 197 Dilution Ratio 50 Display Precision 97 DYN_SPAN 97 DYN_ZERO 97 Dynamic Span 97 Dynamic Zero 97 E
121. 2 123 are all valid integers Hexadecimal integer data are used for the same purposes as integers They consist of the two characters Ox followed by one or more hexadecimal digits 0 9 A F a f which is the programming language convention No plus or minus sign is permitted For example 0x1 0x12 0x1234abcd are all valid hexadecimal integers Floating point numbers are used to specify continuously variable values such as temperature set points time intervals warning limits voltages etc They consist of an optional plus or minus sign followed by zero or more digits an optional decimal point and zero or more digits At least one digit must appear before or after the decimal point Scientific notation is not permitted For example 1 0 1234 5678 0 1 1 are all valid floating point numbers Boolean expressions are used to specify the value of variables or I O signals that may assume only two values They are denoted by the key words ON and OFF Text strings are used to represent data that cannot be easily represented by other data types such as data channel names which may contain letters and numbers They consist of a quotation mark followed by one or more printable characters including spaces letters numbers and symbols and a final quotation mark For example 1 123abe and Q lt gt are all valid text strings It is not possible to include a quotation mark character within a text
122. 236 TELEDYNE ADVANCED POLLUTION INSTRUMENTATION Everywhereyoulook Operation Manual Model T204 Nitrogen Oxides O Analyzer TELEDYNE ADVANCED POLLUTION INSTRUMENTATION TAPI 9480 CARROLL PARK DRIVE SAN DIEGO CA 92121 5201 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 Copyright 2013 2014 07889A DCN6900 Teledyne Advanced Pollution Instrumentation 25 August 2014 NOTICE OF COPYRIGHT 2014 Teledyne Advanced Pollution Instrumentation 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 07889A DCN6900 i Teledyne API T204 Analyzer Manual This page intentionally left blank 07889A DCN6900 SAFETY MESSAGES Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage Please read these messages carefully Each safety message is associated with a safety alert symbol and are placed throughout this manual and inside the instrument The symbols with messages are defined as follows WARNING Electrical Shock Hazard HAZARD Strong oxidizer GENERAL WARNING CAUTION Read the accompanying message for specific information CAUTION Hot Surface Warning Do Not
123. 3 24 Location of AC power Configuration Jumpers 308 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 8 1 1 AC CONFIGURATION INTERNAL PUMP JP7 If your T204 includes an internal pump the following table jumper set JP7 is used to configure the power supplied to it as shown in Figure 13 25 Table 13 5 AC Power Configuration for Internal Pumps JP7 JUMPER LINE LINE JUMPER POWER FREQUENCY COLOR SNES Connects pump pin 3 to 110 115 VAC power line WHITE Connects pump pin 3 to 110 115 VAC power line 110 Connects pump pins 2 amp 4 to Neutral 115 VAC Connects pump pin to 110 115 VAC power line 50 HZ BLACK Connects pump pin 3 to 110 115 VAC power line Connects pump pins 2 amp 4 to Neutral sow Brown Connects pump pins 3 and 4 together 220VAC Connects pump pin 1 to 220 240VAC power line 240 VAC omues Connects pump pins 3 and 4 together Connects pump pin 1 to 220 240VAC power line x A jumper between pins 5 and 10 may be present on the jumper plug assembly but has no function on the Model T204 110 VAC 115 VAC 220 VAC 240 VAC a N 1 oa FF a A O N May be present on 50 Hz version of jumper set but is not functional on the T200 Figure 13 25 Pump AC Power Jumpers JP7 07889A DCN6900 309 Principles of Operation Teledyne API T204 Analyzer Ma
124. 3 6 Analog In Connector Pin assignments for the Analog In connector are presented in Table 3 3 Table 3 3 Analog Input Pin Assignments PIN DESCRIPTION Scar 1 Analog input 1 AIN 1 2 Analog input 2 AIN 2 3 Analog input 3 AIN 3 4 Analog input 4 AIN 4 5 Analog input 5 AIN 5 6 Analog input 6 AIN 6 7 Analog input 7 AIN 7 8 Analog input 8 8 GND Analog input Ground N A 1 See Section 0 for details on setting up the DAS 3 3 1 3 CONNECTING ANALOG OUTPUTS The T204 is equipped with several analog output channels accessible through a connector on the back panel of the instrument Output channels 1 A2 A3 and 4 are assigned to the NO NO NO and analyzer s concentration signals respectively The default analog output voltage setting of these channels is 0 to 5 VDC with a reporting range of 0 to 500 ppb An optional Current Loop output is available for each Section 3 3 1 4 To access these signals attach a strip chart recorder and or data logger to the appropriate analog output connections on the rear panel of the analyzer Figure 3 7 shows the pin assignments for the analog output connector 07889A DCN6900 33 Getting Started Teledyne API T204 Analyzer Manual ANALOG OUT 1 2 4 Figure 3 7 Analog Output Connector Table 3 4 Analog Output Pin Assignments S
125. 5 4 Diagnostic Mode DIAG Functions DIAG SUBMENU SUBMENU FUNCTION Allows observation of all digital and analog signals SIGNAL I O in the instrument Allows certain digital signals such as valves and heaters to be toggled ON and OFF When entered the analyzer performs an analog ANALOG OUTPUT output step test This can be used to calibrate a chart recorder or to test the analog output accuracy The signal levels of the instruments analog outputs may be calibrated either individually or as a group Various electronic parameters such as signal span and offset are available for viewing and configuration When activated the analyzer performs an optic test which turns on an LED located inside the sensor module OPTIC TEST near the PMT Figure 13 18 This diagnostic tests the response of the PMT without having to supply span gas When activated the analyzer performs an electrical test ELECTRICAL which generates a current intended to simulate the PMT TEST output to verify the signal handling and conditioning of the PMT preamp board ANALOG I O CONFIGURATION Allows the user to manually turn the O3 generator on or DVEHBIBES off During initial power up TMR timer is displayed while the Ozone brick remains off for the first 30 minutes These settings are retained after exiting DIAG mode s DIAG ELEC DIAG OZONE FLOW This function is used to calibrate the gas flow output CALIBRATION signals of sample gas and ozo
126. 5 4 3 for instructions If any problems occur while performing the following calibration procedures refer to Section 12 1 for troubleshooting tips 9 1 1 REQUIRED EQUIPMENT SUPPLIES AND EXPENDABLES Calibration of the T204 requires e Zero air source e Span gas source e Gas lines all gas line materials should be stainless steel or Teflon type PTFE or FEP e High concentration NO gas transported over long distances may require stainless steel to avoid oxidation of NO due to the possibility of Os diffusing into the tubing e Arecording device such as a strip chart recorder and or data logger optional e For electronic documentation the internal data acquisition system DAS can be used 07889A DCN6900 167 Calibration Procedures Teledyne API T204 Analyzer Manual 9 1 2 CALIBRATION GASES 9 1 2 1 Note 9 1 2 2 ZERO AIR Zero air or zero calibration gas is defined as a gas that is similar in chemical composition to the measured medium but without the gas to be measured by the analyzer For the T204 this means zero air should be devoid of NO NH or vapor Moderate amounts of NH and H O can be removed from the sample gas stream by installing the optional sample gas dryer and scrubber e f your application is not a measurement in ambient air the zero calibration gas should be matched to the composition of the gas being measured e Pure nitrogen N2 could b
127. 500 ppb and the default span gas concentration is 400 0 ppb To set the span gas concentration NOx shown press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP SELECT CAL GAS To Calibrate press ENTR EXIT Use these keys to select the appropriate range RANGE 500 0 PPB NOX XXXX each range TST TST ZERO SPAN CONC EXIT M P CAL CONCENTRATION MENU NOX NO CONV M P CAL NOX SPAN CONC 80 0 Conc EXIT ignores the new ENTR EXI setting and returns to the previous display 400 0 PPB If this is not the the concentration of the span gas being used toggle For NOx and NO ENTR accepts the these buttons to set the correct new setting and returns to the concentration of the NOx and NO CONCENTRATION MENU calibration gases If using NO span gas in addition to NOx repeat last step For ENTR accepts the new setting and proceeds to the CAL O3 MP Mode 176 07889A DCN6900 Teledyne API T204 Analyzer Manual Calibration Procedures 9 2 7 2 ZERO SPAN POINT CALIBRATION PROCEDURE SAMPLE RANGE 500 0 PPB XXXX Set the Display to show lt TST TST gt CAL CALZ CALS SETUP the NOX STB test function This function calculates the stability of the NO NO Toggle TST gt button until measurement SAMPLE NOX STB XXX XPPB NOX XXX X Analyzer continues to cycle through NOx NO and NO measureme
128. 50201 STEEL CABLE CLAMP SCREW P N HW162 PIN SN72 P di ar ae A CONVERTER HOUSING P N 04016 P N 0187202G Figure 11 4 Converter Assembly 10 Wrap the band heater around the new replacement converter cartridge and tighten the screws using a high temperature anti seize agent Teledyne API P N CH42 such as copper paste e Ensure to use proper alignment of the heater with respect to the converter tubes 11 Replace the Moly converter assembly by routing the cables through the holes in the converter housing and reconnecting them properly 12 Reconnect the steel cable clamp around the power leads for safe operation 13 Reattach the tube fittings to the converter and replace the Moly insulation top layer and corner cut out layers 14 Reinstall the converter assembly cover 15 Reinstall the instrument cover and power up the analyzer 16 Allow the converter to burn in for 24 hours and then recalibrate the instrument 204 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 11 3 7 CLEANING THE REACTION CELL A dirty reaction cell will cause excessive noise drifting zero or span values low response or a combination of all To clean the reaction cell it is necessary to remove it from the sensor housing 1 Turn off the instrument power and vacuum pump Refer to Figure 11 5 for the following procedure 2 Disconnect the black
129. 800 324 5190FAX 858 657 9816 07889A DCN6900 3 29 TELEDYNE erent nepal ADVANCED POLLUTION INSTRUMENTATION 08156 DCN6900 Everywhereyoulook NOX SLOPE 1 0 0 3 NOX OFFS MV 50 TO 150 NO SLOPE 1 0 0 3 NO OFFS MV 50 TO 150 ETEST PMT MV 2000 1000 OTEST PMT MV 2000 1000 Values are in the Signal I O REF_4096_MV MV 4096mv 2my and Must be Stable REF GND MV 0 0 5 and Must be Stable RCELL PRESSURE IN HG A SAMPLE PRESSURE WHAT ARE THE FAILURE SYMPTOMS WHAT ARE THE RCELL SAMPLE amp 03 CELL PRESSURES WITH THE SAMPLE INLET ON REAR OF MACHINE CAPPED IN HG A O3CELL PRESSURE PSIA WHAT TEST S HAVE YOU DONE TRYING TO SOLVE THE PROBLEM THANK YOU FOR PROVIDING THIS INFORMATION YOUR ASSISTANCE ENABLES TELEDYNE API TO RESPOND PERTINENT DATA FASTER TO THE PROBLEM THAT YOU ARE ENCOUNTERING Teledyne API Technical Support IF POSSIBLE PLEASE INCLUDE A PORTION OF A STRIP CHART PERTAINING TO THE PROBLEM CIRCLE EMAIL SDA_techsupport teledyne com TOLL FREE 800 324 5190FAX 858 657 9816 PHONE 858 657 9800 07889A DCN6900 APPENDIX D Interconnect Drawing 07889A DCN6900 D 1 D 2 This page intentionally left blank 07889A DCN6900 AUX I O 067300100 ANALOG IN OPT 06760 KEY 1 All part numbers in falic identify A cables that are refered to in the accompanying document 069110100 2 All it
130. 89A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service Span gas overflow is not properly vented and creates a back pressure on the sample inlet port e Also if the span gas is not vented at all and does not supply enough sample gas the analyzer may be evacuating the sample line e Ensure to create and properly vent excess span gas Diffusion of oxygen into Teflon type tubing over long distances e PTFE or related materials can act as permeation devices In fact the permeable membrane of permeation tubes is made of PTFE e When using very long supply lines gt 1 m between high concentrations span gases and the dilution system oxygen from ambient air can diffuse into the line and react with NO to form This reaction is dependent on NO concentration and accelerates with increasing NO concentration hence affects linearity only at high NO levels Using stainless steel for long span gas supply lines avoids this problem 12 5 7 DISCREPANCY BETWEEN ANALOG OUTPUT AND DISPLAY If the concentration reported through the analog outputs does not agree with the value reported on the front panel you may need to recalibrate the analog outputs This becomes more likely when using a low concentration or low analog output range Analog outputs running at 0 1 V full scale should always be calibrated manually See Section 5 9 3 2 for a detailed description of this procedure 12 5 8 DISCREP
131. 9 312 Hessen Protocol 118 132 134 135 139 and Reporting Ranges 136 Default Settings 135 Gas List 137 138 Latency Period 132 SETUP Parameters 132 Status Flag Default Settings 139 Modes 139 Unassigned Flags 139 Unused Bits 139 Warnings 139 types 134 High voltage power supply HVPS 61 73 HIRES 143 HVPS 73 DAS Parameter 143 HVPS WARNING 61 75 139 2 222 289 295 296 Status LED 222 IND Range Mode 83 85 Interferents 64 Internal Pump 311 Internal Span Gas Generator AutoCal 181 182 Hessen Flags 139 INVALID CONC 139 IZS TEMP WARNING 139 M Machine ID 47 Maintenance Schedule 143 195 266 276 MANIFOLD TEMP WARN 139 Material Safety Data Sheet 281 MEASURE MODE 97 Menu Buttons CAL 76 266 CALS 76 177 266 CALZ 76 177 CONC 97 240 266 ENTR 78 92 153 185 195 EXIT 78 Message Field 29 microcomputer 289 314 Mode Field 29 Modem 164 243 MOLY TEMP 73 Motherboard 75 101 109 218 219 222 235 237 289 291 295 309 Multidrop 47 118 132 N Nafion 282 283 National Institute of Standards and Technology NIST 182 Standard Reference Materials SRM 171 Handbook 190 Website 189 49 64 170 283 NO OFFSET 74 NO SLOPE 74 gt NO Converter 61 64 73 75 196 205 223 229 233 243 244 245 248 257 259 277 278 285 299 NORM PMT 73 NOX OFFSET 74 NXCNC1 146 O2CELL TEMP WARN 139 Generat
132. A trei e eode 94 Accessing the DIAG Submenus ciiir arina arein EEA EAEEREN TIAE nenne 97 Accessing the Analog I O Configuration Submenus sse 100 Setup for Checking Calibrating DCV Analog Output Signal 105 Setup for Checking Calibration Current Output Signal Levels Using an Ammeter 107 Alternative Setup Using 2500 Resistor for Checking Current Output Signal Levels 109 COMM Communication Modes Setup sss enne 117 COMM COMM Port Baud Rate sssssssssseeeeeenneenen mener nennen nennen nennen nennen 118 COMM COM Test ARAA 119 COMM LAN Manual emm 122 COMM LAN Internet Automatic Configuration DHCP sse 124 COMM Change Hostname sss eene a nennen nnne nennen 125 Default DAS Channels Setup sss enne nnn herren ennt nine 142 APICOM Remote Control Program 156 Sample APICOM User Interface for Configuring the 5 157 DAS Configuration Through a Terminal Emulation 158 Remote Access eur
133. AN 97 DYN_ZERO 97 MEASURE_MODE 97 STABIL_GAS 97 TPC_ENABLE 97 Venting 52 53 56 W warm up period 60 Warning Messages 60 61 75 216 218 ANALOG CAL WARNING 61 75 139 AUTOZERO WARNING 139 AZERO WARN 61 75 BOX TEMP WARNING 61 75 139 CANNOT DYN SPAN 61 75 139 CANNOT DYN ZERO 61 75 139 CONFIG INITIALIZED 61 75 CONV TEMP WARNING 61 139 DATA INITIALIZED 61 75 FRONT PANEL WARN 139 HVPS WARNING 61 75 139 INVALID CONC 139 IZS TEMP WARNING 139 MANIFOLD TEMP WARN 139 O2 CELL TEMP WARN 139 OZONE FLOW WARNING 61 75 139 OZONE GEN OFF 61 75 139 PMT TEMP WARNING 61 75 139 320 07889A DCN6900 Teledyne API T204 Analyzer Manual INDEX RCELL PRESS WARN 61 75 139 RCELL TEMP WARNING 61 75 139 REAR BOARD NOT DET 62 75 RELAY BOARD WARN 62 75 139 SAMPLE FLOW WARNING 62 75 139 SYSTEM RESET 61 75 139 WARNING MESSAGES CONV TEMP WARNING 75 Watchdog Circuit 222 Status LED 222 298 Z Zero Air 32 49 52 116 169 170 173 182 ZERO AIR INLET 55 56 ZERO AIR Inlet 32 ZERO SPAN valve 180 ZERO_CAL 240 07889A DCN6900 321 INDEX Teledyne API T204 Analyzer Manual This page intentionally left blank 322 07889A DCN6900 Teledyne T200 T204 and 200E Series 05295F DCN6900 APPENDIX A Version Specific Software Documentation APPENDIX A Version Specific Software Documentation APPENDIX A 1 SOFTWARE ME
134. ANCY BETWEEN NO AND NOX SLOPES If the slopes for NO and NOx are significantly different after software calibration more than 1 consider the following three problems NO impurities in the NO calibration gas NO gases often exhibit NO on the order of 1 296 of the NO value e This will cause differences in the calibration slopes If the NO impurity in NO is known it can easily be accounted for by setting the expected values for NO and NO2 accordingly to different values e g 448 ppb NO and 450 ppb NOx e This problem is worse if NO gas is stored in a cylinder with balance air instead of balance gas nitrogen or large amounts of nitrous oxide N20 e oxygen the air slowly reacts with NO to yield increasing over time The expected concentrations for NO and NOx in the calibration menu are set to different values e Ifa gas with 100 pure NO is used this would cause a bias e See Section 9 2 3 1 on how to set expected concentration values The converter efficiency parameter has been set to a value not equal to 1 000 even though the conversion efficiency is 1 0 e The actual conversion efficiency needs to match the parameter set the CAL menu e See Section 9 1 4 for more information on this feature 07889A DCN6900 231 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 6 OTHER PERFORMANCE PROBLEMS Dynamic problems i e problems that only manifest themselves
135. ARNING on the front panel display and the respective test function reports XXXX instead of a value 0 This message applies to both a flow rate of zero as well as a flow that is outside the standard range 350 600 cm min If the analyzer displays XXXX for the sample flow confirm that the external sample pump is operating and configured for the proper AC voltage e Whereas the T204 can be internally configured for two different power regimes 100 120 V and 220 240 V either 50 or 60 Hz the external pump is physically different for each of three power regimes 100 V 50 Hz 115 V 60 Hz and 230 V 50 Hz e If the pump is not running use an AC Voltmeter to ensure that the pump is supplied with the proper AC power If AC power is supplied properly but the pump is not running replace the pump Sample and vacuum pressures mentioned in this chapter refer to N operation of the analyzer at sea level Pressure values need to be adjusted for elevated locations as the ambient pressure decreases by about 1 in Hg per 300 m 1000 ft If the pump is operating but the unit reports a XXXX gas flow take the following three steps 1 Check for actual sample flow e To check the actual sample flow disconnect the sample tube from the sample inlet on the rear panel of the instrument e Ensure that the unit is in basic SAMPLE mode e Place a finger over the inlet and see if it gets sucked in by the vacuum or more properly use a flow
136. AUTO_ZERO_VALVE OFF PREV NEXT JUMP OFF PRNT On status signals this Pressing the PRNT key will send a key toggles the signal formatted printout to the serial port ON OFF 5 and can be captured with a computer or other output device Figure 12 1 Example of Signal I O Function Mote ONLY until signal I O menu is exited The Analyzer regains control of these signals upon exit See Appendix A for a complete list of the parameters available for review 07889A DCN6900 219 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 2 SENSOR TROUBLESHOOTING WARNING FAULTCONDTION O3 CELL LAMP WARN cell lamp temperature warning CELL PRESS WARN cell pressure warning O3 CELL TEMP WARN sensor sample temperature outside of warning limits 12 3 USING THE INTERNAL ELECTRONIC STATUS LEDS Several LEDs are located inside the instrument to assist in determining if the analyzer s CPU bus and Relay PCA are functioning properly 12 3 1 CPU STATUS INDICATOR 085 a red LED that is located on upper portion of the motherboard just to the right of the CPU board flashes when the CPU is running the main program loop After power up approximately 30 60 seconds 055 should flash on and off If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted contact Teledyne API s Customer Service Department see Sec
137. Air flows through the glass tube between the two conductive coatings in effect creating a capacitor with the air and glass acting as the dielectric The layers of glass also separate the conductive surfaces from the air stream to prevent reaction with the Os As the capacitor charges and discharges electrons are created and accelerated across the air gap and collide with the molecules in the air stream splitting them into elemental oxygen Some of these oxygen atoms recombine with to The quantity of ozone produced is dependent on factors such as the voltage and frequency of the alternating current applied to the CD cells When enough high energy electrons are produced to ionize the molecules a light emitting gaseous plasma is formed which is commonly referred to as a corona hence the name corona discharge generator Dried Ambient Air In Conductive Coating Glass Wall Reaction chamber where is produced Glass Wall Conductive Coating Power Supply w O Out approx 10000 v Figure 13 8 Ozone Generator Principle OZONE GENERATOR DRY AIR SUPPLY Ambient air usually contains enough water vapor to greatly diminish the yield of ozone produced by the ozone generator Water also reacts with chemicals inside the O Generator to produce caustic substances such as ammonium sulfate or highly corrosive nitric acid that will damage the optical filter located between the reaction cell
138. CA 1 2 3 4 Perform a full zero point calibration using zero air see Section 9 Display the NOx STB test function on the front panel Section 4 1 1 Locate the preamplifier board see Figure 3 5 Locate the following components on the preamplifier board Figure 12 8 e HVPS coarse adjustment switch Range 0 9 then A F e HVPS fine adjustment switch Range 0 9 then A F e Gain adjustment potentiometer Full scale is 10 turns Turn the gain adjustment potentiometer 12 turns clockwise or to its maximum setting 07889A DCN6900 259 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 6 Feed NO gas into the analyzer e This should be 90 of the upper limit setting for the T204 s reporting range EXAMPLE if the reporting range is set at 500 ppb use 450 ppb NO 7 Waituntil the STB value is below 0 5 ppb CN210 Connector to TEC control board S2 HVPS Coarse Adjustment 51 HVPS Fine Adjustment R29 Gain Adjustment CN541 Configuration Plug CN480 Connector to Signals CN477 Connector to Power R28 OTEST Adjustment R19 ETEST Adjustment CN561 Connector to HVPS and PMT Figure 12 8 Pre Amplifier Board Layout 8 Scroll to the NORM PMT test function on the analyzer s front panel 9 With the NO gas concentrations mentioned in Step 5 above the norm pmt value should be 900 mV 10 Set the HVPS coarse adjustment to its minimum setting 0 11 Set the HVPS fine a
139. CE HAZARD allowed to cool hours CAUTION Wear gloves prior to changing the NO Converter to ensure that the fiberglass insulation does not come into contact with your skin Turn off the analyzer power Remove the instrument cover and allow the converter to cool Remove the converter assembly cover as well as the Moly insulation top layer and corner cut out layers until the Moly converter assembly can be seen Remove the tube fittings from the Moly converter assembly Disconnect the power and the thermocouple from the Moly converter assembly Unscrew the steel cable clamp for the power leads from the converter housing with a Phillips head screw driver Remove the Moly converter assembly converter cartridge and band heater from the converter housing e Make a note of the orientation of the tubes relative to the heater cartridge Unscrew the band heater and loosen it Remove the old converter cartridge 07889A DCN6900 203 Instrument Maintenance Teledyne API T204 Analyzer Manual CONVERTER COVER ASSEMBLY P N 04230 MOLY INSULATION 2 PLACES TOP amp BOTTOM LAYER P N 00780 THERMOCOUPLE POWER D LEADS HEATER BAND ASSEMBLY P N 052930200 GROMMET EUMD 2 PLACES MOLY INSULATION TUBE 2PLACES 3 PLACES FITTINGS CORNER CUT OUTLAYER P N FT37 MOYE MOLY P N 007901 2 PLACES P ai CONVERTER CARTRIDGE ASSEMBLY P N 06239 P N 0101
140. COMM Used to set up and operate the analyzer s various external I O channels including RS 232 RS 485 modem communication and or Ethernet access System Status Variables VARS Used to view various variables related to the instruments current operational status e Changes made to any variable are not acknowledged and recorded in the instrument s memory until the ENTR button is pressed e Pressing the EXIT button ignores the new setting e f the EXIT button is pressed before the ENTR button the analyzer will beep alerting the user that the newly entered value has been lost 5 8 System Diagnostic Features and Analog Output Configuration DIAG Used to access a variety of functions that are used to configure test or diagnose problems with a variety of the analyzer s basic systems Most notably the menus used to configure the output signals generated by the instruments analog outputs are located here 5 9 5 9 2 IMPORTANT IMPACT ON READINGS OR DATA Any changes made to a variable during the SETUP procedures are not acknowledged by the instrument until the ENTR button is pressed If the EXIT button is pressed before the ENTR button the analyzer will make an audible signal before exiting the menu alerting the user that the newly 76 07889A DCN6900 5 SETUP MENU The SETUP Mode menu is used to set instrument parameters for performing configuration calibration reporting and diagno
141. Configuration for Standard AC Heaters 2 310 xiv 07889A DCN6900 PART GENERAL INFORMATION 07889A DCN6900 16 07889A DCN6900 1 INTRODUCTION FEATURES AND OPTIONS 1 1 OVERVIEW Teledyne API s Model T204 Nitrogen Oxides Analyzer also referred to as T204 uses chemiluminescence detection to measure nitric oxide NO nitrogen dioxide NO and the total nitrogen oxides NO It also uses UV absorption photometry in a separate process to detect and measure ozone 03 The T204 microprocessor controlled software provides sensitive accurate and dependable performance employing such features as Auto Zero Adaptive Filtering and temperature and pressure compensation In addition the T204 analyzer s multi tasking ability allows tracking and reporting of multiple operational parameters in real time These parameters can be logged by the internal data acquisition system DAS and easily retrieved via our APICOM software to facilitate predictive diagnostics and enhanced data analysis by tracking parameter trends 1 2 FEATURES Some other exceptional features of your T204 Nitrogen Oxides Analyzer are e Independent ranges and auto ranging e Simultaneous NO NOx and O readings e Large vivid and durable graphics display with capacitive touch screen interface e Mutti tasking software to allow viewing test variables while operating e Conti
142. D PREV NEXT INS DEL EDIT PRNT EXIT SETUP X X DELETE YES NO DELETED 136 07889A DCN6900 Teledyne API T204 Analyzer Manual Communications Setup and Operation 6 7 2 6 SETTING HESSEN PROTOCOL STATUS FLAGS Teledyne API s implementation of Hessen protocols includes a set of status bits that the instrument includes in responses to inform the host computer of its condition Each bit can be assigned to one operational and warning message flag The default settings for these bit flags are Table 6 6 Default Hessen Status Flag Assignments 3 DEFAULT BIT STATUS FLAG NAME ASSIGNMENT 0000 2000 1000 6000 SPARE UNUSED BITS 0100 FRONTPANELWARN 1 Only applicable if the optional internal span gas generator is installed Only applicable if the T204 is equipped with an oxygenator option 3 It is possible to assign more than one flag to the same Hessen status bit This allows the grouping of similar flags such as all temperature warnings under the same status bit Be careful not to assign conflicting flags to the same bit as each status bit will be triggered if any of the assigned flags is active 07889A DCN6900 137 Communications Setup and Operation Teledyne API T204 Analyzer Manual To assign or reset the status flag bit assignments press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST CAL SETUP Concentration field displays all gases SETUP X
143. D 77 Research Triangle Park N C 27711 EPA 600 4 79 057 September 1979 3 Transfer Standards for Calibration of Ambient Air Monitoring Analyzers for Ozone EPA publication available from EPA Department E MD 77 Research Triangle Park N C 27711 EPA 600 4 79 056 September 1979 4 Ambient Air Quality Surveillance Code of Federal Regulations Title 40 Part 58 U S Environmental Protection Agency Evaluation of Ozone Calibration Procedures EPA 600 S4 80 050 February 1981 6 Quality Assurance Handbook for Air Pollution Measurement Systems Vol I EPA 600 9 76 005 March 1976 7 Field Operations Guide for Automatic Air Monitoring Equipment U S Environmental Protection Agency Office of Air Programs October 1972 Publication No APTD 0736 PB 202 249 and PB 204 650 188 07889A DCN6900 Teledyne API T204 Analyzer Manual EPA Protocol Calibration 8 Appendix A Quality Assurance Requirements for State and Local Air Monitoring Stations SLAMS Code of Federal Regulations Title 40 Part 58 9 Appendix B Quality Assurance Requirements for Prevention of Significant Deterioration PSD Air Monitoring Code of Federal Regulations Title 40 Part 50 Appendix D 10 Aeros Manual Series Volume 11 Aeros User s Manual EPA 450 2 76 029 OAQPS No 1 2 039 December 1976 11 Quality Assurance Handbook for Air Pollution Measurement Systems Volume Il abbreviated Handbook Volume 11 National
144. DINGS OR DATA DAS operation is suspended whenever its configuration is edited using the analyzer s front panel and therefore data may be lost To prevent such data loss it is recommended to use the APICOM graphical user interface for DAS changes Section 7 2 1 Please be aware that all stored data will be erased if the analyzer s disk on module or CPU board is replaced or if the configuration data stored 07889A DCN6900 139 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual Note 7 1 7 1 1 7 1 1 1 DAS STRUCTURE The DAS is designed around the feature of a record A record is a single data point The type of data captured in a record are defined by two properties e PARAMETER type that defines the kind of data to be stored e g the average of concentrations measured with three digits of precision See Section 7 1 3 3 e A TRIGGER event that defines when the record is made e g timer every time a calibration is performed etc See Section 7 1 3 2 The specific PARAMETERS and TRIGGER events that describe an individual record are defined in a construct called a DATA CHANNEL see Section 7 1 3 Each data channel relates one or more parameters with a specific trigger event and various other operational characteristics related to the records being made e g the channels name number or records to be made time period between records whether or not the record is
145. E 500 0PPB XXXX Set the Display to show Analyzer continues to lt TST TST gt CAL SETUP the NOX STB test cycle through NO function NO and This function calculates measurements the stability of the NO NO throughout this Toggle TST gt button until measurement procedure SAMPLE NOX STB XXX X PPB NOX XXX X lt TST TST gt CAL SETUP Allow zero gas to enter the sample port at the rear of the analyzer Wait until NOX STB falls below 0 5 ppB This may take several minutes SAMPLE NOX STB XXX X PPB NOX XXX X lt TST TST gt CAL SETUP Press ENTR to changes M P CAL NOX STB XXX X PPB NOX XXX X the OFFSET amp SLOPE values for both the NO and NO measurements Press EXIT to leave the calibration unchanged and return to the previous lt TST TST gt ZERO CONC EXIT M P CAL NOX STB XXX XPPB NOX X XXX lt TST TST gt ENTR CONC EXIT Allow span gas to enter the sample port at the rear of the analyzer Wait until NOX STB falls below 0 5 PPB This may take several minutes SAMPLE NOX STB XXX X PPB NOX XXX X TST TST gt CAL SETUP The SPAN button now appears during the transition from zero to span Press ENTR to changes M P CAL NOX STB XXX X PPB NOX X XXX the OFFSET amp SLOPE values for both the NO and NO measurements Press EXIT to leave the calibration unchanged and return to the previous You may see both buttons If either the ZERO or SPAN button
146. EDIT ENTR accepts Toggle this button DIAGAIO CONC OUT 2 AUTO CAL ON ihe new setings to turn AUTO CAL pO EXIT ignores the ON or OFF ON ENTR EXIT new setting OFF manual lt calibration mode DIAGAIO CONC_OUT_2 AUTO CAL OFF OFF ENTR EXIT 102 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 9 3 4 AUTOMATIC GROUP CALIBRATION OF THE ANALOG OUTPUTS IMPORTANT IMPACT ON READINGS OR DATA Manual calibration should be used for any analog output set for a 0 1V output range or in cases where the outputs must be closely matched to the characteristics of the recording device See Sections 5 9 3 2 5 9 3 3 IMPORTANT IMPACT ON READINGS OR DATA Before performing this procedure ensure that the AUTO CAL for each analog To calibrate the outputs as a group with the AOUTS CALIBRATION command select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AlO CONFIGURATION SUBMENU DIAG TEST_OUTPUT replaced by CONC_OUT_4 O2 Concentration ANALOG I O CONFIGURATION PREV NEXT ENTR on analyzers with the optional sensor installed DIAG AIO AOUTS CALIBRATED NO SET CAL AIO AUTO CALIBRATING CONC OUT 1 This message in iod DIAG AIO NOT AUTO CAL CONC OUT 2 tion automatically i AUTO CAL is calibrates all channels for which E DIAG AIO AUTO CALIBRATING CONC OUT 3 pos or AUTO CAL is turned a channel 7
147. EEPROM Disk on Module 151 218 Electrical Connections AC Power 309 310 Analog Outputs 35 36 81 Current Loop 37 109 Voltage Ranges 107 Control Inputs 39 240 Ethernet 19 78 123 Modem 164 243 Multidrop 48 Serial COMM Ports 42 44 Electrical Test 98 229 252 306 Electro Static Discharge 25 36 45 ENTR Button 78 92 153 185 195 Environmental Protection Agency EPA 22 169 171 Calibration 50 63 76 171 NIST Traceability 189 Contact Information 191 QA Handbook 189 190 Reference Documents 189 190 Title 40 189 Website 189 ETEST 264 Ethernet 71 123 Configuration using DHCP 125 DHCP 125 316 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual INDEX HOSTNAME 127 Exhaust Gas 32 Exhaust Gas Outlet 32 53 57 EXIT Button 78 EXITZR 148 F Final Test and Validation Data Sheet 26 62 197 Flash Chip 290 flow control assemblies 278 Flow Diagram Pressurized Span Gas Inlet Option 59 Pressurized Zero Air Inlet 59 Front Panel 27 267 314 Concentration Field 29 Display 98 218 Message Field 29 Mode Field 29 Status LED s 29 141 Touchscreen Definition Field 29 FRONT PANEL WARN 139 G Temperature 73 Gas Inlets 218 219 Sample 32 Span 32 SPAN 55 ZERO AIR 55 56 ZERO AIR 32 Gas Outlets 34 63 Exhaust 32 53 57 H 2 50 64 171 Heaters 98 149 205 206 207 208 218 223 224 235 237 243 244 265 289 296 299 300 30
148. FF 07889 DCN6900 17 APPENDIX A 4 Signal lO Definitions Teledyne API T200 T204 and 200E Series 05295F DCN6900 Signal Name Bit or Channel Description Number ST CO2 CAL P ST O3 23 0 1 oll in calibration mode in measure or other calibration r in O3 calibration mode in measure or other calibration r B status outputs U27 J1018 pins 1 8 bits 0 7 default I C Front panel I C keyboard default 2 address 4E MAINT MODE 5 input 1 LANG2_SELECT 6 input SAMPLE_LED 8 output CAL_LED 9 output AUDIBLE_BEEPER 14 output 0 10 output oj oje Oje oje Il pi maintenance mode normal mode select second language select first language English sample LED on off cal LED on off fault LED on off beeper on for diagnostic testinc off Relay board digital output PCF8575 default I C addr 1 IZS_HEATER CO2_CELL_HEATER SPAN_VALVE ZERO VALVE FP OJ JF OFF OFF OFF Alternate between and 1 at least to keep relay board active reaction cell heater on off converter heater on off bypass or dilution manifold heat off IZS heater on off CO sensor cell heater on off sensor cell heater on off let span gas in let zero gas in let zero gas in let sample gas in let cal gas in let sample gas in let zero air in let sample
149. FIED TECHNICIAN The operations outlined in this chapter are to be performed by qualified maintenance personnel only 12 8 1 DISK ON MODULE REPLACEMENT PROCEDURE Note Servicing of circuit components requires electrostatic discharge protection i e ESD grounding straps mats and containers Failure to use ESD protection when working with electronic assemblies will void the instrument warranty Refer to the manual Fundamentals of ESD PN 04786 available on our website at http www teledyne api com under Help Center gt Product Manuals in the Special Manuals section for information on preventing ESD damage Replacing the Disk on Module DOM will cause loss of all DAS data it may also cause loss of some instrument configuration parameters unless the replacement DOM carries the exact same firmware version Whenever changing the version of installed software the memory must be reset Failure to ensure that memory is reset can cause the analyzer to malfunction and invalidate measurements After the memory is reset the A D converter must be re calibrated and all information collected in Step 1 below must be re entered before the instrument will function correctly Also zero and span calibration should be performed 1 Document all analyzer parameters that may have been changed such as range auto cal analog output serial port and other settings before replacing the DOM 2 Turn off power to the instrument fold down the rear pane
150. FO improves data transfer rate for that COMM port COMMAND 4096 Enables a command prompt when in terminal mode PROMPT 1 Modes are listed the order in which they appear in the SETUP gt MORE gt COMM gt COM 1 OR 2 gt MODE menu The default setting for this feature is ON Do not disable unless so instructed by Teledyne API s Customer Service personnel 116 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation Communication Modes for each COMM port must be configured independently To turn on or off the communication modes for either COMI or COMO access the SETUP gt MORE COM1 OR COM2 menu and at the COMI 2 Mode menu press EDIT SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID INET COM1 COM2 Combined Mode ID COM1 MODE 0 displayed here lt SET SET gt EDIT EXIT COM1 QUIET MODE OFF PREV NEXT OFF EXIT Use the PREV and oa NEXT buttons to scroll between the available modes COM1 HESSEN PROTOCOL OFF Activate Deactivate PREV NEXT OFF EXIT the selected mode by toggling the ON OFF button COM1 HESSEN PROTOCOL ON PREV NEXT ON ENTR EXIT EXIT discards the new setting ENTR accepts the new setting PREV and NEXT buttons to contin
151. FS Voltage across Voltage across Resistor for 2 20 mA Resistor for 4 20 mA 0 500 mVDC 1000 mVDC 100 5000 mVDC 5000 mVDC 07889A DCN6900 109 Setup Menu Teledyne API T204 Analyzer Manual 5 9 3 8 TURNING AN ANALOG OUTPUT OVER RANGE FEATURE ON OFF In its default configuration a 5 over range is available on each of the T204 s analog outputs This over range can be disabled if your recording device is sensitive to excess voltage or current To turn the over range feature on or off select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR AOUTS CALIBRATED NO CAL DIAG AIO CONC OUT 2 5V OVR NOCAL SET SET EDIT DIAG AIO CONC OUT 2 RANGE 5V SET EDIT DIAG AIO CONC OUT 2 OVERRANGE ON SET SET EDIT Toggle this CONC OUT 2 OVERRANGE ON button to turn the Over ENTR EXIT Range feature ON OFF CONC OUT 2 OVERRANGE OFF ENTR EXIT 110 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 9 3 9 ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT Some analog signal recorders require that the zero signal be significantly different from the baseline of the recorder in order to record slightly negative readings from noise around the zero point This can be achieved in the T204 by defining a zero offset a small voltage e g 10 of span add a zero offset
152. Figure Auto Zero vacuum luminescence reaction is stopped 13 4 valve manifold 4 65 Analyzer measures background noise without sample gas Cycle repeats every minute 13 3 2 FLOW RATE CONTROL CRITICAL FLOW ORIFICES Sample gas flow in the T204 analyzer is created via the use of several flow control assemblies see Figure 13 6 for an example located in various places in the gas streams of the instrument These assemblies consist of e acritical flow orifice e two o rings Located just before and after the critical flow orifice the o rings seal the gap between the walls of assembly housing and the critical flow orifice e a sintered filter e aspring applies mechanical force needed to form the seal between the o rings the critical flow orifice and the assembly housing High Critical flow Low pressure orifice pressure regime regime A ee m t Gas at sonic speed Spring Filter O rings Figure 13 6 Flow Control Assembly amp Critical Flow Orifice 276 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 3 2 1 CRITICAL FLOW ORIFICE The most important component of each flow control assembly is the critical flow orifice Critical flow orifices are a simple means to regulate stable gas flow rates They operate without moving parts by taking advantage of the laws of fluid dynamics By restricting the flow of gas through
153. Flow 218 Sample Pressure 218 292 Sample Temperature 218 Thermistors 293 Box Temperature 293 Reaction Cell Temperature 293 Sample Temperature 218 Thermocouples Inputs 301 VACUUM PRESSURE 292 Serial I O Ports 22 217 218 289 Modem 164 243 Multidrop 47 118 RS 232 19 45 71 78 142 155 157 161 291 Troubleshooting 243 RS 485 71 118 291 Signal I O OZONE FLOW 239 REF 4096 MV 239 REF GND 239 Sintered Filter 267 Slope 218 316 SLOPE 195 316 SLPCHG 143 148 SNGL 64 82 SNGL Range Mode 82 SO 64 SO FLOW SENSOR 292 Span Gas 32 50 52 56 63 66 80 98 169 170 171 173 175 178 182 266 Dilution Feature 89 Standard Reference Materials SRM s NO NO Span Gas 171 Span Inlet 32 55 SPAN CAL 1 240 Specifications 21 STABIL DAS Parameter 143 STABIL GAS 97 Standard Reference Materials SRM Handbook 190 Standard Temperature and Pressure 88 status LED s 299 Status LED s CPU 222 C 222 Relay PCA 222 297 298 309 Os Option 223 Watchdog 222 298 Status Outputs 38 86 239 240 294 07889A DCN6900 319 INDEX Teledyne API T204 Analyzer Manual ST_CONC_VALID 240 ST_DIAG 240 ST_HIGH_RANGE 240 ST_O2_CAL 240 ST_SPAN_CAL 240 ST_SYSTEM_OK 240 ST_ZERO_CAL 240 STB Stability Test function 73 97 SYSTEM RESET 61 75 139 Teledyne Contact Information Email Address 268 Fax 268 Phone 268 Technical Assistance 268 Website 268 Te
154. IMPORTANT IMPACT ON READINGS OR DATA Sample and calibration gases should only come into contact with PTFE 46 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started ATTENTION IMPORTANT COULD DAMAGE INSTRUMENT AND VOID WARRANTY Venting Pressurized Gas In applications where any gas span gas zero air supply sample gas is received from a pressurized manifold a vent must be provided to equalize the gas with ambient atmospheric pressure before it enters the analyzer to ensure that the gases input do not exceed the maximum inlet pressure of the analyzer as well as to prevent back diffusion and pressure effects These vents should be at least 0 2m long no more than 2m long vented outside the shelter or immediate area surrounding the instrument Dust Plugs Remove dust plugs from rear panel exhaust and supply line fittings before powering on operating instrument These plugs should be kept for reuse in the event of future storage or shipping to prevent debris from entering the pneumatics Leak Check Run a leak check once the appropriate pneumatic connections have been made check all pneumatic fittings for leaks using the procedures defined in Section 11 3 10 1 3 3 2 1 ABOUT ZERO AIR AND CALIBRATION SPAN GAS Note Zero air and span gas are required for accurate calibration specified gas flow rate Therefore the T204 zero and span gases should be supplied to their respective
155. IZS temperature sensor cell temperature Spare sensor cell temperature Diagnostic temperature input Remote box temperature 07889A DCN6900 A 19 APPENDIX A4 Signal lO Definitions Teledyne API T200 T204 and 200E Series 05295F DCN6900 Signal Name Bit or Channel Description Number 6 Diagnostic temperature input MANIFODD TEMP Bypass or dilution manifold tempera Rear board DAC MUX analog inputs MUX default I O add Rear board analog outputs default I O address 3 Concentration output 1 NOx DATA DATAOUT 15 m oe Data output 1 Concentration output 2 NO DATA DATAOUT25 2 Data output 2 Concentration output 3 NO2 Test measurement output Concentration output 4 CO2 O5 External analog input board default I C address 5C hex 20 07889 DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version K3 Signal Name Bit or Channel Description Number Hessen protocol M200EH M200EU M200EUP 5 Triple range option User configurable D A output option 7 Pressurized zero span option 8 Dual NOx option MAS special 10 Factory option 1 O option 12 Optional 13 Probe select special 15 option m a valve option Concentration alarm option MODBUS option High auto range relay option Low span option Remote range co
156. Insufficient time allowed for NO or NO calibration gas source to become stable Wait until stability is low e NO converter temperature is too low Check for proper temperature 12 6 3 AUTO ZERO WARNINGS Note Auto Zero warnings occur if the signal measured during an Auto Zero cycle is higher than 200 mV e If this value is higher than 150 mV check that the Auto Zero valve is operating properly e Todo so use the SIGNAL I O functions in the DIAG menu to toggle the valve on and off e Listen to hear whether the valve is switching and look to see if the respective LED on the relay board is indicating functionality 232 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service Note e Scroll the TST functions until PMT is displayed and observe the PMT value change between the two valve states e Ifthe valve is operating properly you should be able to hear it switch once a minute under normal operation or when manually activated from the SIGNAL menu e the PMT value should drop from span gas reading e g 800 900 mV at 400 ppb NO to less than 150 mV and the LED on the relay board should light up when the valve is activated e If the PMT value drops significantly but not to less than 150 mV the valve is probably leaking across its ports e Inthis case replace the valve e If the PMT value does not change at all the valve is probably not switching at all
157. LIBRATING CONC OUT 2 calibrates the DCV signal output from the analog output channel to the VDC to mA converter LU DIAG AIO CONC OUT 2 CURR Z 0 mV U100 UP10 UP DOWN DN10 D100 ENTR EXIT These button increase decrease the analog output signal level not the value on the display by 100 10 or 1 counts DIAG AIO CONC OUT 2 CURR S 5000 mV signal output by These menus adjust the mAmp converter circuit Continue adjustments until the current signal measured at the output of the analyzer matches the zero and span points of the intended current range e g 0 20 mA 4 mA 20 mA DIAG AIO CONC OUT 2 CALIBRATED YES U100 UP10 UP DOWN DN10 D100 ENTR EXIT SET SET CAL EXIT 108 07889A DCN6900 Teledyne API T204 Analyzer Manual Setup Menu An alternate method for measuring the output of the Current Loop converter is to connect a 250 ohm 1 resistor across the current loop output in lieu of the current meter see Figure 3 7 for pin assignments and diagram of the analog output connector This allows the use of a voltmeter connected across the resistor to measure converter output as VDC or mVDC V OUT VIN ANALYZER Recording Device Figure 5 8 Alternative Setup Using 250Q Resistor for Checking Current Output Signal Levels In this case follow the procedure above but adjust the output for the following values Table 5 8 Current Loop Output Check
158. Manual 9 2 2 PERFORMING A BASIC MANUAL CALIBRATION CHECK The example procedure below illustrates a typical NOx calibration follow the same for O3 SAMPLE RANGE 500 0 PPB NOX XXXX Set the Display to show lt TST TST gt CAL SETUP the NOX STB test function Concentration field This function calculates displays all of the the stability of the NO NO available gas Toggle TST gt button until measurement measurements throughout this procedure SAMPLE NOX STB XXX X PPM NOX XXX X lt TST TST gt CAL SETUP Allow ZERO GAS to enter the sample port at the rear of the analyzer Record NOx NO or zero point readings DO NOT press the ENTR button Allow SPAN GAS to enter the sample port at the rear of the analyzer The ZERO and or SPAN buttons will appear at various points of this process Wait until NOX STB falls below 0 5 ppm This may take several minutes Wait until NOX STB falls below 0 5 ppm This may take several minutes It is not necessary to press them Record NOx NO NO span point readings DO NOT press the ENTR button NOTE In certain instances where low Span gas concentrations are present s 50 ppb both the ZERO amp SPAN buttons may appear simultaneously If the ZERO or SPAN buttons are not displayed the measurement made is Mole outside the allowable range for a reliable calibration See Section 12 for troubleshooting tips
159. Manual Principles of Operation 13 4 3 3 THERMISTOR INTERFACE This circuit provides excitation termination and signal selection for several negative coefficient thermistor temperature sensors located inside the analyzer They are REACTION CELL TEMPERATURE SENSOR The reaction cell temperature sensor is a thermistor embedded in the reaction cell manifold This temperature is used by the CPU to control the reaction cell heating circuit and as a parameter in the temperature pressure compensation algorithm e The value of this signal is viewable via the front panel test function RCEL TEMP and the SIGNAL I O function RCELL TEMP e Itis recorded by the DAS system as the parameter RCTEMP BOX TEMPERATURE SENSOR A thermistor is attached to the motherboard It measures the analyzer s inside temperature This information is stored by the CPU and can be viewed by the user for troubleshooting purposes through the front panel display It is also used as part of the NO NO and NO calculations when the instrument s Temperature Pressure Compensation feature is enabled e The value of this signal is viewable via the front panel test function BOX TEMP and the SIGNAL I O function BOX TEMP e Itis recorded by the DAS system as the parameter BOXTMP Mele assembly One is embedded in the cold block of the PMT s TEC Its signal is conditioned by the PMT preamplifier PCA and reported to the CPU via the motherboard see Section 13 4 3 2 The s
160. N OFF the generator Note This is one of the two settings in the DIAG menu that is retained after you exit the menu 12 7 16 INTERNAL SPAN GAS GENERATOR AND VALVE OPTIONS The zero span valve option needs to be enabled in the software contact the factory on how to do this e Check for the physical presence of the valve option e Check front panel for correct software configuration When the instrument is in SAMPLE mode the front panel display should show CALS and CALZ buttons in the second line of the display The presence of the buttons indicates that the option has been enabled in software The semi permeable PTFE membrane of the permeation tube is severely affected by humidity Variations in humidity between day and night are usually enough to yield very variable output results If the instrument is installed in an air conditioned shelter 07889A DCN6900 255 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 17 12 7 17 1 12 7 17 2 the air is usually dry enough to produce good results If the instrument is installed in an environment with variable or high humidity variations in the permeation tube output will be significant In this case a dryer for the supply air is recommended dew point should be 20 C or less TEMPERATURE SENSOR BOX TEMPERATURE SENSOR The box temperature sensor thermistor is mounted on the motherboard below the bottom edge of the CPU board when looking at i
161. N6900 269 Principles of Operation Teledyne API T204 Analyzer Manual Intensity arbitrary units NO Emission Spectrum Wavelength micrometers Area of Sensitivity Figure 13 2 1204 NOx Sensitivity Spectrum 13 1 3 NOX AND NO DETERMINATION The only gas that is actually measured by the T204 is NO and therefore NO which is defined here as the sum of NO and NO in the sample gas contained in the gas is not detected because does not react with to create chemiluminescence In order to measure the concentration of and therefore the concentration of NO the T204 periodically switches the sample gas stream so that the pump pulls it through a special converter cartridge filled with molybdenum Mo moly chips that are heated to a temperature of 315 C AUTOZERO VALVE To Exhaust Manifold amp Pump Mo NO Mo O from at 315 C O Generator MOLYBDENUM CONVERTER To Exhaust Manifold amp Pump from Sample Gas Inlet Figure 13 3 NO NO Conversion 270 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation The heated molybdenum reacts with NO in the sample gas and produces a NO gas and a variety of molybdenum Equation 13 4 XNO yMo gt xNO M O at 315 C Once the NO in the sample gas has been converted to NO it is routed to the reaction cell where it unde
162. NAL CHECKS AND INITIAL CALIBRATION AN CAUTION If the presence of ozone is detected at any time power down the instrument and contact Teledyne API Customer Service as soon as possible 800 324 5190 or email api customerservice teledyne com T204 users should familiarize themselves with the principles of operation in Section 13 For software menus maps Appendix A 3 4 1 START UP Once electrical and pneumatic connections are made turn on the instrument allow about an hour for warm up and then perform a functional check and an initial calibration Upon power up the pump and exhaust fan should start immediately while the CPU loads the operating system the firmware and the configuration data The display will show a splash screen and other information during this process then the analyzer should automatically switch to Sample Mode and start monitoring the gas During the warm up period the front panel display may show messages in the parameters Param field For Warning messages and how to clear them see Section 3 4 1 1 For functional checks see Section 3 4 2 For initial calibration see Section 3 4 3 Additional calibration instructions are in Section 9 3 4 1 1 WARNING MESSAGES Because internal temperatures and other conditions may be outside the specified limits during the analyzer s warm up period the software will suppress most warning conditions for 30 minutes after power up If warning messages per
163. NDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID HESN 1 COM2 EXIT HESSEN VARIATION TYPE1 lt SET SET gt EDIT EXIT Continue pressing NEXT until HESSEN RESPONSE MODE CMD lt SET SET gt EDIT EXIT HESSEN RESPONSE MODE CMD BCC TEXT CMD ENTR EXIT EXIT discards the new Use these buttons to uii setting choose the Hessen ENTR accepts the new setting Response type 07889A DCN6900 133 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 7 2 5 HESSEN PROTOCOL GAS LIST ENTRY FORMAT AND DEFINITIONS The T204 analyzer keeps a list of available gas types Each entry in this list is of the following format GAS TYPE RANGE GAS ID REPORTED WHERE GAS type of gas to be reported e g NO NO and NO etc RANGE The concentration range for this entry in the gas list This feature permits the user to select which concentration range will be used for this gas list entry The T204 analyzer has two ranges RANGE1 or LOW amp RANGE2 or HIGH see Section 5 4 e O The HESSEN protocol to use whatever range is currently active e 1 The HESSEN protocol will always use RANGE 1 for this gas list entry e 2 The HESSEN protocol will always use RANGE2 for this gas list entry e 3 Not applicable to the T204 analyzer GAS ID An identification number assigned to a specific gas The T204 analyzer is a multiple gas instrument tha
164. NG OPERATIONS DAS Records Calibration Procedures PC 104 BUSS Calibration Data Configuration Procedures System Status Data Autonomic Systems Diagnostic Routines ANALYZER HARDWARE INTERFACE HANDLING Sensor input Data Display Messages MEASUREMENT PC 104 BUSS Touchscreen ALGORYTHM Analog Output Data RS232 amp RS485 External Digital I O Figure 13 28 Basic Software Operation 312 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 10 1 ADAPTIVE FILTER The T204 NOx analyzer software processes sample gas concentration data through a built in adaptive filter Unlike other analyzers that average the output signal over a fixed time period the T204 averages over a defined number of samples with samples being about 8 seconds apart reflecting the switching time of 4 s each for NO and NOx This technique is known as boxcar filtering During operation the software may automatically switch between two different filters lengths based on the conditions at hand During constant or nearly constant concentrations the software by default computes an average of the last 42 samples or approximately 5 6 minutes This provides smooth and stable readings and averages out a considerable amount of random noise for an overall less noisy concentration reading If the filter detects rapid changes in concentration the filter reduces the averaging to only 6 samples or about 48 seconds to all
165. NU TREES AND INDEX VERSION 1 0 4 T200 K 7 200E 3 APPENDIX 2 SETUP VARIABLES FOR SERIAL nennen neni 9 APPENDIX 3 WARNINGS AND TEST 0 10 APPENDIX 4 SIGNAL I O 16 APPENDIX 5 TRIGGER EVENTS AND DAS FUNCTIONS anna anui 21 APPENDIX 6 TERMINAL COMMAND DESIGNATORS sunu aaa n 26 APPENDIX 7 MODBUS REGISTER usus ua uu uua u aua uuu u uua 28 A 1 07889A DCN6900 APPENDIX A Version Specific Software Documentation Teledyne API T200 T204 and 200E Series 05295F DCN6900 A 2 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 APPENDIX A 1 Software Menu Trees and Index Version 1 1 0 T200 T204 Kb7 200E APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204 Kb7 200E SAMPLE TEST lt TST TST gt NO Va ue PPB NOX ValuejPPB RANGE Va uePPB RANGE1 Va uePPB RANGE2 Va uePPB S N serial nbr READ Va uejPPB STAB Va uePPB OS SLOPE Va ue PPB OFFS Va ue PPB OS RNG ValuejPPB MEAS ValueMV OS REF ValueMV OSCEL PR ValuePSIA OSSAMP TMP Va uePC OSLMP TEMP Va uePC NOX STB Va u
166. O NOx and concentrations displayed on the front panel display and reported through the instrument s analog outputs and COMM ports This information is available in several forms e Asaraw voltage signal via the test function PMTDET and the SIGNAL I O function PMT SIGNAL or e Normalized for temperature pressure and auto zero offset via the front panel test function NORM PMT e It is recorded by the DAS system in the following parameters e PMTDET The same as the test function PMT DET e RAWNOx The raw PMT output when the instrument is measuring NOx e RAW NO The raw PMT output when the instrument is measuring NO 07889A DCN6900 289 Principles of Operation Teledyne API T204 Analyzer Manual HIGH VOLTAGE POWER SUPPLY LEVEL The PMT high voltage is based on the drive voltage from the preamplifier board It is digitized and sent to the CPU where it is used to calculate the voltage setting of the HVPS e The value of this signal is viewable via the front panel test function HVPS and the SIGNAL I O function HVPS VOLTAGE e Itis recorded by the DAS system as the parameter HVPS PMT TEMPERATURE The PMT temperature is measured with a thermistor inside the PMT cold block Its signal is amplified by the PMT temperature feedback circuit on the preamplifier board and is digitized and sent to the CPU where it is used to calculate the current temperature of the PMT e The value of this signal is viewable via th
167. ODBUS communications and provides minimal information to get started For additional instruction please refer to the Teledyne API MODBUS manual PN 06276 Also refer to www modbus org for MODBUS communication protocols Minimum Requirements Instrument firmware with MODBUS capabilities installed MODBUS compatible software uses MODBUS Poll for testing see www modbustools com Personal computer Communications cable Ethernet or USB or RS232 Possibly a null modem adapter or cable Actions Set Com Mode parameters Slave Comm through the INET submenu until you reach TCP PORT 2 the standard setting Ethernet Using the front panel menu go to SETUP MORE COMM INET scroll is 502 then continue to TCP PORT 2 MODBUS TCP IP press EDIT and toggle the menu button to change the setting to ON then press ENTR Change Machine ID if needed see Slave ID USB RS232 Using the front panel menu go to SETUP MORE COMM COM2 EDIT scroll through the COM2 EDIT submenu until the display shows COM2 MODBUS RTU OFF press OFF to change the setting to ON Scroll NEXT to COM2 MODBUS ASCII and ensure it is set to OFF Press ENTR to keep the new settings If RTU is not available with your communications equipment set the COM2 MODBUS ASCII setting to ON and ensure that COM2 MODBUS RTU is set to OFF Press ENTR to keep the new settings If your analyzer is connected to a network with at least one other analyze
168. OG OUTPUTS Analog output calibration should be carried out on first startup of the analyzer performed in the factory as part of the configuration process or whenever recalibration is required The analog outputs can be calibrated automatically AUTOCAL either as a group or individually or calibrated manually In its default mode the instrument is configured for automatic calibration of all channels which is useful for clearing any analog calibration warnings associated with channels that will not be used or connected to any input or recording device e g data logger Manual calibration should be used for the 0 1V range or in cases where the outputs must be closely matched to the characteristics of the recording device Disable the AUTOCAL feature first for manual calibration 5 9 3 3 ENABLING OR DISABLING THE AUTOCAL FOR AN INDIVIDUAL ANALOG OUTPUT To enable or disable the AutoCal feature for an individual analog output elect the ANALOG CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO SET gt CAL EXIT NOTE ANALOG OUTPUTS Continue pressing SET gt until you reach the configured for 0 1V full output to be configured scale should always be calibrated manually DIAGAIO CONC_OUT_2 5V OVR NOCAL lt SET SET gt EDIT EXIT DIAGAIO CONC_OUT_2 RANGE 5V SET gt EDIT EXIT DIAGAIO CONC_OUT_2 AUTO CAL ON lt SET SET gt
169. P WARNING CONV TEMP WARNING PMT TEMP WARNING AZERO WARN XXXX HVPS WARNING Ozone generator is off This is the only warning message that automatically clears itself It clears itself when the ozone generator is turned on Upon power up the Ozone generator will remain off for 30 minutes This allows the perma pure dryer to reach its working dew point AutoZero reading too high The value shown in message indicates auto zero reading at time warning was displayed High voltage power supply output is too high or too low for proper operation of the PMT 07889A DCN6900 59 Getting Started Teledyne API T204 Analyzer Manual 1 2 3 4 REAR BOARD NOT DET CPU unable to communicate with motherboard RELAY BOARD WARN CPU is unable to communicate with the relay PCA SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits Clears 45 minutes after power up Clears the next time successful zero calibration is performed Clears the next time successful span calibration is performed Clears 30 minutes after power up 3 4 2 FUNCTIONAL CHECKS After the analyzer s components have warmed up for at least 60 minutes verify that the software properly supports any hardware options that are installed For information on navigating through the analyzer s software menus see the menu trees described in Appendix A Check to ensure that the analyzer is functioning within
170. PREAMPLIFIER RANGE CONTROL The CPU uses this control switch the instrument between its LOW and HIGH physical ranges see Section 5 4 1 e The instrument can be forced into its HIGH physical range setting the SIGNAL I O function PREAMP_RANGE_HI to ON GEN STATUS The CPU uses this control signal to turn the generator ON OFF by setting it to HIGH LOW respectively The CPU turns OFF the generator if there is if there is no or low air flow to it as measured by the O flow sensor or if the instrument has been turned off for more than 30 minutes e The generator can be manually turned ON OFF by using the OZONE GENERATOR OVERIDE feature See Section 12 7 15 1 or by setting the SIGNAL I O function O3GEN_STATUS to ON or OFF Any signals changed while in the signal I O menu will remain in effect ONLY until signal I O menu is exited The analyzer regains control of these signals upon exit and returns them to their normal value setting 13 4 3 7 IC DATA BUS is a two way clocked bi directional digital serial I O bus that is used widely in commercial and consumer electronic systems A transceiver on the Motherboard converts data and control signals from the PC 104 bus to format The data is then fed to the relay board optional analog input board and valve driver board circuitry 13 4 3 8 POWER UP CIRCUIT This circuit monitors the 5V power supply during start up and sets the analog outputs external digital I
171. R NXCNC1 SET SET gt EDIT EXIT i 55i SETUP X X PARAMETER NXCNC1 PREV NEXT ENTR EXIT Toggle these buttons to cycle through the list of available parameters SETUP SAMPLE MODE AVG SET SET EDIT EXIT y 7l SETUP X X PARAMETER NXCNC1 Pressing SET INST AVG SDEV MIN MAX ENTR EXIT returns to the LLL Press the desired MODE button previous Function E SETUP X X PRECISION 4 SET SET EDIT EXIT sETUPXX PRECISION 5 5 ENTR EXIT SETUP X X STOR NUM SAMPLE OFF Toggle this button to set from 1 to 4 SET EDIT EXIT SETUPXX STOR NUM SAMPLE OFF OFF ENTR EXIT Toggle this button to turn ON OFF Note When the STORE NUM SAMPLES feature is turned on the instrument will 148 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 3 4 EDITING SAMPLE PERIOD AND REPORT PERIOD Note The DAS defines two principal time periods by which sample readings are taken and permanently recorded e SAMPLE PERIOD Determines how often DAS temporarily records a sample reading of the parameter in volatile memory SAMPLE PERIOD is only used when the DAS parameter s sample mode is set for AVG SDEV MIN or MAX e The SAMPLE PERIOD is set to one minute by default and generally cannot be accessed from the standard DAS front panel menu but is available via the instruments communication ports by using APICOM or the analyzer s standar
172. RESS SAMP 29 9 IN HG A Sample pressure NOXSLOPE NOX SLOPE 1 000 NOX slope for current range computed during zero span calibration NOXOFFSET NOX OFFS 0 0 MV NOX offset for current range computed during zero span calibration NOSLOPE NO SLOPE 1 000 NO slope for current range computed during zero span calibration z 2 2 gt lt N mn N NO2 0 0 PPB NO concentration for current range NO2 1 7 NO2 120 0 PPB NO concentration for range 1 NOX 396 5 PPB NOX concentration for current range NO2 27 NO2 220 0 PPB NO concentration for range 2 NOX 1 NOX_1 396 5 PPB NOX concentration for range 1 NOX 2 7 NOX_2 396 5 PPB NOX concentration for range 2 NO 396 5 PPB NO concentration for current range NO 1 396 5 PPB NO concentration for range 1 CO2RANGE not 6 CO2 RANGE 100 00 PCT D A 4 range for CO concentration CO2SLOPE CO2 SLOPE 1 000 CO slope computed during zero span calibration 2 CO2 OFFSET 0 000 CO offset computed during zero span calibration O2RANGE et 6 O2 RANGE 100 00 PCT D A 4 range for O concentration O2SLOPE 5 O2 SLOPE 1 000 slope computed during zero span calibration 2 5 O2 OFFSET 0 00 offset computed during zero span calibration TESTCHAN 568 TEST 3627 1 MV Value output to TEST OUTPUT analog output selected with TEST CHAN ID variable XIN1 12 AIN1 37 15 EU External analog input 1 value in engineer
173. REV NEXT gt e MODEL TYPE AND NUMBER e PART NUMBER e SERIAL NUMBER e iCHIP SOFTWARE REVISION CPU TYPE amp OS REVISION e DATE FACTORY 1 ACAL menu and its submenus only appear if the analyzer is equipped with calibration valves or the internal span gas generator Appears whenever the currently displayed sequence is not set for DISABLED 3 Only appears when reporting range is set to AUTO range mode Only Appears if TIME ENABLE is set to ON e SOFTWARE REVISION e LIBRARY REVISION CONFIGURATION SAVED SAMPLE SETUP ACAL DAS RNGE io CLK MORE ON PREV NEXT MODE Lord COMAS TIME DATE Menu Tree SEQ 1 Goto SECONDARY SETUP SEQ 2 Menu Tree SEQ 3 MODE SET UNIT PREV NEXT SNGL IND AUTO PPB PPM UGM MGM DISABLED SETUP X X LOW RANGE 500 0 Conc ZERO ZERO SPAN 0 0 5 0 0 SPAN 0 ENTR EXIT SETUP X X HIGH RANGE 500 0 Conc 0 0 5 0 0 0 ENTR EXIT SET ON TIMER ENABLE OFF STARTING DATE STARTING TIME DELTA DAYS DELTA TIME SET SET gt DURATION ON CALIBRATE EF OFF RANGE TO CAL LOW HIGH Figure A 2 Primary Setup Menu Except DAS 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204 Kb7 200E Teledyne API T200 T204 and 200E Series 05295F DCN6900 SAMPLE SETUP CFG ACAL DAS RNGE PASS CLK MORE COMM VARS DIAG ENTER PA
174. SAMP ValueAN HG A NOX SLOPE Value NOX OFFS ValueMV NO SLOPE Va ue NO OFFS ValueMV TIMEZ HH MM SS 3 4 3 INITIAL CALIBRATION To perform calibration connect sources for zero air and calibration span gas available for input into the inlet outlet fittings on the back of the analyzer see Section 3 3 2 1 Note A start up period of 4 5 hours is recommended prior to performing a This section provides initial calibration instructions Detailed calibration checks and calibration are provided in Section 9 e See Section 3 4 3 2 for instructions for initial calibration of the T204 analyzers in their base configuration e See Section 9 2 4 for information regarding setup and calibration of T204 analyzers with Z S Valve options e If using the T204 analyzer for EPA monitoring follow EPA protocol see Section 10 07889A DCN6900 61 Getting Started Teledyne API T204 Analyzer Manual 3 4 3 1 Interferents for NO NO and NO Measurements The chemiluminescence method for detecting NOx is subject to interference from a number of sources including water vapor H5O ammonia NHs3 sulfur dioxide SO and carbon dioxide CO but the T204 has been designed to reject most of these interferences e Ammonia is the most common interferent which is converted to NO in the analyzer s NO converter and creates a NOx signal artifact e f the T204 is installed in an environment with high ammonia st
175. SETUP CFG ACAL DAS RNGE PASS CLK MORE COMM VARS DIAG ID INET HESN COM1 COM2 ENTER PASSWORD 818 ENTER PASSWORD 818 Tree ENTER PASSWORD 818 Go to DIAG Menu Tree Go to COMM VARS Menu Tree VARIATION RESPONSE MODE GAS LIST STATUS FLAGS TYPE1 2 BCC TEXT CMD PREV NEXT INS EDIT PRNT NOM NO NO2 NOX 0 211 REPORTED NO 0 212 REPORTED GASID 4 NO2 0 213 REPORTED REPORTED zoe 0 216 REPORTED Figure A 4 Secondary Setup Menu HESSEN 07889A DCN6900 APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204yKb7 200E Teledyne API T200 T204 and 200E Series 05295F DCN6900 CFG ACAL SIGNAL I O ANALOG OUTPUT Press ENTR to start test PREV NEXT 0 EXT ZERO CAL 1 EXT SPAN CAL 2 MAINT MODE LANG2 SELECT SAMPLE LED CAL LED FAULT LED 7 AUDIBLE BEEPER 8 ELEC TEST 9 OPTIC TEST 10 PREAMP RANGE HI 11 GEN STATUS 12 ST SYSTEM OK 13 ST CONC VALID 14 ST HIGH RANGE 15 ST ZERO CAL 16 ST SPAN CAL 17 ST DIAG MOD 18 ST SYSTEM OK2 19 ST CONC ALARM 1 20 ST CONC ALARM 2 21 ST HIGH RANGE 2 22 RELAY WATCHDOG 23 RCELL HEATER 24 CONV HEATER 25 MANIFOLD HEATER 26 IZS HEATER 27 SPAN VALVE 28 CAL VALVE 29 AUTO_ZERO VALVE 30 NOX VALVE INTERNAL ANALOG VOLTAGE SIGNALS 31 to 55 see Appendix A Only appea
176. SSWORD 818 ID INET HESN COM1 COM2 PREV NEXT JUMP EDIT ENTER PASSWORD 818 Go to SET SET EDIT PRNT COMM Hessen Menu Tree 0 DAS HOLD OFF SENT EDIT 1 MEASURE MODE MODE BAUD RATE TEST PORT 2 STABIL_GAS 3 TPC_ENABLE TEST 4 DYN_ZERO 5 DYN_SPAN 300 6 IZS_SET 1200 7 CONC_PRECISION 2400 8 CLOCK_ADJ 4800 9 CAL ON CC2 9600 10 SERVICE CLEAR INSTRUMENT QUIET 19200 11 TIME_SINCE_SVC GATEWAY IP SECURE 38400 12 INTERVAL PROTOCOL ENTER PASSWORD 818 RS 485 TCP MULTIDROP PROTOCOL E Series models Only appears if optional Ethernet PCA is HOSTNAME ENABLE MODEM installed ERROR CHECKING NOTE When Ethernet PCA is present in E Series models XON XOFF HANDSHAKE 2 submenu disappears HARDWARE HANDSHAKE Only appears if HESSEN PROTOCOL mode is ON See HARDWARE FIFO COM1 amp COM2 MODE submenu above COMMAND PROMPT 3 INSTRUMENT IP GATEWAY IP amp SUBNET MASK are only editable ON when DHCP is OFF Although TCP PORT is editable regardless of the DHCP state do not OFF change the setting for this property 5 HOST NAME is only editable when DHCP is ON Figure A 3 Secondary Setup Menu COMM amp VARS 07889A DCN6900 A 5 APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204 Kb7 200E Teledyne API T200 T204 and 200E Series 05295F DCN6900 SAMPLE
177. TANDARD CURRENT PIN BNAEOGSUIPHT VOLTAGE OUTPUT LOOP OPTION 1 V Out Out 5 A1 NO Concentration 3 V Out Out 1 A2 NO Concentration PUR mire 3 V Out Out A3 Concentration 7 A4 oc tr li V Out Not Available 8 s eoe Ground Not Available To change the settings for the analog output channels see Section 5 9 2 3 3 1 4 CURRENT LOOP ANALOG OUTPUTS OPTION 41 SETUP If your analyzer had this option installed at the factory there are no further connections to be made Otherwise it can be installed as a retrofit for each of the analog outputs of the analyzer This option converts the DC voltage analog output to a current signal with 0 20 mA output current The outputs can be scaled to any set of limits within that 0 20 mA range However most current loop applications call for either 2 20 mA or 4 20 mA range All current loop outputs have a 5 over range Ranges with the lower limit set to more than 1 mA e g 2 20 or 4 20 mA also have a 5 under range Figure 3 8 provides installation instructions and illustrates a sample combination of one current output and two voltage outputs configuration This section provides instructions for converting current loop analog outputs to standard 0 to 5 VDC outputs Information on calibrating or adjusting these outputs can be found in Section 5 9 3 7 CAUTION AVOID INVALIDATING WARRANTY Servicing or handling of circuit co
178. TST gt ZERO SPAN CONC RANGE 500 0 PPB NOX XXXX EXIT M P CAL CONCENTRATION MENU NOX NO CONV CAL SPAN CONC 80 0 Conc EXIT ignores the new The NOx amp NO span concentration 0 0 ENTR setting and returns to values automatically default to the previous display 400 0 PPB If this is not the the concentration of the span gas being used toggle For NOx and NO ENTR accepts these buttons to set the correct the new setting and returns to the concentration of the NOx and NO CONCENTRATION MENU calibration gases If using NO span gas in addition to NOx repeat last step For ENTR accepts the new setting and proceeds to the CAL MP Mode 07889A DCN6900 173 Calibration Procedures Teledyne API T204 Analyzer Manual 9 2 3 2 ZERO SPAN POINT CALIBRATION PROCEDURE SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Set the Display to show the STABIL test function C This function calculates Loggia button the stability of the NOX measurement SAMPLE NOX STB XXXX PPB NOX XXXX lt TST TST gt CAL SETUP Allow zero gas to enter the sample port at the rear of the analyzer Wait until STB falls below 1 0 PPB This may take several minutes SAMPLE NOX STB XXXX PPB NOX XXXX lt TST TST gt CAL SETUP Press ENTR to change M P CAL NOX STB XXXX PPB NOX XXXX the OFFSET amp SLOPE values based on the zero
179. Touch Touching some parts of the instrument without protection or proper tools could result in damage to the part s and or the instrument Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only Electrical Ground This symbol inside the instrument marks the central safety grounding point for the instrument OP PEPE CAUTION GENERAL SAFETY HAZARD The T204 Analyzer should only be used for the purpose and in the manner described in this manual If you use the T204 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 N Be any other Teledyne API product can be obtained by contacting Teledyne API s Technical Support Department Phone 800 324 5190 Email sda_techsupport teledyne com or by accessing various service options on our website at http www teledyne api com 07889A DCN6900 iii Teledyne API T204 Analyzer Manual CONSIGNES DE SECURITE Des consignes de s curit importantes sont fournies tout au long du pr sent manuel dans le but d viter des blessures corporelles ou d endommager les instruments Veuillez lire attentivement ces consignes Chaque consigne de s curit est repr sent e par un pictogramme d alerte de s curit ces pictogrammes se retrouvent dans ce manuel et l int rieur des
180. URATION The DAS can be configured and operated remotely via either the APICOM interface or a terminal emulation program Once a DAS configuration is edited which can be done offline and without interrupting DAS data collection it is conveniently uploaded to the instrument and can be stored on a computer for later review alteration or documentation and archival 7 2 1 DAS CONFIGURATION VIA APICOM Figure 7 2shows examples of APICOM s main interface which emulates the look and functionality of the instrument s actual front panel Figure 7 3 shows an example of APICOM being used to remotely configure the DAS feature The APICOM user manual Teledyne APPs P N 039450000 is included in the APICOM installation file which can be downloaded at http www teledyne api com software apicom 394 8 PPB 0 0 PPB 394 8 PPB 123 0 PPB p TELEDYNE f ADVANCED POLLUTION INSTRUMENTATION A Teledyne Technologies Company File Edit View Settings Help Rt amp 1 cfg APICOM Graphical Interface DAR E BLocal Instrument Connected For Help press F1 Figure 7 2 APICOM Remote Control Program Interface 156 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM B asic Advanced Basic Settings Channel Name Number of Records Trigger Event 7 Enable Channel C Print Reports Start Date St
181. URE This option allows the user to specify a starting date for any given channel when the user wants to start data acquisition only after a certain time and date If the STARTING DATE is in the past the default condition the DAS ignores this setting and begins recording data as defined by the REPORT PERIOD setting The STARTING DATE generally cannot be accessed from the standard DAS front panel menu but is available via the instrument s communication ports by using APICOM or the analyzer s standard serial data protocol 7 1 3 11 DISABLING ENABLING DATA CHANNELS Data channels can be temporarily disabled which can reduce the read write wear on the Disk on Module DOM To disable a data channel go to the DAS gt EDIT menu as shown in Section 7 1 3 then continue as follows Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 Use the PREV and PREV NEXT INS DEL EDIT PRNT EXIT NEXT buttons to 1 scroll to the DATA CHANNEL to be SETUPX X CONC edited lt SET SET gt EDIT PRNT EXIT Continue pressing lt SET or SET gt until SETUP X X CHANNEL ENABLE ON SET SET EDIT SETUP X X CHANNEL ENABLE ON ON ENTR EXIT EXIT discards the new setting Toggle these buttons ENTR accepts the new setting J to enable or disable the CHANNEL 07889A DCN6900 155 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual 7 2 REMOTE DAS CONFIG
182. Uses for Test Functions ssssssssseeeeeeene eene 195 Table 12 1 Front Panel Warning Messages sssssssseeeeeeneeeenen tutant nemen nennen enne nennen nnn 216 Table 12 2 Relay PCA Watchdog LED Failure Indications sssee 221 Table 12 3 Relay PCA Status LED Failure Indications see e 222 Table 12 4 DC Power Test Point and Wiring Color 234 Table 12 5 DC Power Supply Acceptable Levels sssssssssssseseeneeee eene ennt nnne 235 Table 12 6 Relay PCA Control Devices iuueni n ERR HERRERA UTR DETRAHERE ERREUR REED 236 Table 12 7 Analog Output Test Function Nominal Values Voltage Outputs 237 Table 12 8 Status Outputs Clieck TS A E A 239 Table 12 9 T204 Control Input Pin Assignments and Corresponding Signal I O Functions 239 Table 13 1 T204 Valve Gycle PhaS6 ries Dr da t Le GERE ERR vane se DX 276 Table 13 2 T204 Gas FON RAE S a e tee pere EET Ue e OG PAD DPA Deae tapa RD cease 279 Table 13 3 Relay PGA Status LED S cette ntt erdt dae ce EH casa BO RITTER 296 Table 13 4 Thermocouple Configuration Jumper JP5 Pin Outs sseeenn emen 299 Table 13 5 AC Power Configuration for Internal Pumps JP7 sssssseeene eene 309 Table 13 6 Power
183. V IN 5mV C When present sets Cold Junction TC1 3 13 Type J Compensation Compensation for J type Thermocouple Type K When present sets Cold Junction Compensation Compensation for K type Thermocouple Termination Selects between Isolated and grounded TC IN Isolate TC Selector OUT Grounded TC TC2 NOT USED ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY The correct Thermocouple Type must be used if there is ever the need for replacement If in doubt please consult Teledyne API Customer Service 07889A DCN6900 299 Principles of Operation Teledyne API T204 Analyzer Manual TC2 Not Used Purple Jumpers GL S 10129JoS lt vl uonesueduio I ZL Z 10129JeS ejeos 1ndino LL 40129J8S 1nduJ Figure 13 17 Thermocouple Configuration Jumper JP5 Pin Outs 13 5 SENSOR MODULE REACTION CELL The T204 sensor assembly consists of several subassemblies each with different tasks The Photo Multiplier Tube PMT detects the intensity of the light from the chemiluminescence reaction between NO the reaction cell It outputs a current signal that varies in relationship with the amount of light in the reaction cell The PMT Preamplifier PCA converts the current output by the PMT into a voltage and amplifies it to a signal strong enough to be usable by the motherboard s A gt D converter
184. VOLT S 4500 mV Continue adjustments until the voltage measured at the output U100 UP10 UP DOWN DN10 D100 ENTR EXIT of the analyzer and or the input of the recording device matches the value in the upper right hand corner of the display within the tolerances DIAG AIO CONC OUT 2 CALIBRATED YES listed in Table 8 8 SET SET CAL EXIT 106 07889A DCN6900 Teledyne API T204 Analyzer Manual Setup Menu 5 9 3 7 MANUAL ADJUSTMENT OF CURRENT LOOP OUTPUT SPAN AND OFFSET A current loop option may be purchased for the Al A2 and A3 Analog outputs of the analyzer This option places circuitry in series with the output of the D to A converter on the motherboard that changes the normal DC voltage output to a 0 20 milliamp signal See Section 3 3 1 4 e The outputs can be ordered scaled to any set of limits within that 0 20 mA range however most current loop applications call for either 0 20 mA or 4 20 mA range spans e All current loop outputs have a 5 over range Ranges whose lower limit is set above 1 mA also have a 5 under range To switch an analog output from voltage to current loop follow the instructions in Section 5 9 3 1 select CURR from the list of options on the Output Range menu To adjust the signal zero and span levels of the current loop output raise or lower the voltage output of the D to A converter circuitry on the analyzer s motherboard This raises or lowers the signal level produced
185. XIT discards the new setting Toggle these buttons to select the upper SPAN limit for the reporting range ENTR accepts the new setting 07889A DCN6900 83 Setup Menu Teledyne API T204 Analyzer Manual 5 4 3 3 SETUP gt RNGE gt MODE gt AUTO CONFIGURING THE T204 ANALYZER FOR AUTO RANGE MODE In AUTO range mode the analyzer automatically switches the reporting range between two user defined ranges LOW and HIGH The same low and high span settings are applied equally to NO NO and NOx readings e The unit will switch from LOW range to HIGH range when either the NO or NOx concentration exceeds 98 of the low range span e The unit will return from HIGH range back to LOW range once both the NO and NOx concentrations fall below 75 of the low range span IMPACT ON READINGS OR DATA The LOW amp HIGH ranges referred to here are NOT the same as the low amp Also the RANGE test function displayed on the front panel will be replaced by two separate functions e RANGE1 The LOW range setting for all analog outputs e RANGE2 The HIGH range setting for all analog outputs The LOW HIGH range status is also reported through the external digital status bits Section 3 3 1 4 To set individual ranges press the following menu sequence 84 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu NOTE Avoid accidentally setting the LOW ran
186. ZSC3 NO concentration for range 3 during zero span calibration just before computing new slope and offset N2ZSC1 concentration for range 1 during zero span calibration just before computing new slope and offset N2ZSC2 concentration for range 2 during zero span calibration just before computing new slope and offset N2ZSC3 7 NO concentration for range 3 during zero span calibration just before computing new slope and offset CO2ZSC CO concentration during zero span calibration just before computing new slope and offset O2ZSCN concentration during zero span calibration just before computing new slope and offset NXCNC1 NOx concentration for range 1 NXCNC2 NOx concentration for range 2 NXCNC3 7 NO concentration for range 3 NOCNC1 NO concentration for range 1 NOCNC2 NO concentration for range 2 NOCNC3 7 NO concentration for range 3 N2CNC1 NO concentration for range 1 N2CNC2 NO concentration for range 2 N2CNC3 NO concentration for range 3 CO2CNC 5 CO concentration STABIL Concentration stability AZERO Auto zero offset range de normalized mV 07889A DCN6900 A 23 APPENDIXA 5 Trigger Events and DAS Parameters Teledyne API T200 T204 and 200E Series 05295F DCN6900 Nam Besrpio METEMB T Bypass or dilution manifold temperature PMT c SPFW SMPPRS Sample pressure Hg SRSTMP C BOXTMP C RBXTMP HVPS H
187. a PMT fault is to eliminate the other components using ETEST OTEST and specific tests for other sub assemblies 12 7 12 1 OPTIC TEST The optic test function tests the response of the PMT sensor by turning on an LED located in the cooling block of the PMT see Figure 13 18 The analyzer uses the light emitted from the LED to test its photo electronic subsystem including the PMT and the current to voltage converter on the pre amplifier board e Toensure that the analyzer measures only the light coming from the LED the analyzer should be supplied with zero air e optic test should produce a PMT signal of about 2000 1000 mV To activate the optics test press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration display continuously cycles through all gasses Continue pressing lt TST or TST gt until SAMPLE PMT 2750 MV NOX XXXX lt TST TST CAL SETUP JP X SETUP X X PRIMARY SETUP MENU ENTER PASSWORD CFG DAS RNGE PASS CLK MORE EXIT 8 1 8 ENTR SETUP X X SECONDARY SETUP MENU SIGNAL I O COMM VARS DIAG EXIT PREV NEXT Continue pressing NEXT until OPTIC TEST PREV NEXT ENTR While the OTEST is active PMT should 2000 mv 1000mv SAMPLE PMT 2750 MV NOX XXXX lt TST TST gt CAL EXIT Note 250 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 7 12 2 ELECTRICAL TEST The electrical test function creates a current which
188. able A 4 Signal I O Definitions Signal Name Bit or Channel Description Number Internal inputs U7 J108 pins 9 16 bits 0 7 default I O address 322 hex 0 7 Spare Internal outputs U8 J108 pins 1 8 bits 0 7 default I O 0 off 0 off 0 select low range 1 off I2C RESET p reset I C peripherals normal 1 normal Control inputs U11 J1004 pins 1 6 bits 0 5 default I O address 321 hex EXT_ZERO_CAL 0 go into zero calibration 1 exit zero calibration EXT_SPAN_CAL go into span calibration exit span calibration go into low span calibration exit low span calibration EXT_LOW_SPAN 2 REMOTE RANGE HI CAL MODE 0 CAL MODE 1 3 remote select high range 1 default range 1 2 0 Three inputs taken as binary numbe CAL_MODE_2 is MSB select calibra range 0 amp 7 Measure 1 Zero range 3 Span range 3 3 Zero range 2 Span range 2 5 Zero range 1 Span range 1 CAL_MODE_2 4 5 Spare Always 1 Control inputs U14 11006 pins 1 6 bits 0 5 default I O T Spare Always 1 A 16 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix A3 Wamings and Test Measurements Software Version Signal Name Bit or Channel Description Number Control outputs U17 J1008 pins 1 8 bits 0 7 default I po Spare Control outputs U21 J1008 pins 9 12 bits 0 3 default Alarm
189. after repairs leak is flow paths involving repaired pneumatics Reaction cell Replace Annually Yes O rings amp sintered filters PMT Sensor Low level On PMT Yes Hardware hardware preamp Calibration calibration changes or if slope is outside of 1 0 0 3 Pump Rebuild head when RCEL Yes pressure exceeds 10 in Hg A at sea level Inline Replace Annually No Exhaust Scrubber Every 3 years Yes converter converter or if conversion efficiency drops below 96 Desiccant Replace Any time PMT n a bags housing is opened for maintenance 194 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance CAL DATE PERFORMED ITEM ACTION FREQ CHECK REQ D SENSOR MAINTENANCE Internal Replace Monthly Particulate Filter UV Lamp Adjust As needed UV Lamp Replace When adjustment no longer effective Sensor Replace Every 2 years Module Valve or every 6 mo when external sample line pre filters are used 11 2 PREDICTIVE DIAGNOSTICS Predictive diagnostic functions including failure warnings and alarms built into the analyzer s firmware allow the user to determine when repairs are necessary The Test Functions can also be used to predict failures by looking at how their values change over time Initially it may be useful to compare the state of these Test Functions t
190. ame or new clamps and pushing tightening them until a good seal is achieved Restart the pump and clear any error warnings from the front panel display 10 After about 5 minutes check the RCEL pressure reading and ensure that it is similar to its value before changing the filter but less than 10 in Hg A e Ensure that the three screws are tightened evenly Replace the analyzer cover plug the power cord back in and turn on the analyzer Carry out a span check to see if the new permeation device works The permeation rate may need several days to stabilize COULD DAMAGE INSTRUMENT AND VOID WARRANTY Do not leave instrument turned off for more than 8 hours without removing the permeation tube Do not ship the instrument without removing the permeation tube The tube continues to emit NO2 even at room temperature and will contaminate the entire instrument 202 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Instrument Maintenance 11 3 6 CHANGING THE NO CONVERTER The NO converter is located in the center of the instrument see Figure 3 5 for the location and Figure 11 4 for the assembly The converter is designed for replacement of the cartridge only the heater with built in thermocouple is to be reused AD The converter operates at 315 C Severe burns can result if the assembly is not Do not handle the assembly until it is at room temperature This may take several CAUTION SURFA
191. analyzer s critical inputs and outputs e Many of the components and functions that are normally under algorithmic control of the CPU can be manually exercised e technician can directly control the signal level Analog and Digital Output signals This allows the technician to observe systematically the effect of directly controlling these signals on the operation of the analyzer Following is an example of how to use the Signal I O menu to view the raw voltage of an input signal or to control the state of an output voltage or control signal 218 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service SAMPLE RANGE 500 0 PPB XXXX lt TST TST gt CAL SETUP Concentration display continuously cycles through all gasses SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT DIAG SIGNAL I O SETUP SECONDARY SETUP MENU _ COMM VARS DIAG EXIT DIAG I O 0 EXT_ZERO_CAL OFF SETUP ENTER PASSWORD 818 PREV NEXT EDIT PRNT EXIT ssiheBREVand 8 1 8 ENTR EXIT NEXT keys to cycle through the VARS DIAG I O 1 EXT_SPAN_CAL OFF 7 PREV NEXT JUMP EDIT PRNT EXIT Use the JUMP key to go directly to a specific signal see Appendix A for a list DIAG I O JUMPTO 0 of all 1 0 SIGNALS 0 0 JUMP ENTR EXIT Ll Toggle these keys to set No of the EXAMPLE VAR to JUMP to DIAG I O JUMPTO 29 2 9 JUMP ENTR EXIT DIAG I O 29
192. and the PMT To prevent this the air supply for the generator is dried using a special sample gas single tube permeation dryer The dryer consists of a single tube of Nafion that is mounted within an outer flexible plastic tube Nafion is a co polymer that absorbs water very well but not most other chemicals As gas flows through the inner Nafion tube water vapor is absorbed into the membrane walls The absorbed water is 280 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation transported through the membrane wall and evaporated into the dry purge gas flowing through the outer tube countercurrent to the gas in the inner tube 1 Other C x Nafion Tube Figure 13 9 Semi Permeable Membrane Drying Process The process by which the water vapor molecules are collected and transported through Nafion material is called per evaporation and is driven by the humidity gradient between the inner and outer tubes as well as the flow rates and pressure difference between inner and outer tubing Unlike micro porous membrane permeation which transfers water through a relatively slow diffusion process per evaporation is a simple kinetic reaction Therefore the drying process occurs quickly typically within milliseconds Because this chemical reaction is based on hydrogen bonds between the water molecule and the Nafion material most other chemical components of the gas to be dried are u
193. ar but the critical flow orifices do not See Section 11 for instructions How do set up and use the Contact Closures Control Inputs on the Rear Panel of the analyzer See Section 3 3 1 6 12 10 TECHNICAL ASSISTANCE If this manual and its troubleshooting amp service section do not solve your problems technical assistance may be obtained from Teledyne API Technical Support 9480 Carroll Park Drive San Diego California 92121 5201USA Toll free Phone 800 324 5190 Phone 858 657 9800 Fax 858 657 9816 Email sda_techsupport teledyne com Website http www teledyne api com Before you contact Teledyne API s Technical Support fill out the problem report form in Appendix C which is also available online for electronic submission at http www teledyne api com manuals 266 07889A DCN6900 13 PRINCIPLES OF OPERATION The T204 Nitrogen Oxides Ozone Analyzer is a microprocessor controlled instrument that determines both the concentration of ozone O3 and the concentrations of nitric oxide NO nitrogen dioxide NO and total nitrogen oxides NOx This section discusses the principles of operation of each sensor nitrogen oxides in Section 13 1 and ozone in Section 13 2 e It requires that sample and calibration gases be supplied at ambient atmospheric pressure in order to establish a constant gas flow through the reaction cell where the sample gas is exposed to ozone O initiating a
194. arameters would be configured in the Instrument Properties window in APIcom when configuring a new instrument See the APlcom manual PN 07463 for more details n Instrument Properties Code Activated Switch Handshaking Security Direct Cable Connection Properties Basic Automatic Disconnect 2 Instrument Name Local Instrument Comm Port COM1 x Settings OK Instrument D Enable Cancel Connection Type Direct Cable Settings 4 Instrument Port 9 Pot 1 Pot 2 r XY Mode Var Name 1 Properties Emm Site Name Home Port Settings Defaults Bits per second 115200 OK Cancel s Data bits 8 X Party None Y Stop bits 1 How control None Bestore Defaults OK Cancel Apply USB configuration requires that the baud rates of the instrument and the PC match check the PC baud rate and change if needed Using the USB port disallows use of the rear panel COM2 port except for multidrop communication 07889A DCN6900 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 7 COMMUNICATIONS PROTOCOLS Two communications protocols available with the analyzer MODBUS and Hessen MODBUS setup instructions are provided here Section 6 7 1 and registers are provided in Appendix A Hessen setup and operation instructions are provided in Section 6 7 2 6 7 1 MODBUS The following set of instructions assumes that the user is familiar with M
195. are Device Manager This is the com port that should be set in the communications software such as APlcom or Hyperterminal Device Manager File Action View Help g SDAENPC21 j Computer Disk drives 2 Display adapters JA DVD CD ROM drives Floppy disk controllers Floppy disk drives E IDE ATA ATAPI controllers te Keyboards T5 Mice and other pointing devices Monitors Network adapters Ports COM amp LPT Communications Port COM1 Printer Port LPT1 F 9 Processors Sound video and game controllers System devices Universal Serial Bus controllers f Refer to the Quick Start Direct Cable Connection section of the Teledyne APIcom Manual PN 07463 126 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation Note 5 In the instrument s SETUP gt MORE gt COMM gt COM2 menu make the following settings Baud Rate 115200 COM2 Mode Settings Quiet Mode ON Computer Mode ON MODBUS RTU OFF MODBUS ASCII OFF E 8 1 MODE OFF E 7 1 MODE OFF RS 485 MODE OFF SECURITY MODE OFF MULTIDROP MODE OFF ENABLE MODEM OFF ERROR CHECKING ON XON XOFF HANDSHAKE OFF HARDWARE HANDSHAKE OFF HARDWARE FIFO ON COMMAND PROMPT OFF Next configure your communications software such as APIcom Use the COM port determined in Step 4 and the baud rate set in Step 5 The figures below show how these p
196. ariables Setup Variable Default Value Range Description Value DAS HOLD OFF Minutes 0 5 20 Duration of DAS hold off period MEASURE MODE NO NOX NO Gas measure mode Enclose value in N NOX NOX NO double quotes when setting from the NON OX RS 232 interface STABIL GAS OX NO Selects gas for stability measurement NO2 Enclose value in double quotes when NOX setting from the RS 232 interface 02 Cco2 TPC ENABLE N OFF ON ON enables temperature pressure compensation OFF disables it DYN ZERO FF ON OFF ON enables remote dynamic zero calibration OFF disables it DYN SPAN FF ON OFF ON enables remote dynamic span calibration OFF disables it IZS SET 30 70 IZS temperature set point and warning 1 a l FF O 5 AUTO Number of digits to display to the right of the decimal point for concentrations on the display Enclose value in double quotes when setting from the RS 232 interface Selects gas to report in TAI protocol status message Enclose value in double quotes when setting from the RS 232 interface O2 REM CAL DURATI Minutes 1 120 Duration of automatic calibration initiated ON from TAI protocol CLOCK ADJ pem 60 60 Time of day clock speed adjustment y CAL ON NO2 O ON OFF ON enables span calibration on OFF disables it SERVICE CLEAR m ON resets the service interval timer ON SVC INTERVAL Hours 0 100000 Sets the interval between service reminders T200 an
197. art Time Sample Period DDD HH MM Beport Period DDD HH MM Figure 7 3 Local Instrument at iDAS Configuration and Downloaded Data iDAS Channel Properties Automatic Timer Settings Configuration CONC ATIMER 4032 Records Maximum A Get Config C CONC1 PPB AVG Set 0 0 Records CI STABIL PPB AVG Set 0 0 Records Send To Inst To Inst C PNUMTC ATIMER 360 Records Maximum Data C SMPFLW cc m AVG Set 0 0 Record CI SMPPRS InHg AVG Set 0 0 Records C CALDAT SLPCHG 200 Records Maximum C SLOPE1 PPMZmV INST Set 0 0 Rec CI OFSET1 mV INST Set 0 0 Records New Config O ZSCNC1 INST Set 0 0 Records JETAILED ATIMER 480 Records Maximu PMTDET mv AVG Set 0 0 Records C Samples Selection 100 ATIMER v C Hold Off C Compact Reports 1 1 2010 Y iDAS Parameter Properties 12 00 00 AM T z a Parameter 0 0 1 r r sean eds met Y Precision 0 C Store number of samples in average Sample APICOM User Interface for Configuring the DAS 07889A DCN6900 157 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual 7 2 2 DAS CONFIGURATION VIA TERMINAL EMULATION PROGRAMS IMPORTANT Although Teledyne API recommends the use of APICOM the DAS can also be accessed and co
198. aspect and including attention to the built in warning features of the analyzer periodic inspection regular zero span checks regular evaluation of test parameters for predictive diagnostics and data analysis and routine maintenance of the instrument are paramount to achieving this goal The US EPA strongly recommends that you obtain a copy of the publication Quality Assurance Handbook for Air Pollution Measurement Systems abbreviated Q A Handbook Volume ID USEPA Order Number EPA454R98004 or NIST Order Number PB99 129876 This manual can be purchased from e EPA Technology Transfer Network http www epa gov ttn amtic e National Technical Information Service NTIS http www ntis gov Specific regulations regarding the use and operation of ambient NO analyzers can be found in Section 10 1 Reference 1 and those relating to analyzers can be found in Section10 2 Reference 1 If the T204 is used for EPA compliance monitoring it must be calibrated in accordance with EPA guidelines The instrument s supplying the zero air and Span calibration gasses used must themselves be calibrated and that calibration must be traceable to an EPA NIST primary standard 10 1 REFERENCES RELATING TO NO MONITORING 1 Environmental Protection Agency Title 40 Code of Federal Regulations Part 50 Appendix F Measurement Principle and Calibration Procedure for the Measurement of Nitrogen Dioxide in the Atmosphere Gas Phase Chemilu
199. assembly A Preamplifier board PMT insulation inside housing around PMT Insulating gasket Photo Multiplier Tube PMT TEC driver connector to preamplifier board PMT cold block 12V power High voltage power supply connector Therm o electric cooler TEC Heat exchange fins TEC driver board Cooling fan duct Figure 12 9 T204 NOx Sensor Assembly 6 Remove the two connectors on the PMT housing end plate facing towards the front panel 7 Remove the end plate itself 4 screws with plastic washers If the black PMT housing end plate for the Sensor Assembly is removed Mote ensure to replace the 5 desiccant bags inside the housing 8 Remove the dryer packages inside the PMT housing 9 Unscrew the PMT assembly which is held to the cold block by two plastic screws 10 Discard the plastic screws and replace with new screws at the end of this procedure the threads get stripped easily and it is recommended to use new screws 11 Along with the plate slide out the OPTIC TEST LED and the thermistor that measures the PMT temperature e Thermistor will be coated with a white thermal conducting paste e contaminate the inside of the housing with this grease as it may contaminate the PMT glass tube on re assembly 12 Carefully take out the assembly consisting of the HVPS the gasket and the PMT 13 Change the PMT or the HVPS or both clean the PMT glass tube with a clean anti static
200. ate span gas would be 800 ppb e These examples are applicable to O3 Even though NO gas in nitrogen could be used as a span gas the matrix of the balance gas is different and may cause interference problems or yield incorrect calibrations e The same applies to gases that contain high concentrations of other compounds for example CO or H20 e The span gas should match all concentrations of all gases of the measured medium as closely as possible SPAN GAS FOR MULTIPOINT CALIBRATION Some applications such as EPA monitoring require a multipoint calibration where span gases of different concentrations are needed We recommend using an NO gas of higher concentration combined with a gas dilution calibrator such as a Teledyne API Model 700 This type of calibrator mixes a high concentration gas with zero air to accurately produce span gas of the desired concentration Linearity profiles can be automated with this model and run unattended overnight If a dynamic dilution system such as the Teledyne API Model 700 is used to dilute high concentration gas standards to low ambient concentrations ensure that the NO concentration of the reference gas matches the dilution range of the calibrator Choose the NO gas concentration so that the dynamic dilution system operates in its mid range and not at the extremes of its dilution capabilities EXAMPLE e A dilution calibrator with 10 10000 dilution ratio will not be able to accurately dilute
201. ation is performed and the result changes the value of the slope triggering event SLPCHG The NOx stability to evaluate if the calibration value was stable as well as the converter efficiency for trend reference are also stored e This data channel will store data from the last 200 calibrations and can be used to document analyzer calibration and is useful for detect trends in slope and offset instrument response when performing predictive diagnostics as part of a regular maintenance schedule See Section 11 1 e The CALDAT channel collects data based on events e g a calibration operation rather than a timed interval and therefore does not represent any specific length of time As with all data channels a date and time stamp is recorded for every logged data point CALCHECK This channel logs concentrations and the stability each time a zero or span check not calibration is finished triggered by exiting any calibration menu e data of this channel enable the user to track the quality of zero and span responses over time and assist in evaluating the quality of zero and span gases and the analyzer s noise specifications e The STABIL parameter documents if the analyzer response was stable at the point of the calibration check reading The last 200 data points are retained DIAG Daily averages of temperature zones flow and pressure data as well as some other diagnostic parameters HVPS AZERO e This data is useful for
202. aws about 1 5 A at 115 V and 2 0 A during start up WARNING ELECTRICAL SHOCK HAZARD Should the AC power circuit breaker trip investigate and correct the condition causing this situation before turning the analyzer back on Power enters the analyzer through a standard International Electrotechnical Commission IEC 320 power receptacle located on the rear panel of the instrument From there it is routed through the ON OFF Switch located in the lower right corner of the front panel AC Line power is stepped down and converted to DC power by two DC power supplies PS e One PS provides 5 VDC 3 A and 15 VDC 1 5 0 5 A for logic and analog circuitry as well as the power for the O3 generator e Asecond PS provides 12 VDC 5 A for the PMT s thermoelectric cooler fans and as well as the various gas stream valves both standard and optional All AC and DC Voltages are distributed via the relay PCA 306 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation NOx SENSOR MODULE Pre Amplifiers KEY amp Amplifiers ANALOG AC POWER lt a SENSORS e g Tem DC POWER end Flow Sensor Control L Sensors amp I O Logic LOGIC DEVICES TTT e g CPU bus MotherBoard etc Generator o B 5 VDC 15 VDC Configuration PUMP Internal Only Jumpers SENSOR AC HEATERS MODULE NO
203. ay are designed so that each stage multiplies the number of emitted electrons by emitting multiple new electrons The greatly increased number of electrons emitted from one end of electron multiplier are collected by a positively charged anode at the other end which creates a useable current signal This current signal is amplified by the preamplifier board and then reported to the motherboard 07889A DCN6900 301 Principles of Operation Teledyne API T204 Analyzer Manual Current Flow Dynode Focusing Electrode Electron Multiplier Figure 13 19 Basic PMT Design A significant performance characteristic of the PMT is the voltage potential across the electron multiplier The higher the voltage the greater the number of electrons emitted from each dynode of the electron multiplier in effect making the PMT more sensitive and responsive to smaller variations in light intensity but also more noisy this is referred to as dark noise e The gain voltage of the PMT used in the T204 is usually set between 400 V and 800 V e This parameter is viewable through the front panel as test function HVPS see Section 4 1 1 e For information on when and how to set this voltage see Section 12 8 4 The PMT is housed inside the PMT module assembly see Figure 13 18 This assembly also includes the high voltage power supply required to drive the PMT an LED used by the instrument s optical test function a thermistor
204. b Due to the critical importance and complexity calibration operations are described in detail in other sections of the manual e Section 9 details setting up and performing standard calibration operations or checks e Section 10 details setting up and performing EPA protocol calibrations For information on using the automatic calibrations feature ACAL in conjunction with the one of the calibration valve options see Sections 9 2 7 and 9 3 IMPACT ON READINGS OR DATA To avoid inadvertent adjustments to critical settings activate calibration security by enabling password protection in the SETUP PASS menu Section 5 5 74 07889A DCN6900 Teledyne API T204 Analyzer Manual Overview of Operating Modes 4 3 SETUP MODE The SETUP Mode contains a variety of choices that are used to configure the analyzer s hardware and software features perform diagnostic procedures gather information on the instruments performance and configure or access data from the internal data acquisition system DAS For a visual representation of the software menu trees refer to Appendix A SETUP Mode is divided between Primary and Secondary Setup menus and can be protected through password security 4 3 1 PASSWORD SECURITY SETUP Mode can be protected by password security through the SETUP gt PASS menu Section 5 5 to prevent unauthorized or inadvertent configuration adjustments 4 3 2 PRIMARY SETUP MENU The areas ac
205. becomes less efficient at converting NO into NO To ensure accurate operation of the T204 it is important to check the NO conversion efficiency periodically and to update this value as necessary e For the analyzer to function correctly the converter efficiency must be greater than 0 9600 96 conversion efficiency as per US EPA requirements e fthe converter s efficiency is below this limit the converter should be replaced e The current converter efficiency level is also recorded along with the calibration data in the DAS for documentation and performance analysis Section 0 12 7 10 3 CALCULATING CHECKING CONVERTER EFFICIENCY The T204 automatically calculates the current conversion efficiency by comparing a known starting concentration of NO gas to the measured NO output of the converter This can be accomplished through Gas Phase Titration GPT which is the recommended method see Section 12 7 11 or by using bottled NO There are three steps to performing the bottled NO method Step 1 Supply the analyzer with known concentration of NO gas to the analyzer Source of VENT here if input EUNT RENE EN ALR cC E SAMPLE GAS Tt Removed during A calibration I A MODEL 700E I A sS Gas Dilution i c v Ys Calibrator I 9o Sire o B m I c LLI MODEL 701 Zero Gas Generator Figure 12 7 Setup for determining NO gt NO Efficiency T204 Base Configuration 244 07889A
206. by the current loop option circuitry This adjustment can be made in 100 10 or 1 count increments Since the exact amount by which the current signal is changed per D to A count varies from output to output and instrument to instrument you will need to measure the change in the signal levels with a separate current meter placed in series with the output circuit See Figure 3 7 for pin assignments and diagram of the analog output connector Current Meter I OUT I OUT IIN Recording ANALYZER Device Figure 5 7 Setup for Checking Calibration Current Output Signal Levels Using an Ammeter CAUTION GENERAL SAFETY HAZARD Do not exceed 60 V peak voltage between current loop outputs and instrument ground 07889A DCN6900 107 Setup Menu Teledyne API T204 Analyzer Manual To adjust the zero and span signal levels of the current outputs select the ANALOG I O CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED NO SET gt CAL DISPLAYED AS CONC_OUT_1 CONC_OUT_2 CHANNEL CONC_OUT_3 CONC_OUT_4 tou m uu DIAG CONC OUT 2 5V CONC2 NOCAL SET SET EDIT EXIT DIAG AIO CONC OUT 2 RANGE CURR SET EDIT Continue pressing SET until DIAG AIO CONC OUT 2 CALIBRATED NO SET SET CAL EXIT Analyzer automatically DIAGAIO AUTO CA
207. causing it to emit electrons These electrons are accelerated by an applied high voltage and multiplied through a sequence of similar acceleration steps dynodes until a useable current signal is generated see Section 13 6 for a more detailed description The more light present in this case photons given off by the chemiluminescent reaction described above the more current is produced Therefore the more NO present in the reaction cell the more current is produced by the PMT The current produced by the PMT is converted to a voltage and amplified by the preamplifier board and then communicated to the T204 s CPU via the A gt D converter circuitry on the analyzer 13 1 22 OPTICAL FILTER A high pass optical filter only transparent to wavelengths of light above 645nm placed between the reaction cell and the PMT see Figure 13 1 in conjunction with the response characteristics of the PMT creates a very narrow window of wavelengths of light to which the T204 will respond Reaction Cell INIT TTT qom PMT HOUSING Figure 13 1 Reaction Cell with PMT Tube and Optical Filter Optical Filter The narrowness of this band of sensitivity allows the T204 to ignore extraneous light and radiation that might interfere with the T204 s measurement For instance some oxides of sulfur can also be chemiluminescent emitters when in contact with O but give off light at much shorter wavelengths usually around 260nm to 480nm 07889A DC
208. ccess and control any of Teledyne API s main line of ambient and stack gas instruments from a remote connection through direct cable modem or Ethernet Running APICOM a user can e Establish a link from a remote location to the T204 through direct cable connection via RS 232 modem or Ethernet e View the instrument s front panel and remotely access all functions that could be accessed manually on the instrument e Remotely edit system parameters and set points e Download view graph and save data for predictive diagnostics or data analysis e Retrieve view edit save and upload DAS configurations Section 7 2 1 e Check on system parameters for troubleshooting and quality control APICOM 15 very helpful for initial setup data analysis maintenance and troubleshooting Refer to the APICOM manual available for download from http www teledyne api com software apicom 07889A DCN6900 159 Remote Operation Teledyne API T204 Analyzer Manual 8 2 INTERACTIVE MODE Interactive mode is used with a terminal emulation programs or a dumb computer terminal 8 2 1 REMOTE CONTROL VIA A TERMINAL EMULATION PROGRAM Start a terminal emulation programs such as HyperTerminal All configuration commands must be created following a strict syntax or be pasted in from a text file which was edited offline and then uploaded through a specific transfer procedure The commands that are used to operate the analyzer in thi
209. ce PCA Powered Powered Ethernet Port USB Analog Input Terminal Block Aux PCA Figure 13 27 Front Panel and Display Interface Block Diagram 07889A DCN6900 311 Principles of Operation Teledyne API T204 Analyzer Manual 13 9 1 LVDS TRANSMITTER BOARD The LVDS low voltage differential signaling transmitter board converts the parallel display bus to a serialized low voltage differential signal bus in order to transmit the video signal to the LCD interface PCA 13 9 2 FRONT PANEL TOUCHSCREEN DISPLAY INTERFACE PCA The front panel interface PCA controls the various functions of the display and touchscreen For driving the display it provides connection between the CPU video controller and the LCD display module This PCA also contains e power supply circuitry for the LCD display module e aUSB hub that is used for communications with the touchscreen controller and the two front panel USB device ports circuitry for powering the display backlight 13 10 SOFTWARE OPERATION The T204 NO Analyzer has a high performance VortexX86 based microcomputer running WINDOWS CE Inside the WINDOWS CE shell special software developed by Teledyne API interprets user commands via the various interfaces performs procedures and tasks stores data in the CPU s various memory devices and calculates the concentration of the sample gas API FIRMWARE ANALYZER MEMORY HANDLI
210. cessed and configured under the primary SETUP Mode menu are shown in Table 4 4 Table 4 4 Primary Setup Mode Features and Functions CONTROL MANUAL MODE OR FEATURE BUTTON DESCRIPTION SECTION LABEL Analyzer Configuration CFG Lists button hardware and software configuration information 5 1 Used to set up and operate the AutoCal feature Auto Cal Feature ACAL e Only appears if the analyzer has the zero span valve option 5 2 9 3 installed Internal Data Acquisition DAS DAS Used to set up the DAS system and view recorded data 0 Analog Output Reporting Used to configure the output signals generated by the Range Configuration RNGE instruments analog outputs 2 Calibration Password Security PASS Turns the calibration password feature ON OFF 5 5 Internal Clock Configuration CLK Used to set or adjust the instrument s internal clock 5 6 Secondary SETUP Mode See MORE Advanced SETUP features This button accesses the instruments secondary setup menu Table 4 5 07889A DCN6900 75 Overview of Operating Modes Teledyne API T204 Analyzer Manual 4 3 3 SECONDARY SETUP MENU SETUP gt MORE The areas accessed and configured under the secondary SETUP Mode menu are shown in Table 4 5 Table 4 5 Secondary Setup Mode Features and Functions MODE OR FEATURE CONTROL BUTTON LABEL DESCRIPTION MANUAL SECTION External Communication Channel Configuration
211. cing excessive noise gt 100 mV p p Table 12 5 Power Supply Acceptable Levels aa o _ SUPPLY Test Point Test Point NAME amp Name Operation of the bus can be verified by observing the behavior of D1 on the relay PCA amp D2 on the Valve Driver PCA Assuming that the DC power supplies are operating properly bus is operating properly if D1 on the relay PCA and D2 of the Valve Driver PCA are flashing There is a problem with the I C bus if both D1 on the relay PCA and D2 of the Valve Driver PCA are ON OFF constantly 07889A DCN6900 235 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 4 LCD DISPLAY MODULE TOUCHSCREEN INTERFACE Assuming that there are no wiring problems and that the DC power supplies are operating properly the display screen should light and show the splash screen and other indications of its state as the CPU goes through its initialization process 12 7 5 RELAY PCA The Relay PCA can be most easily checked by observing the condition of the status LEDs on the Relay PCA see Section 12 3 2 and using the SIGNAL I O submenu under the DIAG menu see Section 12 1 3 to toggle each LED ON or OFF If D1 on the Relay PCA is flashing and the status indicator for the output in question Heater power Valve Drive etc toggles properly using the Signal I O function then the associated control device on the Relay PCA is ba
212. critical flow orifices in the T204 those controlling the sample gas and O3 flow into the cell itself are located in the reaction cell where they can be maintained at a constant temperature 13 3 3 OZONE GAS GENERATION AND AIR FLOW The excess ozone needed for reaction with NO in the reaction cell is generated inside the analyzer because of the instability and toxicity of ozone Besides the ozone generator itself this requires a dry air supply and filtering of the gas before it is introduced into the reaction cell Due to its toxicity and aggressive chemical behavior must also be removed from the gas stream before it can be vented through the exhaust outlet CAUTION GENERAL SAFETY HAZARD Ozone is a toxic gas Obtain a Material Safety Data Sheet MSDS for this gas Read and rigorously follow the safety guidelines described there Always ensure that the plumbing of the O4 generation and supply system is maintained and leak free 07889A DCN6900 279 Principles of Operation Teledyne API T204 Analyzer Manual 13 3 3 1 13 3 3 2 THE GENERATOR The T204 uses a dual dielectric Corona Discharge CD tube for creating its which is capable of producing high concentrations of ozone efficiently and with low excess heat see Figure 13 8 The primary component of the generator is a glass tube with hollow walls of which the outermost and innermost surfaces are coated with electrically conductive material
213. ct your IT Network Administrator ID COM2 EXIT Figure 6 4 COMM LAN Internet Manual Configuration 122 07889A DCN6900 Teledyne API T204 Analyzer Manual Communications Setup and Operation Table 6 3 LAN Ethernet Default Configuration Properties PROPERTY DEFAULT STATE DESCRIPTION This displays whether the DHCP is turned ON or OFF Press DHCP ON EDIT and toggle ON for automatic configuration after first consulting network administrator INSTRUMENT This string of four packets of 1 to 3 numbers each e g IP ADDRESS 192 168 76 55 is the address of the analyzer itself Can only be edited when DHCP is set to OFF GATEWAY IP 0 0 0 0 A string of numbers very similar to the Instrument IP address ADDRESS e g 192 168 76 1 that is the address of the computer used by your LAN to access the Internet Can only be edited when DHCP is set to OFF Also a string of four packets of 1 to 3 numbers each e g 255 255 252 0 that identifies the LAN to which the device is SUBNET MASK 0 0 0 0 connected All addressable devices and computers on a LAN must have the same subnet mask Any transmissions sent to devices with different subnets are assumed to be outside of the LAN and are routed through the gateway computer onto the Internet 3000 This number defines the terminal control port by which the TCP PORT instrument is addressed by terminal emulation software such as Int
214. ctions provide information about the various functional parameters related to the analyzer s operation and its measurement of gas concentrations This information is particularly useful when troubleshooting a performance problem with the T204 see Section 12 Test Functions are displayed on the front panel screen in the Main Menu TEST TST TST gt Table 4 2 lists the available TEST functions Table 4 2 Test Functions Defined DISPLAY UNITS DESCRIPTION The Full Scale limit at which the reporting range of the analyzers ANALOG OUTPUTS is currently set THIS IS NOT the Physical Range of the instrument See Section 5 4 1 for more information If AUTO Range mode has been selected two RANGE functions will RANGE1 appear one for each range RANGE2 e RANGE1 The range setting for all analog outputs e RANGE2 The HIGH range setting for all analog outputs If the IND Range mode has been selected three RANGE functions will RANGE1 appear one for each range RANGE2 RANGE1 NO concentration output on A1 RANGE3 e RANGE2 NO concentration output on A2 e RANGE3 NO concentration output on O3S N O3STAB concentration stability O3SLOPE calibration slope OFFS calibration offset O3 photometer measurement signal 3 REF O3 photometer reference signal O3CEL PR PSIA cell pressure O3SAMP TMP sample temperature O3LMP TEMP O3 photometer lamp temperature P M M M V The
215. d Several of the control devices are in sockets and can be easily replaced The following table lists the control device associated with a particular function Table 12 6 Relay PCA Control Devices FUNCTION CONTROL DEVICE SOCKETED All valves U5 Yes Reaction Cell Heater K1 Yes gt NO Converter heater K2 Yes Permeation Tube Heater for Optional Internal Soan Gas Generator I Jes 12 7 6 MOTHERBOARD 12 7 6 1 TEST CHANNEL ANALOG OUTPUTS VOLTAGE The ANALOG OUTPUT submenu located under the SETUP gt MORE gt DIAG menu is used to verify that the T204 analyzer s three analog outputs are working properly The test generates a signal on all three outputs simultaneously as shown in the following table 236 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service Table 12 7 Analog Output Test Function Nominal Values Voltage Outputs FULL SCALE OUTPUT OF VOLTAGE RANGE see Section 5 9 3 1 100MV 1V 5V 10V STEP 96 NOMINAL OUTPUT VOLTAGE 1 0 0 0 0 0 2 20 20 mV 0 2 1 2 3 40 40 mV 0 4 2 4 4 60 60 mV 0 6 3 6 5 80 80 mV 0 8 4 8 6 100 100 mV 1 0 5 10 For 10V output increase the Analog Output Calibration Limits AOUT CAL LIM in the DIAG gt Analog I O Config menu to 4 offset limit and 20 slope limit For each of the steps the output should be within 1 of the nominal value listed except
216. d serial data protocol e REPORT PERIOD Sets how often the sample readings stored in volatile memory are processed e g average minimum or maximum are calculated and the results stored permanently in the instruments Disk on Module DOM as well as transmitted via the analyzer s communication ports The Report Period may be set from the front panel If the INST sample mode is selected the instrument stores and reports an instantaneous reading of the selected parameter at the end of the chosen report period In AVG SDEV MIN or MAX sample modes see Section 7 1 3 3 the settings for the Sample Period and the Report Period determine the number of data points used each time the parameters are calculated stored and reported to the COMM ports The actual sample readings are not stored past the end of the chosen report period When the STORE NUM SAMPLES feature is turned on the instrument will store the number of measurements that were used to compute the AVG SDEV MIN or MAX value but not the actual measurements themselves 07889A DCN6900 149 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual To define the REPORT PERIOD follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 Use the PREV and PREV NEXT INS DEL EDIT PRNT EXIT NEXT buttons to scroll to the DATA CHANNEL to be SETUP CONC
217. d M200E T200H and M200EH T200U and M200EU N Warnings limits 50 52 CONC PRECISION N STAT REP GAS 4 3 20 TAI protocol option CO option 07889A DCN6900 A 9 APPENDIX 3 Wamings and Test Measurements Teledyne API T200 T204 and 200E Series 05295F DCN6900 APPENDIX A 3 Warnings and Test Measurements Table A 2 Warning Messages WSYSRES SYSTEM RESET Instrument was power cycled or the CPU was reset WDATAINIT DATA INITIALIZED Data storage was erased WCONFIGINIT CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased WNOXALARM1 NOX ALARM 1 WARN NOx concentration alarm limit 1 exceeded WNOXALARM2 NOX ALARM 2 WARN NOx concentration alarm limit 2 exceeded WNOALARM1 NO ALARM 1 WARN NO concentration alarm limit 1 exceeded WNOALARM 2 NO ALARM 2 WARN NO concentration alarm limit 2 exceeded WNO2ALARM1 NO2 ALARM 1 WARN NO concentration alarm limit 1 exceeded WNO2ALARM2 NO2 ALARM 2 WARN NO concentration alarm limit 2 exceeded WO2ALARM1 O2 ALARM 1 WARN concentration alarm limit 1 exceeded WO2ALARM2 O2 ALARM 2 WARN concentration alarm limit 2 exceeded WCO2ALARMi CO2 ALARM 1 WARN CO concentration alarm limit 1 exceeded WCO2ALARM2 8 9 CO2 ALARM 2 WARN CO concentration alarm limit 2 exceeded WO3ALARM1 13 O3 ALARM1 WARNING O3 concentration alarm limit 1 exceeded WO3ALARM2 13 ALARM2 WARNING O3 concentration
218. d channel When editing the data channels the top line of the display indicates some of the configuration parameters For example the display line 0 NOxCNC1 ATIMER 5 800 Translates to the following configuration Channel No 0 NAME NOxCNC1 TRIGGER EVENT ATIMER PARAMETERS Five parameters are included in this channel EVENT This channel is set up to store 800 records 144 07889A DCN6900 Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 3 1 EDITING DAS DATA CHANNEL NAMES To edit the name of a DAS data channel follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU SETUP 0 CONC ATIMER 5 800 lt SET SET gt EDIT PRNT SETUP X X NAME CONC lt SET SET gt EDIT PRNT SETUP NAME CONC C C EXIT discards the new setting ENTR accepts the new setting Press each button repeatedly to cycle through the available character set 0 9 A Z space amp _ lt gt 07889 6900 145 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual 7 1 3 2 Note EDITING DAS TRIGGERING EVENTS Triggering events define when and how the DAS records a measurement of any given data channel Triggering events are firmware specific and a complete list of Triggers for this model analyzer can be found in Appendix A The most commonly u
219. d data from the serial or analog outputs of the T204 e f analog readings are used the response of the recording system should be checked against a NIST traceable voltage source or meter e Data recording devices should be capable of bi polar operation so that negative readings can be recorded For electronic data recording the T204 provides an internal data acquisition system DAS which is described in detail in Section 0 APICOM a remote control program is also provided as a convenient and powerful tool for data handling download storage quick check and plotting see Sections 7 2 1 and the APICOM software manual downloadable from http www teledyne api com manuals 07889A DCN6900 169 Calibration Procedures Teledyne API T204 Analyzer Manual 9 1 4 NO CONVERSION EFFICIENCY CE In order for the NO converter to function properly oxygen must be present in the sample stream In addition to ensure accurate operation of the T204 it is important to check the NO conversion efficiency CE periodically and to update this value as necessary e See Section 12 7 10 for instructions on checking or calculating the current NO gt NO converter efficiency using T204 s onboard firmware e See Section 12 7 11 for instructions on checking or calculating the current NO gt NO converter efficiency using a simplified Gas Phase Titration Method 9 2 MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE T2
220. de Se 121 6 5 1 Configuring Ethernet Communication Manually Static IP Address 121 6 5 2 Configuring Ethernet Communication Using Dynamic Host Configuration Protocol DHCP AE 123 6 6 USB Port for Remote ACCESS arien aii 126 6 7 Communications Protocols oriri eana aaa rede res DRE ERE RR daa red 128 6 7 1 cct eerte pae eto rta RE re he ER ERR DR bad Rd dade bed 128 6 7 2 m 130 7 DATA ACQUISITION SYSTEM DAS AND 139 FEDAS STU E dote Deut edible A ime intei 140 7 1 1 DAS Channels oo ertum ete mrs 140 7 1 2 Viewing DAS Data and Settings 143 7 1 3 Editing DAS Data Channels eeeessseeneeeeee tese rennen nnne anah 144 7 2 Remote DAS Configuration niara A A a a aaa a G ea aea 156 7 2 1 DAS Configuration via APICOM sssesssseeeneeeenenene nennen nnne nennen enr nene 156 7 2 2 DAS Configuration via Terminal Emulation 158 8 REMOTE OPERATION e eeeee enne nnnnnnnnnneeensss 159 8 1 Computer MOGe etui a etes tuae teda 159 8 1 1 Remote Control via APICOM
221. described in Section 9 2 3 2 BUT DO NOT press the ENTR button at the end of each operation Pressing the ENTR button resets the stored values for OFFSET and SLOPE and alters the instruments Calibration Alternately use the Auto Cal feature described in Section 9 3 with the WARNING ELECTRICAL SHOCK HAZARD Disconnect power before performing any of the following operations that require entry into the interior of the analyzer A CAUTION QUALIFIED PERSONNEL These maintenance procedures must be performed by qualified technicians only 07889A DCN6900 193 Instrument Maintenance Teledyne API T204 NO 03 Analyzer Manual Table 11 1 T204 Maintenance Schedule CAL DATE PERFORMED ITEM ACTION FREQ CHECK REQ D TEST Review and Weekly No functions evaluate Particulate Change Weekly if in No filter particle filter stack system As Needed Zero span Evaluate Weekly No check offset and slope Zero span Zero and Every 3 months Yes calibration span calibration External zero Exchange Every 3 months No air scrubber chemical option External Replace When indicator No dryer option chemical color changes Ozone Change Annually Yes cleanser chemical Reaction cell Clean Annually or as Yes window necessary optical filter in Figure 11 5 DFU filters Change Annually No particle filter Pneumatic Check for Annually or Yes if a sub system leaks in gas
222. development to be inserted prior to initial release of this manual Note Note 07889A DCN6900 Use of replacement parts other than those supplied by Teledyne Advanced Pollution Instrumentation TAPI may result in non compliance with European standard EN 61010 1 Due to the dynamic nature of part numbers please refer to the TAPI Website at http www teledyne api com or call Customer Service at 800 324 5190 for more recent updates to part numbers B 1 B 2 This page intentionally left blank 07889A DCN6900 T204 Spare Parts List PN 07887A DCN6919 06 17 2014 1 of page s Part Number Description O 000940400 ORIFICE 4 MIL OZONE FLOW amp O2 OPTION 000940600 001330000 01761800 02270100 02730000 04330000 05960000 05970000 08830000 09690200 09690300 AKIT TFE FLTR ELEM FL19 3021 47mm 11310000 11340500 11420500 11630000 11930000 13140000 14080100 16290000 16900800 18720100 18720200 37860000 39700100 40010000 40030800 40400000 40410100 40420200 40900000 41800500 41920000 42680100 43170000 44600000 44610000 45230200 45500100 045500300 45500400 46030000 46480000 47150000 048830000 049310100 049760300 050610700 Part Number 000940400 000940600 001380000 001761800 002270100 002730000 004330000 005960000 045500300 045500400 046030000 046480000 047150000 _ 048830000 049310100 049760300
223. digital control inputs that can be used to remotely activate the zero and span calibration modes Access to these inputs is provided via a 10 pin connector labeled CONTROL IN on the analyzer s rear panel There are two methods for energizing the Control Inputs The internal 5V available from the pin labeled is the most convenient method however to ensure that these inputs are truly isolated a separate external 5 VDC power supply should be used CONTROL IN CONTROL IN U PESSIMUS A F lt ZERO SPAN ZERO mw SPAN ies 5 VDC Power Supply Local Power Connections External Power Connections Figure 3 10 Energizing the T204 Control Inputs Table 3 6 Control Input Pin Assignments de ON Condition Definition The analyzer is placed in remote Zero Calibration mode The mode field of the display ZERO CAL will read ZERO CAL R REMOTE The analyzer is placed in remote Span Calibration mode The mode field of the display SPAN CAL will read SPAN CAL R Digital Ground The ground level from the analyzer s internal DC Power Supplies same as chassis ground U aa wee Input pin for 5 VDC required to activate pins A F Internally generated 5V DC power To activate inputs A F place a jumper between 5 VDC output this pin and the U pin The maximum amperage through this port is 300 mA combined with the analog output supply if used
224. displays the desired identifier 07889A DCN6900 93 Setup Menu Teledyne API T204 Analyzer Manual Toggle to cycle through the available character set 0 9 SETUP COMMUNICATIONS MENU COM2 ENTR accepts the new SETUP X MACHINE ID 204 ID settings EXIT ignores the new ENTR EXIT settings Figure 5 3 COMM Machine ID The ID can be any unique 4 digit number and can also be used to identify analyzers in any number of ways e g location numbers company asset number etc 5 7 2 NET ETHERNET Use SETUP gt COMMSINET to configure Ethernet communications whether manually or via DHCP Please see Section 6 5 2 for configuration details 5 7 3 COM1 COM2 MODE BAUDE RATE AND TEST PORT Use the SETUP gt COMM gt COM1 COM2 menus to configure communication modes Section 6 2 1 view set the baud rate Section 6 2 2 test the connections of the com ports Section 6 2 3 Configuring COMI or COM2 requires setting the DCE DTE switch on the rear panel Section 6 1 provides DCE DTE information 94 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 8 SETUP gt VARS VARIABLES SETUP AND DEFINITION Through the SETUP gt MORE gt VARS menu there are several user adjustable software variables that define certain operational parameters Usually these variables are automatically set by the instrument s firmware but can be manually re defined using the VARS
225. djustment switch to its maximum setting F e Set the HVPS coarse adjustment switch to the lowest setting that will give you just above the target value for NORM signal 12 Adjust the HVPS fine adjustment such that the NORM PMT value is close to the target value e t may be necessary to go back and forth between coarse and fine adjustments if the proper value is at the threshold of the min max coarse setting ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Do not overload the PMT by accidentally setting both adjustment switches to their maximum setting Start at the lowest setting and increment slowly Wait 10 seconds between adjustments Note During these adjustments the NORM PMT value will fluctuate as the analyzer continues to switch between NO and NOx streams as well as between measure and Auto Zero modes 260 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 13 Perform a span point calibration see Section 9 to normalize the sensor response to its new PMT sensitivity 14 Review the slope and offset values e The slope values should be 1 000 0 300 e offset values should be approximately 0 0 20 to 150 mV is allowed 12 8 5 REPLACING THE PMT HVPS OR TEC The photo multiplier tube PMT should last for the lifetime of the analyzer however the high voltage power supply HVPS or the thermo electric cooler TEC components may fail Replacing any of
226. e most leaks It also verifies the sample pump condition 1 Turn the analyzer ON and allow at least 30 minutes for flows to stabilize 2 Capthe sample inlet port cap must be wrench tight 3 After several minutes when the pressures have stabilized note the SAMP sample pressure and the RCEL vacuum pressure readings e f both readings are equal to within 10 and less than 10 in Hg A the instrument is free of large leaks e Itis stil possible that the instrument has minor leaks f both readings are lt 10 in Hg A the pump is in good condition e Anew pump will create a pressure reading of about 4 in Hg A at sea level 11 3 10 2 DETAILED PRESSURE LEAK CHECK If a leak cannot be located by the above procedure obtain a leak checker similar to Teledyne API s P N 01960 which contains a small pump shut off valve and pressure gauge to create both over pressure and vacuum Alternatively a tank of pressurized gas with the two stage regulator adjusted to lt 15 psi a shutoff valve and a pressure gauge may be used ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Once tube fittings have been wetted with soap solution under a pressurized system do not apply or reapply vacuum as this will cause soap solution to be sucked into the instrument contaminating inside surfaces 1 Turn OFF power to the instrument and remove the instrument cover 2 Install a leak checker or a tank of gas compressed oil free air or nitrog
227. e specifications that each meets Table 2 1 T204 Basic Unit Specifications PARAMETER SPECIFICATION Nitrogen Oxides NOx Sensor Ozone Sensor Min Max Range Min 0 50 ppb Full Scale Min 0 50 ppb Full Scale Physical Analog Output Max 0 20 000 ppb Full Scale selectable Max 0 1000 ppb Full Scale independent NO NO ranges and auto ranges supported Measurement Units ppb ppm ug m mg m selectable Zero Noise lt 0 2 ppb RMS lt 001 ppm RMS Span Noise lt 0 5 of reading RMS above 50 ppbor0 2 lt 0 5 of reading RMS above 0 1 ppm ppb whichever is greater Lower Detectable Limit 0 4 ppb lt 002 PPM Zero Drift lt 0 5 ppb at constant temperature and lt 1 Full Scale 24 hours voltage 24 hours Span Drift lt 0 5 of Full Scale at constant temperature 196 Full Scale 24 hours and voltage 24 hours Lag Time lt 20 seconds lt 10 seconds Rise Fall Time lt 60 seconds to 95 lt 30 seconds to 95 Linearity 1 of Full Scale Precision 0 5 of reading above 50 ppb 0 5 of reading above 100 ppb Sample Flow Rate 500 cm min 10 800 cm min Power Rating Typical Power Consumption 110 120 V 60 Hz 3 0 A 133W 220 240 V 50 60 Hz 2 5 A 127 W Power Ext Pump 100 V 50 60 Hz 3 25 A 115 V 60 Hz 3 0 A 220 240 V 50 60 Hz 2 5 A 10V 5V 1V 0 1V selectable Analog Output Ranges All Ranges with 5 Under Ove
228. e 13 21 Typical Thermo Electric Cooler In the case of the T204 the current flow is controlled by the TEC Control PCA which adjusts the amount of current applied to the TEC based on the temperature sensed by a thermistor embedded in the PMT s cold block The higher the temperature of the PMT the more current is pumped through the TEC The hot side of the TEC is cooled by a constant flow of ambient air that is directed across a set of heat sinks by a fan 304 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation Preamp PCA sends buffered and TEC PCA sets amplified thermistor appropriate signal to TEC PCA drive voltage for cooler Thermistor outputs temp of cold block to preamp PCA Heat Sink Cold Block Heat form PMT is absorbed by the cold block and transferred to the heat sink via the TEC then bled off into the cool air stream SS Cooling Fan Figure 13 22 PMT Cooling System Block Diagram The target temperature at which the TEC system keeps the PMT is approximately 8 0 C Arriving at this temperature may take up to 30 minutes after the instrument is turned on The actual temperature of the PMT can be viewed via the front panel as the test function PMT TEMP see Section 4 1 1 13 6 2 1 TEC CONTROL BOARD The TEC control PCA is located on the sensor housing assembly under the slanted shroud next to the cooling fins and directly above the cooling fan
229. e 5 1 Analog Output Connector Pin Out The Al A2 A3 and A4 channels output a signal that is proportional to the NO NO and O concentrations of the sample gas respectively The T204 can be set so that these outputs operate in one of three modes single range mode independent range mode or automatic range mode Section 5 4 3 Additionally the signal levels of outputs A1 A2 A3 and A4 outputs can be e Configured full scale outputs of 0 0 1 VDC 0 1 VDC 0 5 VDC or 0 10 VDC e Equipped with optional 0 20 mADC current loop drivers see Section 3 3 1 4 and configured for any current output within that range analog output e g 0 20 mA 2 20 mA 4 20 mA etc Together these two set of parameters allow the user a great deal of flexibility in how the instrument reports NO NO and concentrations to external devices IMPACT ON READINGS OR DATA The instrument does not remember upper range limits settings associated with the individual modes Changes made to the range limits e g 400 ppb gt 600 ppb when in one particular mode will alter the range limit settings for the other modes When switching between reporting range modes ALWAYS check and reset the upper range limits for the new mode selection 07889A DCN6900 79 Setup Menu Teledyne API T204 Analyzer Manual 5 4 2 2 ANALOG OUTPUT REPORTING RANGE DEFAULT SETTINGS The default setting for these the repor
230. e Check the power supply to the valve 12 V to the valve should turn on and off when measured with a voltmeter It takes only a small leak across the ports of the valve to show excessive Auto Zero values when supplying high concentrations of span gas Another reason for high although not necessarily out of range values for Auto Zero could be the ozone air filter cartridge if its contents have been exhausted and needs to be replaced e This filter cartridge chemicals that can cause chemiluminescence and if saturated these chemicals can break through to the reaction cell causing an erroneously high Auto Zero value background noise A dirty reaction cell can cause high Auto Zero values e Clean the reaction cell according to Section 11 3 7 Finally a high HVPS voltage value may cause excess background noise and a high AZERO value e The HVPS value changes from analyzer to analyzer and could show nominal values between 450 and 800 V e Check the low level hardware calibration of the preamplifier board and if necessary recalibrate exactly as described in Section 12 8 4 in order to minimize the HVPS 12 7 SUBSYSTEM CHECKOUT The preceding sections of this manual discussed a variety of methods for identifying possible sources of failures or performance problems within the analyzer In most cases this included a list of possible causes and in some cases quick solutions or at least a pointer to the appropriate sections describin
231. e Filter 197 11 3 3 Changing the Ozone Generator Cleanser 198 11 3 4 Maintaining the External Sample Pump Pump 201 11 3 5 Changing the Pump DFU Filter nemen 201 11 3 6 Changing the NO nennen enn 203 11 3 7 Cleaning the Reaction a 205 11 3 8 Replacing Critical Flow Orifices 2 207 11 3 9 Checking for Light Leaks 208 11 3 10 Checking for Pneumatic Leaks sssssseeeeeeeneneeneenen eee nnne 209 11 3 11 Ozone Sensor Maintenance ssssssssssseeeeee eene nennen nennen nnne 211 12 TROUBLESHOOTING amp SERVICE nennen nennen 213 12 1 General Instrument and NOx Troubleshooting sseseseeeeenm eem een eren 214 12 1 1 Fault Diagnosis with WARNING Messages ssee eene 214 12 1 2 Fault Diagnosis With Test Functions ssssseeeenn enne 218 12 1 3 DIAG gt SIGNAL I O Using the Diagnostic Signal I O 218 12 2 03 Sensor Troubleshooting
232. e NO Concentration RANGE1 Set for 0 800 ppb amp output A1 set for 0 10 VDC e NO Concentration RANGE2 Set for 0 200 ppb amp output A2 set for 0 5 VDC e NO Concentration RANGES Set for 0 400 ppb amp output A3 set for 0 5 VDC e Concentration RANGE4 Set for 0 500 ppb amp output A4 set for 0 5 VDC Setting analog range limits to different values does not affect the instrument s calibration To select the IND range mode press the following buttons SAMPLE RANGE 500 0 PPM NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X RANGE MODE SNGL SNGL IND AUTO ENTR EXIT SETUP RANGE MODE IND SNGL IND AUTO ENTR EXIT SETUP RANGE MODE MENU MODE SET UNIT DIL 82 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu To set the upper range limit for each independent reporting range press SAMPLE RANGE 500 0 PPB XXXX lt TST TST gt CAL Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X RANGE 500 0 Conc 5 0 0 0 SETUP X X RANGE 500 0 Conc 0 0 5 0 0 0 Toggle these buttons to select the upper SPAN limit for the reporting ranges SETUP X X NO2 RANGE 500 0 Conc 0 0 0 O3 RANGE 100 00 0 0 E
233. e PPB SAMP FLW Va uefCC M O3GEN FL Va uejCC M PMT Value MV NORM PMT Va ue MV AZERO ValueJ MV HVPS Va lue V RCELL TEMP Va uePC BOX TEMP Va uePC TEMP Va uePC IZS TEMP Va uePC MOLY TEMP Va uePC ZERO SPAN NOX EH oa CALZ OW CONC NO CONV NO2 CAL CFG d HIGH ZERO SET ACAL CALS to SPAN DAS MSG CLR SETUP HIGH Press to cycle through the active warning messages CONC 1 Press to clear an active warning messages PRIMARY SETUP MENU RNGE PASS CLK MORE SECONDARY SETUP MENU COMM VARS DIAG ALRM RCEL Va ue N HG A SAMP Value N HG A NOX SLOPE Value NOX OFFS Va ueMV NO SLOPE Value NO OFFS ValueMV TEST ValueMV TIME HH MM SS Only appears when warning messages are active This function can be set to display the stability of any gas the analyzer is equipped to measure 3 Only appears if analyzer is equipped with Calibration Valve or Internal Span Gas Generator options Only appears if analyzer is equipped with the Internal Span Gas Generator option 5 These submenus only apply to NOx calibrations not Os Only appears when the Concentration Alarm option is active 7 T204 ozone sensor Figure A 1 Basic Sample Display Menu 07889A DCN6900 APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204yKb7 200E CFG lt P
234. e Particulate Filter 3 Carefully remove the filter nut PTFE o ring glass filter cover and filter element 4 Replace the filter element being careful that it is fully seated and centered in the bottom of the holder 196 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 5 Reinstall the Teflon retaining ring with the notches up the o ring and the window then screw on the filter nut and hand tighten Inspect the seal between the edge of filter and the Teflon retaining ring to assure a proper seal 6 Restart the Analyzer 11 3 2 CHANGING THE O GENERATOR DRYER PARTICULATE FILTER The air for the generator passes through a sample gas dryer which is equipped with a small particulate filter at its inlet This filter prevents dust from entering the sample gas dryer and degrading the dryer s performance over time Change the filter according to the service interval in Table 11 1 as follows 1 Before starting the procedure check and write down the average RCEL pressure and the OZONE FLOW values Turn off the analyzer unplug the power cord and remove the cover 3 Unscrew the nut around the port of the filter using two 5 8 wrenches ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Ensure to use proper wrenches Hold the main dryer fitting with a 5 8 wrench to ensure that it does not turn against the sample gas dryer Performing this procedure improperly or with incorrect
235. e filter see Section 11 3 5 and on for replacement procedures e Appendix B lists a spare part kit with a complete orifice assembly that allows a quick replacement with minimum instrument down time 12 4 1 3 HIGH FLOW Flows that are significantly higher than the allowed operating range typically 10 11 of the nominal flow should not occur in the T204 unless a pressurized sample zero or span gas is supplied to the inlet ports e Ensure to vent excess pressure and flow just before the analyzer inlet ports When supplying sample zero or span gas at ambient pressure a high flow would indicate that one or more of the critical flow orifices are physically broken very unlikely case allowing more than nominal flow or were replaced with an orifice of wrong specifications e the flows are within 15 higher than normal we recommend measuring and recalibrating the flow electronically using the procedure in Section 9 followed by a regular review of these flows over time to see if the new setting is retained properly e Also check the flow assembly o rings and replace as needed 12 4 1 4 SAMPLE FLOW IS ZERO OR LOW BUT ANALYZER REPORTS CORRECT FLOW Note that the T204 analyzer can report a correct flow rate even if there is no or a low actual sample flow through the reaction cell e The sample flow on the T204 is only calculated from the sample pressure and critical flow condition is verified from the difference between sample press
236. e front panel test function PMT TEMP and the SIGNAL I O function TEMP e tis recorded by the DAS system as the parameter PMTTMP SAMPLE GAS PRESSURE SENSOR This sensor located on the flow pressure sensor PCA measures the gas pressure in the sample chamber upstream of the sample gas stream flow control assembly Its functions are described in Section 13 3 4 1 e The value of this signal is viewable via the front panel test function SAMP and the SIGNAL I O function SAMPLE PRESSURE e Itis recorded by the DAS system as the parameter SMPPRS VACUUM PRESSURE SENSOR This sensor also located on the flow pressure sensor PCA is pneumatically located downstream from the reaction cell and measures the pressure of the gas mixture inside the reaction cell Its functions are described in Section 13 3 4 2 e The value of this signal is viewable via the front panel test function RCEL and the SIGNAL I O function RCEL PRESSURE e Itis recorded by the DAS system as the parameter RCPRES O FLOW SENSOR This sensor located on the flow pressure sensor PCA measures the flow rate of the gas stream as it is supplied to the reaction cell Its functions are described in Section 13 3 4 4 e The value of this signal is viewable via the front panel test function OZONE FLOW and the SIGNAL I O function OZONE FLOW e Itis recorded by the DAS system as the parameter O3FLOW 290 07889A DCN6900 Teledyne API T204 Analyzer
237. e new Use these setting buttons to choose the ENTR accepts the Hessen typey gt new setting While Hessen Protocol Mode can be activated independently for COM1 and 2 the TYPE selection affects both Ports Note 132 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation 6 7 2 4 SETTING THE HESSEN PROTOCOL RESPONSE MODE The Teledyne API s implementation of Hessen Protocol allows the user to choose one of several different modes of response for the analyzer Table 6 5 Teledyne API s Hessen Protocol Response Modes MODE ID MODE DESCRIPTION CMD This is the Default Setting Reponses from the instrument are encoded as the traditional command format Style and format of responses depend on exact coding of the initiating command BCC Responses from the instrument are always delimited with lt STX gt at the beginning of the response lt ETX gt at the end of the response followed by a 2 digit Block Check Code checksum regardless of the command encoding TEXT Responses from the instrument are always delimited with lt CR gt at the beginning and the end of the string regardless of the command encoding To Select a Hessen response mode press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP SECO
238. e orientation of the dryer on the bracket Cut the tie wraps that hold the dryer to the mounting bracket and take out the old dryer e f necessary unscrew the two mounting screws on the bracket and take out the entire assembly Attach the replacement dryer to the mounting bracket in the same orientation as the old dryer Fix the dryer to the bracket using new tie wraps Cut off excess length of the wraps Put the assembly back into the chassis and tighten the mounting screws Re attach the tubes to vacuum manifold flow meter and or NO NOx valve using at least two wrenches e Take extra care not to twist the dryer s white plastic fittings as this will result in large leaks that are difficult to trouble shoot and fix Carry out a detailed leak check see Section 11 3 10 2 Close the analyzer Power up pump and analyzer and re calibrate the instrument after it stabilizes 12 8 4 PMT SENSOR HARDWARE CALIBRATION The sensor module hardware calibration is used in the factory to adjust the slope and offset of the PMT output and to optimize the signal output and HVPS If the instrument s slope and offset values are outside of the acceptable range and all other more obvious causes for this problem have been eliminated the hardware calibration can be used to adjust the sensor as has been done in the factory This procedure is also recommended after replacing the PMT or the preamplifier board To calibrate the PMT preamplifier P
239. e right hand side of the front 07889A DCN6900 213 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 1 12 1 1 GENERAL INSTRUMENT AND NOX TROUBLESHOOTING The T204 NOx O3 analyzer has been designed so that problems can be rapidly detected evaluated and repaired During operation it continuously performs diagnostic tests and provides the ability to evaluate its key operating parameters without disturbing monitoring operations A systematic approach to troubleshooting will generally consist of the following five steps 1 Note any WARNING MESSAGES and take corrective action as necessary 2 Examine the values of all TEST functions and compare them to factory values Note any major deviations from the factory values and take corrective action 3 Use the internal electronic status LEDs to determine whether the electronic communication channels are operating properly e Verify that the DC power supplies are operating properly by checking the voltage test points on the relay PCA e Note that the analyzer s DC power wiring is color coded and these colors match the color of the corresponding test points on the relay PCA 4 Suspecta leak first e Customer service data indicate that the majority of all problems are eventually traced to leaks in the internal pneumatics of the analyzer or the diluent gas and Source gases delivery systems e Check for gas flow problems such as clogged or blocked
240. e this value at 308 atm at STP The value of this number reflects the fact that ozone is a very efficient absorber of UV radiation which is why stratospheric ozone protects the life forms lower in the atmosphere from the harmful effects from solar UV radiation Lastly the absorption path length determines how many molecules are present in the column of gas in the absorption tube The intensity of light is converted into a voltage by a high resolution A D analog to digital converter The digitized signal and other variables are used by the CPU to compute the concentration using the above formula About every 2 5 seconds the 465L completes a measurement cycle consisting of a 1 second wait period for the sample tube to flush followed by a 150 ms measurement of the UV light intensity to obtain I The sample valve is switched to admit scrubbed sample gas for 1 second followed by a 150 ms measurement of the UV light intensity to obtain Ig Measurement of the Ig every 2 5 seconds eliminates instrument drift due to changing intensity of the lamp caused by aging and dirt 07889A DCN6900 273 Principles of Operation Teledyne API T204 Analyzer Manual 13 3 PNEUMATIC OPERATION IMPORTANT Note IMPACT ON READINGS OR DATA Could either affect accuracy of instrument readings or cause loss of data The sample gas is the most critical flow path in the analyzer At any point before and in the reaction cell the inte
241. e used as a zero gas for applications where NOx is measured in nitrogen e f your analyzer is equipped with an external zero air scrubber option it is capable of creating zero air from ambient air For analyzers without the external zero air scrubber a zero air generator such as the Teledyne API s Model 701 can be used Please visit the company website for more information If your analyzer is equipped with an external zero air scrubber option it is capable of creating zero air from ambient air e If your application is not a measurement in ambient air the zero calibration gas should be matched to the composition of the gas being measured e nitrogen could be used as a zero gas for applications where NOx is measured in nitrogen SPAN GAS Span calibration gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired reporting range NOx To measure NOx with the T204 it is recommended that you use a span gas with an NO concentration equal to 80 of the measurement range for your application EXAMPLE e If the application is to measure NOx in ambient air between 0 ppm and 500 ppb appropriate span gas would be 400 ppb e Ifthe application is to measure NOx in ambient air between 0 ppm and 1000 ppb an appropriate span gas would be 800 ppb We strongly recommend that span calibration be carried out with NO span gas 168 07889A DCN6900
242. ear Panel 55 ANALOG CAL WARNING 61 75 139 Analog Inputs 114 Analog Outputs 21 35 36 37 39 74 77 78 80 81 98 237 238 294 AIN Calibration 114 Configuration amp Calibration 78 102 103 104 105 106 108 110 112 113 114 Automatic 29 77 106 Manual Current Loop 109 111 MANUAL VOLTAGE 107 Converting Voltage to Current Output 37 Current Loop 81 Electronic Range Selection 82 103 IND Mode Assignments 83 OUTPUT LOOP BACK 294 Reporting Range 64 73 74 77 Test Channel 36 237 APICOM 19 118 161 and DAS 141 143 146 151 153 155 157 159 and Ethernet 123 and Failure Prediction 197 Approvals 21 ATIMER 146 148 AUTO 86 AutoCal 74 77 180 181 182 AutoZero 202 228 233 234 261 273 278 281 285 Pneumatic Flow 274 289 Valve 74 202 233 277 278 298 Warnings 61 233 AUTOZERO WARNINGS 139 AZERO 61 73 75 143 197 218 234 273 278 DAS Parameter 143 AZERO WARN 61 75 B Baud Rate 132 BOX TEMP 61 73 75 139 BOX TEMP WARNING 61 75 139 C CAL Button 76 266 CALCHEK 143 CALDAT 143 Calibration AIN 114 Analog Ouputs 29 77 106 ANALOG OUTPUTS Current Loop 109 111 VOLTAGE 107 Initial Calibration Basic Configuration 63 64 67 Calibration Checks 172 173 177 Calibration Gases 170 Span Gas 50 52 56 63 66 80 98 169 170 171 173 175 178 182 266 Dilution Feature 89 Standard Reference Materials SRM s NO NO Span Gas 171 Zero Air
243. ear Panel Connector Pin Outs for RS 232 Mode The signals from these two connectors are routed from the motherboard via a wiring harness to two 10 pin connectors on the CPU card J11 and J12 Figure 3 13 07889A DCN6900 41 Getting Started Teledyne API T204 Analyzer Manual Note NC CTS DSR DTR RXD Figure 3 13 Default Pin Assignments for CPU COMM Port Connector RS 232 Teledyne API offers two mating cables one of which should be applicable for your use e P N WR000077 a DB 9 female to DB 9 female cable 6 feet long Allows connection of the serial ports of most personal computers P N WR000024 a DB 9 female to DB 25 male cable Allows connection to the most common styles of modems e g Hayes compatible and code activated switches Both cables are configured with straight through wiring and should require no additional adapters Cables that appear to be compatible because of matching connectors may incorporate internal wiring that makes the link inoperable Check cables acquired from sources other than Teledyne API for pin assignments before using To assist in properly connecting the serial ports to either a computer or a modem there are activity indicators just above the RS 232 port Once a cable is connected between the analyzer and a computer or modem both the red and
244. econd is located on the PMT Preamplifier PCA and is used only as a reference for the preamplifier circuitry Its output is neither reported nor stored 07889A DCN6900 291 Principles of Operation Teledyne API T204 Analyzer Manual 13 4 3 4 13 4 3 5 13 4 3 6 ANALOG OUTPUTS The analyzer comes equipped with four analog outputs On the instrument s rear panel analog connector see Figure 3 4 they are labeled A1 A2 and A4 CONCENTRATION OUTPUTS Outputs labeled Al A2 and 4 carry the concentration signals of NOx NO NO and respectively A variety of scaling measurement and electronic factors apply to these signals e See Sections 3 3 1 3 and 5 4 for information on setting the reporting range type and measurement range scaling factors for these output channels e See Sections 5 9 3 2 for instructions calibrating and scaling the electronic output of these channels e In its standard configuration the T204 comes with all four of these channels set up to output a DC voltage However 4 20mA current loop drivers can be purchased OUTPUT LOOP BACK AII of the functioning analog outputs are connected back to the A D converter through a Loop back circuit This permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures see Section 5 9 3 4 EXTERNAL DIGITAL I O This external digital I O performs two functions STATUS OUTPUTS Logic Level vol
245. ect a sample gas line to the SAMPLE inlet e Use PTFE tubing minimum OD e Sample Gas pressure must equal ambient atmospheric pressure 1 0 psig e In applications where the sample gas is received from a pressurized manifold and the analyzer is not equipped with one of the T204 s pressurized span options a vent must be placed on the sample gas line This vent line must be e No than 10 meters long e Vented outside the shelter or immediate area surrounding the instrument CALIBRATION GAS SOURCES e CAL GAS amp ZERO AIR SOURCES The source of calibration gas is also attached to the SAMPLE inlet but only when a calibration operation is actually being performed e Use PTFE tubing minimum OD 74 50 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started Note VENTING In order to prevent back diffusion and pressure effects both the span gas and zero air supply lines should be e Vented outside the enclosure e Minimum OD 74 e Not less than 2 meters in length e Not greater than 10 meters in length EXHAUST OUTLET Attach an exhaust line to the EXHAUST outlet fitting The exhaust line should be e Use PTFE tubing minimum OD 74 e Amaximum of 10 meters long e Vented outside the T204 analyzer s enclosure Once the appropriate pneumatic connections have been made check all pneumatic fittings for leaks using the procedures defined in Sections 11 3 10 or 11 3 10 2 for detai
246. ection describes how to determine the NO2 NO converter s efficiency using a GPT method where the actual concentration of ozone is not a factor in the accuracy of the calculation This procedure is based on the Code of Federal Regulations Title 40 Chapter subchapter C Part 50 Appendix F In the following example a reference point of 450 ppb NO gas will be used This is only an example Any other reference points within measurement range of the instrument may be used For this procedure use a calibrated generator such as a Teledyne API s T700 07889A DCN6900 247 Troubleshooting amp Service Teledyne API T204 Analyzer Manual Note There must be a minimum of 10 more NO than produced Example if the Ozone concentration used is 400 ppb then the NO concentration must be used must be 440 ppb or more PART 1 PREPARATION 1 Leak check machine to ensure that there are no leaks in the analyzer 2 Calibrate the instrument at the same NO span gas value as being used in this method e For this example 450 ppb NO span gas 3 f you have input a converter efficiency CE factor into the instrument firmware see Section 12 7 10 3 other than 100 change this back to 100 for the duration of this test CAL gt CONC gt CONV gt SET PART2 DETERMINE THE AMOUNT OF NO OUTGASSED BY THE NO2 gt NO CONVERTER 4 Bypass the NO2 NO converter by placing a short piece of tubing in the gas stream in place
247. ed during the most recent NO zero span calibration TEST MV Displays the signal level of the Test Function that is currently being produced by the Analog Output Channel A4 X The current time This is used to create a time stamp on DAS readings TIME 55 and by the AutoCal feature to trigger calibration events NO SLOPE Ps The slope calculated during the most recent NO zero span calibration IMPORTANT IMPACT ON READINGS OR DATA A value of XXXX displayed for any of the TEST functions indicates an out of range reading or the analyzer s inability to calculate it All pressure measurements are represented in terms of absolute pressure Absolute atmospheric pressure is 29 92 in Hg A at sea level It decreases about 1 in Hg per 300 m gain in altitude A variety of factors such as air conditioning and passing storms can cause changes in the absolute atmospheric pressure 72 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Overview of Operating Modes 4 1 2 WARNING MESSAGES The most common and serious instrument failures will activate Warning Messages that are displayed on the analyzer s Front Panel They are listed in Table 4 3 as follows Table 4 3 Warning Messages Defined ANALOG CAL WARNING The A D or at least one D A channel has not been calibrated Auto zero reading above limit Value shown in message indicates auto zero reading at time warning was displayed OZONE GEN OFF Ozone generator is off
248. edic RC EID acc NM ex LER abd dee thane 163 Set up for Manual Calibrations Checks of T204 s in Base Configuration w a Gas Dilution E 171 Set up for Manual Calibrations Checks of T204 s in Base Configuration w Bottled Gas 171 Replacing the Particulate Filter ient nennen nnne hte hne 196 Particle Filter on Generator Supply Air 197 Ozone Generator Cleanser Assembly sss meer enne 199 NO GConverter Assembly hide 204 Reaction Cell Assembly dt tating cto tace eina ee iive eb abba e ta iE 205 Critical Flow Orifice Assembly eiie eene nett 207 OQ3 S nsor Detail dieti dicte rab etui abo tiis ta bc bn Gt tamdiu esl dut doe Fabi du din adde 211 Examiple of Signal l O FU rlGtiOn ciis nita t E ce ab Rn 219 CRU Status INGICAtOn gc P 220 Relay PCA Status LEDS Used for Troubleshooting see 221 Location of DC Power Test Points on Relay PCA 235 xii 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Table of Contents Figure 12 5 Figure 12 6 Figure 12 7 Figure 12 8 Figure 12 9 Figure 12 10 Figure 12 11 Figure 13 1 Figure 13 2 Fi
249. edited lt SET SET gt EDIT EXIT Continue pressing SET gt until SETUP X X REPORT PERIOD 000 01 00 lt SET SET gt EDIT EXIT SETUP X X REPORT PERIOD DAYS 0 0 0 0 ee ENTR EXIT Toggle these buttons to set the days between reports 0 366 SETUP X X REPORT PERIOD TIME 01 00 0 1 0 0 ENTR EXIT EXIT discards the new C setting Press buttons to set amount of time between reports in hours HH and or minutes MM ENTR accepts the new setting 7 max 23 59 01 00 sets a report to be made every hour The SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to the beginning and end of the appropriate interval of the instruments internal clock e lf SAMPLE PERIOD is set for one minute the first reading would occur at the beginning of the next full minute according to the instrument s internal clock e If the REPORT PERIOD is set for of one hour the first report activity would occur at the beginning of the next full hour according to the instrument s internal clock EXAMPLE Given the above settings if DAS parameters are activated at 7 57 35 the first sample would occur at 7 58 and the first report would be calculated at 8 00 consisting of data points for 7 58 7 59 and 8 00 During the next hour from 8 01 to 9 00 the instrument will take a sample reading every minute and include 60 sample readings 150 07889A DCN6900 Teledyne API T204 Analyzer Manua
250. egisters 32 bit IEEE 754 format read write in high word low word order read write Maps to NOX SPANI variable target conc for range 1 Conc units Maps to NO_SPAN1 variable target conc for range 1 Conc units Maps to NOX SPAN 2 variable target conc for range 2 Conc units Maps to NO SPAN2 variable target conc for range 2 Conc units Maps to NOX SPAN3 variable target conc for range 3 Conc units Conc units Maps to NO_SPAN3 variable target conc for range 3 Maps to O2 TARG SPAN CONC variable target conc for range O gas Maps to CO2 TARG SPAN CONC variable target conc for range CO gas Maps to ID VAR O3 TARG SPAN CONC variable target PPB span concentration Maps to ID VAR O3 PRESSURE OFFSET variable cell pressure compensation offset Maps to ID VAR O3 PRESSURE SLOPE variable O cell pressure slope compensation Maps to ID VAR O3 TEMP SET variable temperature x setpoint Maps to ID VAR O3 DWELL variable dwell time Seconds Maps to ID VAR O3 RANGE variable analog output PPB range 9o PSIA O MODBUS Discrete Input Registers single bit read only Manifold temperature warning Converter temperature warning Auto zero warning Box temperature warning PMT detector temperature warning Reaction cell temperature warning Sample flow warning Ozone flow warning Reaction cell pressure warning HVPS warning HG System reset warning 07889A DCN6900 A 31
251. eledyne API T204 Analyzer Manual To access the ANALOG I O CONFIGURATION sub menu press SAMPLE RANGE 500 0 PPB XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG SETUP X X ENTER PASSWORD 818 ENTR EXIT Toggle these buttons to enter the correct PASSWORD SIGNAL I O ENTR Continue pressing NEXT until AIO Configuration Submenu DIAG ANALOG CONFIGURATION PREV NEXT ENTR DIAG AIO A OUTS CALIBRATED NO lt SET SET gt CAL DIAG AIO CONC OUT 1 5V OVR NOCAL Press EDIT to adjust the SET SET EDIT signal output for Analog Output A1 DIAG AIO CONC OUT 2 5V OVR NOCAL SET SET EDIT DIAG AIO CONC OUT 3 5V OVR NOCAL SET SET EDIT DIAG AIO CONC OUT 4 5V OVR NOCAL SET SET EDIT DIAG AIO AIN CALIBRATED NO SET SET CAL DIAG AIO XIN1 1 00 0 00 V OFF SET SET CAL 4 Press SET gt to scroll to 8 channels Figure 5 5 Accessing the Analog I O Configuration Submenus 100 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 9 3 1 ANALOG OUTPUT VOLTAGE CURRENT RANGE SELECTION In its standard configuration the analog outputs is set to output a 0 5 VDC signals Several other output ranges are available see Table 5 6 Each range is usable from 5 to 5 of the ra
252. eledyne API T204 Analyzer Manual Teledyne API T204 Analyzer Manual Data Acquisition System DAS and APICOM 7 1 3 7 RS 232 REPORT FUNCTION The DAS can automatically report data to the communications ports where they can be captured with a terminal emulation program or simply viewed by the user using the APICOM software To enable automatic COMM port reporting follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 Use the PREV and PREV NEXT INS DEL EDIT PRNT EXIT NEXT buttons to r scroll to the DATA CHANNEL to be SETUP CONC edited lt SET SET gt EDIT EXIT Continue pressing SET or SET gt until SETUP X X RS 232 REPORT OFF lt SET SET gt EDIT PRNT SETUP X X RS 232 REPORT OFF OFF ENTR EXIT EXIT discards the new Toggle these buttons a setting to turn the RS 232 new setting 77 REPORT feature ON OFF 07889A DCN6900 153 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual 7 1 3 8 HOLDOFF FEATURE The DAS HOLDOFF feature prevents data collection during calibration operations To enable or disable the HOLDOFF follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 Use the PREV and PREV NEXT INS DEL EDIT PRNT EXIT NEXT buttons to scroll to
253. em Failure to use Electrostatic Discharge ESD protection when working with electronic assemblies will void the instrument warranty Refer to the manual Fundamentals of ESD PN 04786 downloadable from our website at http www teledyne api com under Help Center gt Product Manuals in the Special Manuals section for more information on Preventing ESD damage In each instrument with the Multidrop option there is a shunt jumpering two pins on the serial Multidrop and LVDS printed circuit assembly PCA as shown in Figure 3 14 This shunt must be removed from all instruments except that designated as last in the multidrop chain which must remain terminated This requires powering off and opening each instrument and making the following adjustments 1 With NO power to the instrument remove its top cover and lay the rear panel open for access to the Multidrop LVDS PCA which is seated on the CPU 2 the Multidrop LVDS PCA s JP2 connector remove the shunt that jumpers Pins 21 o 22 as indicated in Do this for all but the last instrument in the chain where the shunt should remain at Pins 21 lt 22 3 Check that the following cable connections are made in all instruments again refer to Figure 3 14 e J3on the Multidrop LVDS PCA to the CPU s COM1 connector Note that the CPU s COM2 connector is not used in Multidrop 07889A DCN6900 43 Getting Started Teledyne API T204 Analyzer Manual e J4 on the Multidrop LVDS
254. ems in Dashed boxes are optional 07889A DCN6900 RX Cell P1 Therm Htr Motherboard 04192 058021100 72 P1 Therm Htr _ _05282 O2 Sensor 1 ThermHtr 04342 _ n2 Manifold V P1 Therm Htr J108 7109 J15 7107 _ 00329 _ 602 1 Therm Htr REVISIONS B CHG D 0404202 TO 07228XX 12 4 10 5936 AC POWER ENTRANCE 036490100 AC POWER C SWITCH Manifold P1 Heater 1 o 04434 e n NO NOX 1 Mano Pi Valve 04434 0426801 CS i Preamp E11 04180055 RX Cell J5 P1 Heater 04040 CN g Htr Config Plug J2 04030 RELAY BOARD J15 0452301 Cntrl Mod J8 07215 LCD Interface J2 0 5 JP7 TC Prog Plug Config Plug J20 04976XXXX 04289 LCD w Touchscreen 06790 The information hereon is the property of UNLESS OTHERWISE SPECIFIED and is submitted in strictest DIMENSIONS ARE IN INCHES confidence for reference only TOLERANCES ARE Unauthorized use by anyone for any 1 32 03 0 76 ANGULAR other purposes is prohited this 01010 25 document an information contained DO NOT SC ojo dn AWING in it may not be duplicated without TREATMENT proper authorization N A SIMILAR TO THIRD ANGLE PROJECTION 10 SOS O 04024 Sample Cal 1 1 0426801 04176 Auto Zero P1 Valve sgl 0426801 q s seat ZerolSpan 1 Valve PS2
255. en as described above on the sample inlet at the rear panel 3 Disconnect the pump tubing on the outside rear panel and cap the pump port e Cap the DFU particle filter on the sample gas dryer 4 Pressurize the instrument with the leak checker or tank gas allowing enough time to fully pressurize the instrument through the critical flow orifice e Check each tube connection fittings hose clamps with soap bubble solution looking for fine bubbles 07889A DCN6900 209 Instrument Maintenance Teledyne API T204 Analyzer Manual 5 e Once the fittings have been wetted with soap solution do not reapply vacuum as it will draw soap solution into the instrument and contaminate it e Do not exceed 15 psi pressure If the instrument has the zero and span valve option the normally closed ports on each valve should also be separately checked 6 Connect the leak checker to the normally closed ports and check with soap bubble solution 11 3 10 3 IMPORTANT T Once the leak has been located and repaired the leak down rate of the indicated pressure should be less than 1 in Hg A 0 4 psi in 5 minutes after the pressure is turned off Clean surfaces from soap solution reconnect the sample and pump lines and replace the instrument cover Restart the analyzer PERFORMING A SAMPLE FLOW CHECK IMPACT ON READINGS OR DATA Use a separate calibrated flow meter capable of measuring flows between 0 and 1000 cm
256. ent atmospheric pressure no greater than 1 0 psig e In applications where the sample gas is received from a pressurized manifold a vent must be placed on the sample gas line This vent line must be no more than 10 meters long CALIBRATION GAS SOURCES SPANGAS Attach a gas line from the source of calibration gas e g a Teledyne API s T700 Dynamic Dilution Calibrator to the SPAN inlet see Figure 3 19 Use PTFE tubing minimum 74 ZERO AIR Zero air is supplied by the zero air generator such as a Teledyne API s M701 Attach a gas line from the source of zero air to the ZERO AIR inlet VENTING In order to prevent back diffusion and pressure effects both the span gas and zero air supply lines should be e Vented outside the enclosure e Not less than 2 meters in length e Not greater than 10 meters in length 54 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started EXHAUST OUTLET Attach an exhaust line to the EXHAUST OUTLET fitting The exhaust line should be e 4 PTFE tubing e maximum 10 meters long e Vented outside the T204 analyzer s enclosure Once the appropriate pneumatic connections have been made check all pneumatic fittings for leaks using the procedures defined in Section 11 3 10 To find instructions on calibrating a T204 with this option installed see section 9 2 Note 07889A DCN6900 55 Getting Started Teledyne API T204 Analyzer Manual
257. ent ee ee 37 Zero Span Valves Operating States OPT 50A 57 Possible Warning Messages at 59 Analyzer Operating Modes seess ieii aa eiaa 70 Test Functions Defined 2 tienen cente eate pere ace ee te de eda prp ea ee ded ate et da 71 Warning Messages Defined sssssssssssseseeeeenen nen enne en nennen nennen nnn nennen nis 73 Primary Setup Mode Features and Functions 75 Secondary Setup Mode Features and Functions ssssssseeee eee 76 IND Mode Analog Output Assignments ssssssssseeeeeene nennen nnnm 81 Password Levels nice ede ede dude ed de a uvae ede tu e edo dV aut d dia 88 Variable Names VARS i cicero mee atate ed am eaedem 95 07889A DCN6900 xiii Table of Contents Teledyne API T204 Analyzer Manual Table 5 4 Diagnostic Mode amp e 96 Table 5 5 DIAG Analog VO FUNCIONS rer tete HE ete ect E t e hives 99 Table 5 6 Analog Output Voltage Range Min Max 101 Table 5 7 Voltage Tolerances for the TEST CHANNEL 105 Table 5 8 Current loop Output
258. eps should be taken to remove the interferent from the sample gas before it enters the reaction cell e Carbon dioxide CO diminishes the NOx signal when present in high concentrations e Ifthe analyzer is used in an application with excess contact Teledyne API s Technical Support Department see Section 12 10 for possible solutions The detection of is subject to interference from a number of sources including SO NO H20 and aromatic hydrocarbon meta xylene and mercury vapor The Model T204 successfully rejects interference from all of these with the exception of mercury vapor If the Model T204 is installed in an environment where the presence of mercury vapor is suspected steps should be taken to remove the mercury vapor from the sample gas before it enters the analyzer 3 4 3 2 INITIAL CALIBRATION PROCEDURE FOR T204 ANALYZERS WITHOUT OPTIONS The following procedure assumes that e instrument DOES NOT have any of the available calibration valve or gas inlet options installed e cal gas will be supplied through the SAMPLE gas inlet on the back of the analyzer e pneumatic setup matches that described in Section 3 3 2 VERIFYING THE REPORTING RANGE SETTINGS While it is possible to perform the following procedure with any range setting we recommend that you perform this initial checkout using the following reporting range settings e Unit of Measure PPB e Reporting Range 500 ppb e Mode Setting SNGL
259. ernet or Teledyne API s APICOM The name by which your analyzer will appear when addressed from other computers on the LAN or via the Internet To assign or change see Section 6 5 2 1 HOST NAME initially blank Do not change the setting for this property unless instructed to by Teledyne API s Customer Service personnel 6 5 2 CONFIGURING ETHERNET COMMUNICATION USING DYNAMIC HOST CONFIGURATION PROTOCOL DHCP The default Ethernet setting is DHCP 1 Consult with your network administrator to affirm that your network server is running DHCP Access the Communications Menu SETUP gt MORE gt COM M see Figure 5 2 Enter the INET menu and follow the setup sequence as shown in Figure 6 5 07889A DCN6900 123 Communications Setup and Operation Teledyne API T204 Analyzer Manual SETUP COMMUNICATIONS MENU From this point on Dd NEE EXIT returns to COMMUNICATIONS MENU SAMPLE ENTER SETUP PASS 818 DHCP ON is DHCP OFF _ default setting DHCP ON If it has been ENTR EXIT set to OFF press EDIT and set to ON DHCP ON SET gt EDIT INST IP 0 0 0 0 GATEWAY IP 0 0 0 0 EDIT button disabled SET gt SUBNET MASK 0 0 0 0 SET gt Do not alter unless directed to by Teledyne Instruments Customer Service personnel TCP PORT2 502 HOSTNAME Figure 6 5 COMM LAN Internet Automatic Configuration DHCP 0 0 0 0 the was n
260. ew drying packages and carefully replace the end plate by making sure that the O ring is properly in place e Improperly placed O rings will cause leaks which in turn cause moisture to condense on the inside of the cooler and likely cause a short in the HVPS Reinsert the PMT HVPS subassembly in reverse order e Don t forget the gasket between HVPS and e Use new plastic screws to mount the PMT assembly on the PMT cold block Install new silica gel packets desiccant bags Reconnect the cables and the reaction cell evenly tighten these screws Replace the sensor assembly into the chassis and fasten with four screws and washers Reconnect all electrical and pneumatic connections Leak check the system see Section 11 3 10 Turn ON the analyzer Verify the basic operation of the analyzer using the ETEST 12 7 12 2 and OTEST features 12 7 12 1 or zero and span gases then carry out a hardware calibration of the analyzer followed by a zero span point calibration See Section 9 2 7 2 07889A DCN6900 263 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 8 6 REMOVING REPLACING THE RELAY PCA FROM THE INSTRUMENT This is the most commonly used version of the Relay PCA It includes a bank of solid state AC relays This version is installed in analyzers where components such as AC powered heaters must be turned ON amp OFF A retainer plate is installed over the relay to
261. f the CPU to J12 of the motherboard is properly seated 12 7 9 2 TROUBLESHOOTING ANALYZER MODEM OR TERMINAL OPERATION These are the general steps for troubleshooting problems with a modem connected to a Teledyne API s analyzer 1 Check cables for proper connection to the modem terminal or computer 2 Check to ensure that the DTE DCE is in the correct position as described in Section 6 1 3 Check to ensure that the set up command is correct see Section 8 3 Verify that the Ready to Send RTS signal is at logic high The T204 sets pin 7 RTS to greater than 3 volts to enable modem transmission 5 Ensure that the BAUD rate word length and stop bit settings between modem and analyzer match See Section 6 2 2 6 Use the RS 232 test function to send w characters to the modem terminal or computer See Section 6 2 3 7 Get your terminal modem or computer to transmit data to the analyzer holding down the space bar is one way the green LED should flicker as the instrument is receiving data 8 Ensure that the communications software or terminal emulation software is functioning properly Further help with serial communications is available in a separate manual RS 232 Programming Notes Teledyne API s P N 01350 Note 242 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 7 10 NO2 gt NO CONVERTER Provided that oxygen was present in the Sample stream du
262. for the 0 step which should be within 0mV 2 to 3 mV Ensure you take into account any offset that may have been programmed into channel See Section 5 9 3 9 If one or more of the steps fails to be within these ranges it is likely that there has been a failure of the either or both of the Digital to Analog Converters DACs and their associated circuitry on the motherboard To perform the test connect a voltmeter to the output in question and perform an analog output step test as follows SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST CAL SETUP SETUP X X PRIMARY SETUP MENU ENTER PASSWORD CFG DAS RNGE PASS CLK MORE EXIT 8 1 8 ENTR SETUP X X SECONDARY SETUP MENU SIGNAL I O COMM VARS DIAG EXIT PREV NEXT ANALOG OUTPUT Performs analog output step 5 test 0 to 100 0 2 Pressing the x96 button pauses the ANALOG OUTPUT test Brackets will appear around the 10 EXIT value EXAMPLE 10 Pressing the x button resumes the test 07889A DCN6900 237 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 6 2 12 7 6 3 A D FUNCTIONS The simplest method to check the operation of the A to D converter on the motherboard is to use the Signal I O function under the DIAG menu to check the two A D reference voltages and input signals that can be easily measured with a voltmeter 1 Use the Signal I O function see Section 12 1 3 and Appendix to view the value of REF_4
263. from the instrument Various rack mount kits are available for this analyzer Contact TAPI Sales for more information 24 07889A DCN6900 Teledyne API T204 NO 03 Analyzer Manual Getting Started 3 2 INSTRUMENT LAYOUT Instrument layout shows front panel and display rear panel connectors and internal chassis layout 3 2 1 FRONT PANEL Figure 3 1 shows the analyzer s front panel layout followed by a close up of the display screen in Figure 3 2 and description in Error Reference source not found The two USB ports on the front panel are provided for the connection of peripheral devices e plug in mouse not included to be used as an alternative to the touchscreen interface e flash drive not included to download updates to instruction software contact Technical Support for information USB Ports Display Screen T Series Model Name Label Power On Off Switch Figure 3 1 Front Panel Layout 07889A DCN6900 25 Getting Started Teledyne API T204 Analyzer Manual 394 8 PPB 0 0 PPB 394 8 PPB 123 0 PPB aaa Figure 3 2 Display Screen and Touch Control The front panel liquid crystal display screen includes touch control Upon analyzer start up the display shows a splash screen and other initialization indicators before the main display appears similar to Figure 3 2 above Error Reference source not found provides detailed informa
264. g real time clock See Section 5 6 e Avoid setting two or more sequences at the same time of the day e Any new sequence that is initiated whether from a timer the COMM ports or the contact closure inputs will override any sequence that is in progress The CALIBRATE attribute must always be set to OFF on analyzers with 125 Options installed and functioning e Calibrations should ONLY be performed using external sources of Zero Air and Span Gas whose accuracy is traceable to EPA standards 180 07889A DCN6900 Teledyne API T204 Analyzer Manual Calibration Procedures 9 3 1 SETUP gt ACAL PROGRAMMING AND AUTO CAL SEQUENCE To program the example sequence shown in Table 9 3 press SAMPLE RANGE 500 0 PPB NOX XXX X lt TST TST gt CAL CALZ CZLS SETUP SETUP X X CFG ACAL DAS RNGE PASS CLK MORE EXIT a rs SETUP X X SEQ 1 DISABLED NEXT MODE EXIT SETUP SEQ 2 DISABLED PREV NEXT MODE EXIT SETUP X X MODE DISABLED NEXT ENTR EXIT SETUP X X MODE ZERO PREV NEXT ENTR EXIT SETUP MODE ZERO SPAN PREV NEXT ENTR EXIT SETUP X X SEQ 2 ZERO SPAN 1 00 00 PREV NEXT MODE SET SETUP X X TIMER ENABLE ON SET gt EDIT EXIT SETUP X X STARTING DATE 01 JAN 07 SET SET EDIT EXIT Z SETUP X X STARTING DATE 01 JAN 02 0 4 SEP 0 8 ENTR EXIT Toggle buttons to set Day Month amp Year Fo
265. g them This section describes how to determine if a certain component or subsystem is actually the cause of the problem being investigated 07889A DCN6900 233 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 1 AC MAIN POWER The T204 analyzer s electronic systems will operate with any of the specified power regimes As long as system is connected to 100 120 VAC or 220 240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display e Internally the status LEDs located on the Relay PCA Motherboard and CPU should turn on as soon as the power is supplied e f they do not check the circuit breaker built into the ON OFF switch on the instruments front panel e Ifthe instrument is equipped with an internal pump it will begin to run If it does not e Verify that the pump power configuration plug is properly wired see Section 13 8 1 1 and Figure 13 25 e f the configuration plug is set for 230 VAC and the instrument is plugged into 115 VAC or 100 VAC the sample pump will not start e If the configuration plug is set for 115 or 100 VAC and the unit is plugged into a 230 VAC circuit the circuit breaker built into the ON OFF Switch on the front panel will trip to the OFF position immediately after power is switched on T204 s without internal pumps that are configured for 230 V will still turn on at 115 V but the heaters may burn out or not heat up fast
266. gas in A 18 07889A DCN6900 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix A3 Wamings and Test Measurements Software Version NOX_VALVE 0 let NOx gas into reaction cell 1 let NO gas into reaction cell Signal Name Bit or Channel Description Number mwsvoua s NO2 CONVERTER NO2 VALVE VENT pu turn on NO converter meas 1 turn off NO converter meas 0 let low span gas in 1 let high span sample gas in 0 let span gas in 1 let sample gas in 0 let gas into reaction cell 1 let NO NO gas into reaction open vent valve close vent valve Rear board primary MUX analog inputs MUX default I C WIN FR O2 SENSOR Reen Pressure 8 mramemv _ 9 TEST_INPUT_11 SAMP_REST_TEMP y O HV power supply output PMT temperature concentration sensor Temperature MUX Spare concentration sensor Sample pressure Reaction cell pressure 4 096V reference from MAX6241 Ozone flow rate Diagnostic test input Sample restrictor temperature Converter temperature Diagnostic test input DAC loopback MUX Ground reference Rear board temperature MUX analog inputs MUX default I IZS_TEMP CO2 CELL TEMP 5 CO2 CELL TEMP 5 TEMP INPUT 5 REM BOX TEMP Internal box temperature Reaction cell temperature
267. gas line Once the instrument passes a leak check do a flow check this chapter to ensure that the instrument is supplied with adequate sample and ozone air Confirm the sample pressure sample temperature and sample flow readings are correct and steady Verify that the sample filter element is clean and does not need to be replaced 12 5 4 INABILITY TO SPAN NO SPAN BUTTON CALS In general the T204 will not display certain buttons whenever the actual value of a parameter is outside of the expected range for that parameter If the calibration menu does not show a SPAN button when carrying out a span calibration the actual concentration must be outside of the range of the expected span gas concentration which can have several reasons 1 Verify that the expected concentration is set properly to the actual span gas concentration in the CONC sub menu Confirm that the NO span gas source is accurate e This can be done by comparing the source with another calibrated analyzer or by having the NO source verified by an independent traceable photometer Check for leaks in the pneumatic systems as described in Section 11 3 10 e Leaks can dilute the span gas and hence the concentration that the analyzer measures may fall short of the expected concentration defined in the CONC sub menu If the low level hardware calibration has drifted changed PMT response or was accidentally altered by the user a low level calibration ma
268. ge RANGE1 of the instrument with a higher span limit than the HIGH range RANGE2 This will cause the unit to stay in the low reporting range perpetually and defeat the function of the AUTO range mode P The LOW and HIGH ranges have separate Slopes and offsets for computing each of the gas concentrations The two ranges must be independently calibrated Toggle these buttons to select the upper SPAN limit for the reporting range SAMPLE lt TST TST gt CAL SETUP RANGE 500 0 PPB NOX XXXX SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X RANGE MODE SNGL SNGL IND AUTO DIL ENTR EXIT SETUP X X RANGE MODE AUTO SNGL IND AUTO ENTR EXIT SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X LOW RANGE 50 0 Conc 0 0 5 0 0 0 ENTR EXIT SETUP X X HIGH RANGE 200 0 Conc 0 0 5 0 0 0 ENTR EXIT Concentration field displays all gases EXIT discards the new setting ENTR accepts the new setting 07889A DCN6900 85 Setup Menu Teledyne API T204 Analyzer Manual 5 4 3 4 SETUP gt RNGE gt UNIT SETTING THE REPORTING RANGE UNITS OF MEASURE The T204 can display and report concentrations in ppb ppm ug m mg m units Changing units affects all of the COMM port values and all of the display values for all reporting ranges To change the units of measure press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST
269. gnments and diagram of the analog output connector V OUT VIN Recording ANALYZER Device Figure 5 6 Setup for Checking Calibrating DCV Analog Output Signal Levels Table 5 7 Voltage Tolerances for the TEST CHANNEL Calibration MINIMUM FULL ZERO SPAN SCALE TOLERANCE SPAN VOLTAGE TOLERANCE ET 0 1 VDC 0 0005V 0 001V 0 02 mV 1 VDC 0 001V 900 mV 0 001V 0 24 mV 5 VDC 0 002V 4500 mV 0 003V 1 22 mV 10 VDC 0 004V 4500 mV 0 006V 2 44 mV 07889A DCN6900 105 Setup Menu Teledyne API T204 Analyzer Manual DISPLAYED AS To adjust the signal levels of an analog output channel manually select the ANALOG CONFIGURATION submenu see Figure 5 5 then press From the AlO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED NO SET gt CAL CHANNEL CONC_OUT_1 CONC_OUT_2 CONC_OUT_3 CONC_OUT_4 These buttons increase ou m n ul Al A2 4 DIAG AIO CONC_OUT_2 5V CONC2 NOCAL lt SET SET gt EDIT EXIT DIAG AlO CONC_OUT_2 RANGE 5V SET gt EDIT Continue pressing SET gt until DIAG AIO CONC_OUT_2 CALIBRATED NO lt SET SET gt CAL EXIT DIAG CONC_OUT_2 VOLT Z 0 mV U100 UP10 UP DOWN DN10 D100 ENTR EXIT These menus decrease the analog output onlv appear if signal level not the value on the y app display AUTO CAL is by 100 10 or 1 counts turned OFF DIAG AIO CONC OUT 2
270. grity of the sample gas cannot be compromised Therefore it is important that the sample airflow system is both leak tight and not pressurized over ambient pressure Regular leak checks should be performed on the analyzer as presented in the maintenance schedule Section 11 1 Procedures for correctly performing leak checks can be found in Section 11 3 10 13 3 1 SAMPLE GAS FLOW Note In this section of the manual vacuum readings are given in inches of mercury absolute In Hg A This pressure value is referenced against zero a perfect vacuum The gas flow for the T204 is created by a pump that is pneumatically downstream from the rest of the instrument s components This is either e An external pump pneumatically connected to the analyzer s exhaust port located on the rear panel This is the most common configuration for the T204 or e An optional internal pump pneumatically connected between the vacuum manifold and the exhaust outlet special order In either case the pump creates a vacuum of approximately 6 7 in Hg A at one standard liter minute which is provided to various pneumatic components by a vacuum manifold located in proximity to the rear panel see Figure 3 5 Gas flow is created by keeping the analyzer s sample gas inlet near ambient pressure usually by means of a small vent installed in the sample line at the inlet in effect pulling the gas through the instrument s pneumatic systems By placing the pu
271. gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT The following equations give approximate conversions between volume volume units and weight volume units SETUP X X RANGE CONTROL MENU NO MODE SET UNIT DIL EXIT ppb x 1 34 pg m ppm x 1 34 mg m NO2 ppb x 2 05 ppm x 2 05 mg m y PPB PPM UGM MGM ENTR EXIT SETUP X X CONC UNITS PPB EXIT discards the new setting Toggle these buttons to select the units of measure ENTR accepts the for the reporting ranges new setting IMPORTANT IMPACT ON READINGS OR DATA Concentrations displayed in mg m3 and ug m3 use 0 C 760 mmHg for Standard Temperature and Pressure STP Consult your local regulations for the STP used by your agency Example US EPA uses 25 C as the reference temperature Once the Units of Measurement have been changed from volumetric ppb or ppm to mass units ug m3 or mg m3 the analyzer MUST be recalibrated as the expected span values previously in effect will no longer be valid Simply entering new expected span values without running the entire calibration routine is not sufficient This will also counteract any 86 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 4 3 5 SETUP gt RNGE gt DIL USING THE OPTIONAL DILUTION RATIO FEATURE Toggle these buttons to The dilution ratio feature is a software util
272. gure 13 3 Figure 13 4 Figure 13 5 Figure 13 6 Figure 13 7 Figure 13 8 Figure 13 9 Figure 13 10 Figure 13 11 Figure 13 12 Figure 13 13 Figure 13 14 Figure 13 15 Figure 13 16 Figure 13 17 Figure 13 18 Figure 13 19 Figure 13 20 Figure 13 21 Figure 13 22 Figure 13 23 Figure 13 24 Figure 13 25 Figure 13 26 Figure 13 27 Figure 13 28 TABLES Table 2 1 Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 3 7 Table 3 8 Table 4 1 Table 4 2 Table 4 3 Table 4 4 Table 4 5 Table 5 1 Table 5 2 Table 5 3 Typical Set Up of Status Output 238 Pressure Flow Sensor 2 240 Setup for determining gt NO Efficiency T204 Base Configuration 244 Pre Amplifier Board Layout a 260 T204 NOx Sensor Assembly thee de Rennen tenda da th a teh 262 Relay PCA with AC Relay Retainer In Place 264 Relay PCA Mounting Screw Locations ssssesseeeeee ener 264 Reaction Cell with PMT Tube and Optical Filter 269 T204 NOx Sensitivity enn 270 NO NO COnvVe rsion iie ni i e eec dere
273. hange Gain Offset Units and whether to display the channel in the Test functions OFF ON lt SET SET gt EDIT DIAG AIO XIN1 GAIN 1 00V V SET EDIT EXIT DIAG AIO XIN1 OFFSET 0 00V DIAG AIO XIN1 GAIN 1 00V V SET SET EDIT ENTR EXIT DIAG AIO XIN1 UNITS V Press to change SET SET EDIT Gain value DIAG AIO XIN1 DISPLAY OFF Pressing ENTR records the new setting and returns to the previous menu Pressing EXIT ignores the new setting and returns to the previous menu SET EDIT 07889A DCN6900 113 Setup Menu Teledyne API T204 Analyzer Manual 5 9 4 OPTIC TEST The OPTIC TEST function tests the response of the PMT sensor by turning on an LED located in the cooling block of the PMT The analyzer uses the light emitted from the LED to test its photo electronic subsystem including the PMT and the current to voltage converter on the pre amplifier board To ensure that the analyzer measures only the light coming from the LED the analyzer should be supplied with zero air The optic test should produce a PMT signal of about 200041000 mV Section 12 7 12 1 presents instructions for use in troubleshooting and service IMPORTANT IMPACT ON READINGS OR DATA This is a coarse test for functionality and not an accurate calibration tool The resulting PMT signal can vary significantly over time and also 5 9 5
274. hat there is no apparent external shipping damage If damage has occurred please advise the shipper first then Teledyne API For your Quality records the Final Test and Validation Data Sheet P N 04490 was included in your shipment as important quality assurance and calibration documentation Remove the top cover and check for internal shipping damage as follows with NO POWER to the unit 1 Remove the setscrew located in the top center of the Front panel 2 Slide the cover backward until it clears the analyzer s front bezel 3 Liftthe cover straight up 4 Inspect the interior of the instrument to ensure all circuit boards and other components are in good shape and properly seated 5 Check the connectors of the various internal wiring harnesses and pneumatic hoses to ensure they are firmly and properly seated 6 Verify that all of the optional hardware ordered with the unit has been installed These are listed on the accompanying paperwork Never disconnect PCAs wiring harnesses or electronic subassemblies WARNING ELECTRICAL SHOCK HAZARD while under power 3 1 1 PROPER CLEARANCE FOR VENTILATION AND ACCESS Whether the analyzer is set up on a bench or installed into an instrument rack be sure to leave sufficient clearance e Rear at least 4 in 10 cm at the rear or more as needed to facilitate disconnect e Sides 1 in 2 5 cm e Above Below 1 in 2 5 cm e Access for quickly disconnecting power
275. he following conditions on any full scale range between 0 100 ppb and 0 500 ppb at any operating temperature from 5 C to 40 C with either a user or vendor supplied vacuum pump capable of providing an absolute pressure of 10 inches mercury or less at 3 slpm in accordance with this T204 manual with or without any of the following options o Zero Span valves o external communication and data monitoring interfaces APPROVALS AND CERTIFICATIONS The Teledyne API Model T204 was designed tested and certified for Safety and Electromagnetic Compatibility EMC This section presents the compliance statements for those requirements and directives For additional certifications please contact Technical Support by telephone at 1 800 324 5190 or by email at sda techsupport teledyne com 20 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Specifications Approvals amp Compliance 2 3 1 SAFETY 2 3 2 EMC IEC EN 61010 1 2010 3 Edition safety requirements for electrical equipment for the measurement control and laboratory use CE 2006 95 EC Low Voltage Directive IEC EN 61326 1 Class A Emissions Industrial Immunity EN55011 CISPR 11 Group 1 Class A Emissions FCC 47 CFR Part 15B Class A Emissions CE 2004 108 EC Electromagnetic Compatibility Directive 07889A DCN6900 21 Specifications Approvals amp Compliance Teledyne API T204 NO 03 Analyzer Manual This page intentionally
276. hen coverts the selected voltage into a digital word The A D consists of a Voltage to Frequency V F converter a Programmable Logic Device PLD three multiplexers several amplifiers and some other associated devices The V F converter produces a frequency proportional to its input voltage The PLD counts the output of the V F during a specified time and sends the result of that count in the form of a binary number to the CPU The A D can be configured for several different input modes and ranges but in the T204 it is used in unipolar mode with 5V full scale The converter includes a 1 over and under range This allows signals from 0 05V to 5 05 to be fully converted For calibration purposes two reference voltages are supplied to the A D converter Reference ground and 4 096 VDC During calibration the device measures these two voltages outputs their digital equivalent to the CPU The CPU uses these values to compute the converter s offset and slope and uses these factors for subsequent conversions See Section 5 9 3 10 for instructions on performing this calibration 13 4 3 2 SENSOR INPUTS The key analog sensor signals are coupled to the A D through the master multiplexer from two connectors on the motherboard 100K terminating resistors on each of the inputs prevent cross talk from appearing on the sensor signals PMT DETECTOR OUTPUT The PMT detector output from the PMT preamplifier is used in the computation of the N
277. here are three levels of password protection which correspond to operator maintenance and configuration functions Each level allows access to all of the functions in the previous level Table 5 2 Password Levels PASSWORD LEVEL MENU ACCESS ALLOWED Null 000 All functions of the MAIN menu TEST GEN initiate SEQ MSG CLR 101 Configuration Maintenance Access to Primary Setup and Secondary SETUP Menus when PASSWORD is enabled 818 Configuration Maintenance Access to Secondary SETUP Submenus VARS and DIAG whether PASSWORD is enabled or disabled 88 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu To enable passwords press SAMPLE RANGE 500 0 PPB XXXX lt TST TST gt CAL SETUP SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SYSTEM PASSWORD ENABLE OFF Toggle this OFF ENTR EXIT button to enable disable PASSWORD feature 7 SETUP X X PASSWORD ENABLE ON EXIT discards the new ON ENTR EXIT setting ENTR accepts the new setting 7 Example If all passwords are enabled the following touchscreen control sequence would be required to enter the VARS or DIAG submenus 07889A DCN6900 89 Setup Menu Teledyne API T204 Analyzer Manual SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X SECONDARY SETUP MENU COMM VARS DIAG Press individual buttons to set number
278. here being too few molecules present and a corresponding decrease in chemiluminescence 13 3 2 2 LOCATIONS AND DESCRIPTIONS OF CRITICAL FLOW ORIFICES INSIDE THE T204 The T204 uses several of the following critical flow orifices Figure 13 7 to create and maintain the proper flow rate of gas through its various components Please note that Figure 13 7 represents the standard configuration and is provided for reference 07889A DCN6900 277 Principles of Operation Teledyne API T204 Analyzer Manual INSTRUMENT CHASSIS Measurement Cell MEASURE REFERENCE REFERENCE CYCLE GAS PATH i SAMT GAS Os Destruct Particulate Filter MEASURE CYCLE GAS PATH PSS 2 Flow Control P GAS PRESSURE SENSOR Absorption Tube PRESSURE NSOR PCA VACUUM PRESSURE SENSOR SAMPLE PRESSURE NO Converter EXHAUST GAS OUTLET Flow 500 Orifice Dia 0 010 Cleanser GENERAT w Flow 80 cm min Orifice Dia 0 004 EXHAUST MANIFOLD piss Prem vid Orifice s Figure 13 7 Location of Flow Control Assemblies amp Critical Flow Orifices 278 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation Table 13 2 T204 Gas Flow Rates i Orifice Flow rate Location Purp
279. idental recalibration of the analyzer to an out of range response curve EXAMPLE The span set point is 400 ppb but gas concentration being measured is only 50 ppb How do enter or change the value of my Span Gas Press the CONC button found under the CAL or CALS buttons of the main SAMPLE display menus to enter the expected NO span concentration See Section 9 2 3 1 or for more information Can automate the calibration of my analyzer Any analyzer with a zero span valve option can be automatically calibrated using the instrument s AutoCal feature How do measure the sample flow Sample flow is measured by attaching a calibrated flow meter to the sample inlet port when the instrument is operating The sample flow should be 500 cm min 10 Section 11 3 10 3 includes detailed instructions on performing a check of the sample gas flow Can use the DAS system in place of a strip chart recorder or data logger Yes Section 0 describes the setup and operation of the DAS system in detail How often do need to change the particulate filter Once per week or as needed Section 11 contains a maintenance schedule listing the most important regular maintenance tasks Highly polluted sample air may require more frequent changes How long does the sample pump last The sample pump should last one to two years and the pump head should be replaced when necessary Use the RCEL pressure indica
280. idrop A code activated switch CAS can also be used on either port to connect typically between 2 and 16 send receive instruments host computer s printers data loggers analyzers monitors calibrators etc into one communications hub Contact Teledyne API Sales for more information on CAS systems To configure the analyzer s communication ports use the SETUP gt MORE gt COMM menu Refer to Section 5 7 for initial setup and to Section 6 2 for additional configuration information RS 485 OPTION The COM2 port of the instrument s rear panel is set up for RS 232 communication but can be reconfigured for RS 485 communication Contact Customer Service If this option was elected at the time of purchase the rear panel was preconfigured at the factory 120 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation 6 5 ETHERNET When using the Ethernet interface the analyzer can be connected to any standard 10BaseT or 100BaseT Ethernet network via low cost network hubs switches or routers The interface operates as a standard TCP IP device on port 3000 This allows a remote computer to connect through the network to the analyzer using APICOM terminal emulators or other programs The Ethernet connector has two LEDs that are on the connector itself indicating its current operating status Table 6 2 Ethernet Status Indicators LED FUNCTION amber link On when
281. igh voltage power supply output Volts REFGND Ground reference REF_GND mV XIN1 Channel 1 Analog In XIN1SLPE Channel 1 Analog In Slope XIN1OFST Channel 1 Analog In Offset XIN2 Channel 2 Analog In XIN2SLPE Channel 2 Analog In Slope XIN2OFST Channel 2 Analog In Offset XIN3 Channel 3 Analog In XIN3SLPE Channel 3 Analog In Slope XIN3OFST Channel 3 Analog In Offset XIN4 Channel 4 Analog In XINASLPE Channel 4 Analog In Slope XINAOFST Channel 4 Analog In Offset XIN5 Channel 5 Analog In XIN5SLPE Channel 5 Analog In Slope XIN5OFST Channel 5 Analog In Offset XING Channel 6 Analog In XINGSLPE Channel 6 Analog In Slope XINGOFST Channel 6 Analog In Offset P XIN7 Channel 7 Analog In EE XIN7SLPE Channel 7 Analog In Slope li XIN7TOFST Channel 7 Analog In Offset i ll XIN8 Channel 8 Analog In P Sample restrictor temperature Internal box temperature Remote box temperature A 24 07889A DCN6900 Teledyne 200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version Name Description DENBSLPE Channel AnatoginSope O anors GwesAwbemoe ooo Factory option Current instrument units option Optional CO option Engineering firmware only Triple range option M200EUP Analog In option T Series only 07889A DCN6900 A 25
282. ing a 2 Phillips screwdriver See Figure 11 7 Note that there are four screw heads visible on the top of the valve body only two 2 of these should be removed Remove valve body from sensor manifold Clean any residue or dirt off the surface of the manifold using a lint free cloth and distilled or DI water Install the new valve by reversing steps 1 7 212 07889A DCN6900 12 TROUBLESHOOTING amp SERVICE This section contains a variety of methods for identifying the source of performance problems with the analyzer Also included in this section are procedures that are used in repairing the instrument Note CAUTION The operations outlined in this section must be performed by qualified maintenance personnel only WARNING RISK OF ELECTRICAL SHOCK Some operations need to be carried out with the analyzer open and running Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to the analyzer Do not drop tools into the analyzer or leave those after your procedures Do not short or touch electric connections with metallic tools while operating inside the analyzer Use common sense when operating inside a running analyzer Note The front panel of the analyzer is hinged at the bottom and may be opened to gain access to various components mounted on the panel itself or located near the front of the instrument Such as the particulate filter Remove the locking screw located at th
283. ing units XIN2 12 AIN2 37 15 EU External analog input 2 value in engineering units A 14 07889A DCN6900 NOOFFSET NO OFFS 0 0 MV NO offset for current range computed during zero span calibration NO 2 NO_2 396 5 PPB NO concentration for range 2 Teledyne API T200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version XIN3 12 AIN3 37 15 EU External analog input 3 value in engineering units XIN4 12 AIN4 37 15 EU External analog input 4 value in engineering units XIN5 12 AIN5 37 15 EU External analog input 5 value in engineering units XIN6 72 AIN6 37 15 EU External analog input 6 value in engineering units XIN7 12 AIN7 37 15 EU External analog input 7 value in engineering units XIN8 AIN8 37 15 EU External analog input 8 value in engineering units CLOCKTIME TIME 10 38 27 Current instrument time of day clock The name is used to request a message via the RS 232 interface as T BOXTEMP Engineering firmware only Current instrument units Factory option option User configurable D A output option Optional CO option Concentration alarm option M200EUP M200EU and M200EU_NO External analog input option option 1 ow ON DH KF WN PoP FP on w N e 07889A DCN6900 A 15 APPENDIX A4 Signal lO Definitions Teledyne API T200 T204 and 200E Series 05295F DCN6900 APPENDIX A 4 Signal I O Definitions T
284. inlets in excess of 1000 cc min 500 ZERO AIR Zero air or zero calibration gas is defined as a gas that is similar in chemical composition to the measured medium but without the gas to be measured by the analyzer For the T204 this means zero air should be devoid of NO NO vapor e lf your application is not a measurement in ambient air the zero calibration gas should be matched to the composition of the gas being measured e nitrogen N2 could be used as a zero gas for applications where NOx is measured in nitrogen e For analyzers without the external zero air scrubber a zero air generator such as the Teledyne API s Model 701 can be used Please visit the company website for more information 07889A DCN6900 47 Getting Started Teledyne API T204 Analyzer Manual CALIBRATION SPAN GAS Calibration gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired reporting range To measure NOx and with the T204 analyzer it is recommended that you use a span gas with an NO or O concentration equal to 80 of the measurement range for your application EXAMPLE e Ifthe application is to measure NOx in ambient air between 0 ppm and 500 ppb appropriate span gas would be 400 ppb e Ifthe application is to measure NOx in ambient air between 0 ppm and 1000 ppb an appropri
285. instruments Les symboles correspondent aux consignes suivantes AVERTISSEMENT Risque de choc lectrique DANGER Oxydant puissant AVERTISSEMENT G N RAL MISE EN GARDE Lire la consigne compl mentaire pour des renseignements sp cifiques MISE EN GARDE Surface chaude Ne pas toucher Toucher certaines parties de l instrument sans protection ou sans les outils appropri s pourrait entrainer des dommages aux pi ces ou l instrument Pictogramme technicien Toutes les op rations portant ce symbole doivent tre effectu es uniquement par du personnel de maintenance qualifi Mise la terre Ce symbole l int rieur de l instrument d termine le point central de la mise la terre s curitaire de l instrument MISE EN GARDE Cet instrument doit tre utilis aux fins d crites et de la maniere d crite dans ce manuel Si vous utilisez cet instrument d une autre mani re que celle pour laquelle il a t pr vu l instrument pourrait se comporter de facon impr visible et entrainer des cons quences dangereuses NE JAMAIS utiliser un analyseur de gaz pour chantillonner des gaz combustibles gt ODRPPPP iv 07889A DCN6900 WARRANTY WARRANTY POLICY 02024G COVERAGE Teledyne Advanced Pollution Instrumentation TAPI a business unit of Teledyne Instruments Inc provides that Prior to shipment TAPI equipment is thoroughly inspected and tested Should equipment failure occur TAPI ass
286. iom ee HH MR I Men m Hr c po Hem eds 232 12 6 2 SIOWRES PONS C a ini eeu D tende NU dee re enean 232 12 6 3 Auto Zero Warthlngs dre ert Ce OH ue Mna d Mrd re He edt 232 12 7 Subsystem CheckOUL eee etd d ce e HE etie Me 233 12 7 1 AC Main POWOE 2 init emet M e en Det S eo e e pdt 234 12 7 2 DC Power Supplyz i terti be tae eere ko ere eoe a Pega IRL ua cedes 234 127 3 FOBUS NE RETE 235 12 7 4 LE GD Display Mod le e eet le e etae teres 236 12 7 5 Relay PGA a cel de eet e e ditata 236 12 7 6 Motherboard ite oett e oett el eter uds 236 12 7 T Pressure Flow Sensor Assembly ssssssssssseeeeeene nemen 240 12 7 8 CB mista t rU rti rM TU qu otia TUN TREE HILF ead tested etui 241 12 7 9 RS 232 COMMUNICATIONS 242 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Table of Contents 12 7 10 NO2 gt NO Converters eMe ini aee Rs 243 12 7 11 Determining CE by Simplified GPT Calibration sssee e 247 12 7 12 Photomultiplier Tube PMT Sensor 250 12 7 13 PMT Preamplifier Board eder eere tus 252 12 7 14 PMT Temperature Control PCA ncn 253 12 7 15 Os GehetatOora siat cenae e aided eri ed ea er o v d dus 254 12 7 16 Internal Span
287. is manual The Mode Param parameters and Conc gas concentration fields in the display screen are represented across the top row of each menu chart The eight touch control buttons along the bottom of the display screen are represented in the bottom row of each menu chart 07889A DCN6900 27 Getting Started Teledyne API T204 Analyzer Manual Menu Chart Layout Param Touch Control Buttons Display Example 394 8 PPB 0 0 PPB 394 8 PPB 123 0 PPB While the LCD screen displays multiple gases at the same time the 6 menu charts show only one gas AARE d Menu Chart Representing Display Example SAMPLE SYSTEM RESET NO 394 8 1 lt TST TST gt CAL SETUP Figure 3 3 Display Touch Control Screen Mapped to Menu Charts The menu charts in this manual contain condensed representations of the analyzer s display during the various operations being described These menu charts are not intended to be exact visual representations of the actual display Note 28 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started 3 2 2 REAR PANEL Sample Port Cooling Exhaust COMM port Status Analog Digital Control Ethernet Analog Inputs Fan Port LEDs Outputs Outputs Inputs Port Option i r
288. is string can be altered to match your modem s initialization and can be up to 100 characters long To change this setting press SAMPLE RANGE 500 0 PPB NOX XXXX Concentration field lt TST TST gt CAL SETUP displays all gases SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT COM1 MODE 0 lt SET SET gt EDIT EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT Continue pressing SET or SET gt until COMMUNICATIONS MENU M1 MODEM INIT AT YO DO HO ID INET COM2 eo 9 BO HU 3040 SET SET EDIT EXIT COM1 MODEM INIT AT YO DO HO 10 SO 0 EXIT discards the CH CH INS DEL A ENTR EXIT new setting The lt CH and CH gt buttons move the ENTR accepts the new setting 77 cursor left and right along the text string The INS and CH gt Toggle this button to cycle through button inserts a new DEL deletes the available character set character before the character at Alpha A Z Upper and Lower cursor position gt gt the cursor e Alpha Upp Case e Special Characters space amp _ lt gt e Numerals 0 9 position Figure 8 1 Remote Access by Modem 07889A DCN6900 163 Remote Operation Teledyne API T204 Analyzer Manual To initialize the modem press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU
289. isappear when trying to specify more than that number of records This check for memory space may also make an upload of a DAS configuration with APICOM or a terminal program fail if the combined number of records would be exceeded In this case it is suggested to either try to determine what the maximum number of records available is using the front panel interface or use trial and error in designing the DAS script or calculate the number of records using the DAS or APICOM manuals 07889A DCN6900 151 Data Acquisition System DAS and APICOM To set the NUMBER OF RECORDS follow the instruction shown in Section 7 1 3 then press Use the PREV and NEXT buttons to scroll to the DATA CHANNEL to be edited YES deletes all data currently stored for this data channel and continues into EDIT mode Toggle these buttons to set the Number of Records to record 0 100 000 Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 PREV MEXT INS DEL EDIT PRNT EXIT SETUP NAME CONC lt SET SET gt EDIT EXIT Continue pressing SET or SET gt until SETUP X X NUMBER OF RECORDS 800 SET SET EDIT SETUP X X EDIT PARAMS DELETE DATA NO retains the data and returns to the previous menu YES NO NUMBER OF RECORDS 200 ENTR EXIT EXIT discards the new setting SETUP X X 0 0 0 2 0 0 ENTR accepts the new setting 7 152 07889A DCN6900 T
290. ists the analog I O functions that are available in the T204 analyzer Table 5 5 DIAG Analog I O Functions MANUAL SUB MENU FUNCTION SECTION Initiates a calibration of the A1 A2 A3 and A4 analog output channels that AOUT CALIBRATED determines the slope and offset inherent in the circuitry of each output 59 3 4 These values are stored and applied to the output signals by the CPU automatically Sets the basic electronic configuration of the A1 output NO Concentration There are four options e RANGE Selects the signal type voltage or current loop and level of the output CONC OUT 1 e REC OFS Allows them input of a DC offset to let the user manually adjust the output level e AUTO CAL Enables Disables the AOUT CALIBRATION Feature 5 92 e CALIBRATED Performs the same calibration as AOUT CALIBRATED but on this one channel only CONC OUT 2 e Same as for CONC OUT 1 but for analog channel A2 NO Concentration CONC OUT 3 Same as for CONC OUT 1 but for analog channel NO Concentration CONC OUT 4 Same as for OUT 1 but for analog channel A4 Concentration AIN CALIBRATED Initiates a calibration of the A to D Converter circuit located on the Motherboard 5 9 3 10 XIN1 For each of 8 external analog inputs channels shows the gain offset engineering units and whether the channel is to show up as a Test 5 9 3 11 function XIN8 07889A DCN6900 99 Setup Menu T
291. it 3 Remove the top cover Remove the set screw located in the top center of the rear panel e Remove the screws fastening the top cover to the unit one per side e Slide the cover back and lift the cover straight up 4 Remove the screw holding the current loop option to the motherboard 5 Disconnect the current loop option PCA from the appropriate connector on the motherboard see Figure 3 8 6 Each connector J19 and J23 requires two shunts Place one shunt on the two left most pins and the second shunt on the two adjacent pins see Figure 3 8 7 Reattach the top case to the analyzer The analyzer is now ready to have a voltage sensing recording device attached to that output Calibrate the analog output as described in Section 5 9 3 2 07889A DCN6900 35 Getting Started Teledyne API T204 Analyzer Manual 3 3 1 5 CONNECTING THE STATUS OUTPUTS The status outputs report analyzer conditions via optically isolated NPN transistors which sink up to 50 mA of DC current These outputs can be used to interface with devices that accept logic level digital inputs such as Programmable Logic Controllers PLCs Each Status bit is an open collector output that can withstand up to 40 VDC All of the emitters of these transistors are tied together and available at pin D ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Most PLC s have internal provisions for limiting the current that the input will dra
292. ity option designed for applications where the sample gas is diluted before being analyzed by the T204 Typically this occurs in continuous emission monitoring CEM applications where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas Once the degree of dilution is known this feature allows the user to add an appropriate scaling factor to the analyzer s NO NO and NO concentration calculations so that the measurement range and concentration values displayed on the instrument s front panel display and reported via the instruments various outputs reflect the undiluted values Using the Dilution Ratio option is a 4 step process 1 Select the appropriate units of measure see Section 5 4 3 4 2 Select the reporting range mode and set the reporting range upper limit see Section 5 4 2 e Ensure that the upper span limit entered for the reporting range is the maximum expected concentration of the UNDILUTED gas 3 Setthe dilution factor as a gain e g a value of 20 means 20 parts diluent and 1 part of sample gas SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X NOX DIL FACTOR 1 0 Gain 0 0 0 0 1 0 ENTR EXIT select dilution ratio
293. izing the T204 Control Inputs sssssesssseeeeneeeenen enne nnne nnns 37 Concentration Alarm Relay a a ener nennen nnn 38 Rear Panel Connector Pin Outs for RS 232 41 Default Pin Assignments for CPU COMM Port Connector RS 232 42 Jumper and Cables for Multidrop enne 44 RS 232 Multidrop PCA Host Analyzer Interconnect Diagram 45 Gas Line Connections from Calibrator Basic T204 49 Gas Line Connections from Bottled Span Gas Basic T204 Configuration 50 Pneumatics Basic Configuration 52 Rear Panel Layout with Z S Valve Options OPT 504A 53 Gas Line Connections for T204 with Z S Valves Option OPT 50 54 Pneumatics with Zero Span Valves OPT 50A nennen enne 56 Front Panel Display acer e PREMIO RR OR ROTER RID ode a are ee 69 Analog Output Connector Pin 79 SETUP COMM REPRE RR I Eee 93 GOMM Machine ID 5 ito PER PR
294. keep them securely seated in their sockets Retainer Mounting Screws AC Relay Retainer Plate Figure 12 10 Relay PCA with AC Relay Retainer In Place The Relay retainer plate installed on the relay PCA covers the lower right mounting screw of the relay PCA Therefore when removing the relay PCA the retainer plate must be removed first 7 AC Relay Retain Occludes lu Mounting Screw on P N 045230200 Figure 12 11 Relay PCA Mounting Screw Locations 264 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service 12 9 FREQUENTLY ASKED QUESTIONS The following list was compiled from the Teledyne APIs Customer Service Department s 10 most commonly asked questions relating to the T204 NOx Analyzer QUESTION ANSWER Why does the ENTR button sometimes disappear on the front panel display Sometimes the ENTR button will disappear if you select a setting that is invalid or out of the allowable range for that parameter such as trying to set the 24 hour clock to 25 00 00 or a range to less than 1 or more than 20000 ppb Once you adjust the setting to an allowable value the ENTR button will re appear Why is the ZERO or SPAN button not displayed during calibration The T204 disables certain these buttons expected span or zero value entered by the users is too different from the gas concentration actually measured value at the time This is to prevent the acc
295. l Data Acquisition System DAS and APICOM 7 1 3 5 REPORT PERIODS IN PROGRESS WHEN INSTRUMENT IS POWERED OFF If the instrument is powered off in the middle of a REPORT PERIOD the samples accumulated during that period are lost Once the instrument is turned back on the DAS restarts taking samples and temporarily stores them in volatile memory as part of the REPORT PERIOD currently active at the time of restart At the end of this REPORT PERIOD only the sample readings taken since the instrument was turned back on will be included in any AVG SDEV MIN or MAX calculation The STORE NUM SAMPLES feature will also report the number of sample readings taken since the instrument was restarted 7 1 3 6 EDITING THE NUMBER OF RECORDS The number of data records in the DAS is limited by its configuration one megabyte of space on the DOM However the actual number of records is also limited by the total number of parameters and channels and other settings in the DAS configuration Every additional data channel parameter number of samples setting etc will reduce the maximum amount of data points In general however the maximum data capacity is divided amongst all channels max 20 and parameters max 50 per channel The DAS will check the amount of available data space and prevent the user from specifying too many records at any given point If for example the DAS memory space can accommodate 375 more data records the ENTR button will d
296. l I O settings will remain in effect only until the signal I O menu is exited Exceptions are the ozone generator override and the flow sensor calibration which remain as entered when exiting Access the signal I O test mode from the DIAG Menu Figure 5 4 then press DIAG SIGNAL I O Press NEXT amp PREV to move between signal types PREV NEXT JUMP ENTR EXIT DIAG 1 0 0 EXT_ZERO_CAL OFF Press JUMP to go directly to a specific signal PREV NEXT JUMP PRNT EXIT See Appendix A 4 for a complete list of EXAMPLE available SIGNALS DIAG I O JUMP TO 12 EXAMPLE ENTR EXIT Enter 12 to Jump to 12 ST SYSTEM OK ON DIAG 1 0 12 ST SYSTEM OK ON Exit to return to the PREV NEXT JUMP ON PRNT EXIT Peeve Pressing the PRNT button will send a formatted Toggle ON OFF button to printout to the serial port and can be captured change status with a computer or other output device 98 07889A DCN6900 Teledyne API T204 Analyzer Manual Setup Menu 5 9 2 ANALOG OUTPUT DIAG AOUT Analog Output is used to verify functionality and accuracy of the analog outputs The test forces all analog output channels to produce signals ranging from 0 to 100 of the full scale range in 20 increments This test is useful to verify the operation of the data logging recording devices attached to the analyzer Section 12 7 6 1 presents instructions for use in troubleshooting and service 5 9 3 ANALOG I O CONFIGURATION DIAG AIO The following table l
297. l by loosening the mounting screws 07889A DCN6900 257 Troubleshooting amp Service Teledyne API T204 Analyzer Manual While looking at the electronic circuits from the back of the analyzer locate the Disk on Module in the right most socket of the CPU board The DOM should carry a label with firmware revision date and initials of the programmer Remove the nylon standoff clip that mounts the DOM over the CPU board and lift the DOM off the CPU Do not bend the connector pins Install the new Disk on Module making sure the notch at the end of the chip matches the notch in the socket It may be necessary to straighten the pins somewhat to fit them into the socket Press the chip all the way in Close the rear panel and turn on power to the machine If the replacement DOM carries a firmware revision re enter all of the setup information 12 8 2 O GENERATOR REPLACEMENT The ozone generator is a black brick shaped device with printed circuit board attached to its rear and two tubes extending out the right side in the front of the analyzer see Figure 3 5 The board has a red LED that when lit indicates ozone is being generated To replace the ozone generator Note 1 2 Turn off the analyzer power remove the power cord and the analyzer cover Disconnect the 1 8 black tube from the ozone cleanser and the 74 clear tube from the plastic extension tube at the brass fitting nearest to the oz
298. led check if leak suspected 07889A DCN6900 51 Getting Started Teledyne API T204 Analyzer Manual PNEUMATIC LAYOUT INSTRUMENT CHASSIS O3 Measurement Cell MEASURE REFERENCE REFERENCE CYCLE GAS PATH VALVE SAMPLE GAS Particulate Filter Destruct INLET E gt MEASURE CYCLE GAS PATH um 2 9 GAS PRESSURE SENSOR 2 FLOW PRESSURE SENSOR PCA SAMPLE VACUUM 1 PRESSURE PRESSURE SENSOR SENSOR NO e FLOW EXHAUST Converter SENSOR GAS OUTLET Flow 500 Orifice Dia up GENERATOR Flow 80 cm min Orifice Dia 0 004 Flow 500 Orifice Dia 0 010 EXHAUST MANIFOLD O Destruct PERMAPURE Flow 80 Orifice Dia 0 004 Figure 3 18 Pneumatics Basic Configuration 52 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started 3 3 2 3 CONNECTIONS W AMBIENT ZERO AMBIENT SPAN Z S VALVES OPT 50A This valve package includes e Two solenoid valves located inside the analyzer that allow the user to switch either zero span or sample gas to the instrument s sensor e Two additional gas inlet ports ZERO AIR and SPAN1 Sample
299. left blank 22 07889A DCN6900 3 GETTING STARTED This section addresses the procedures for unpacking inspecting setting up the instrument and conducting an initial calibration check 3 1 UNPACKING AND INSPECTING THE T204 ANALYZER A CAUTION To avoid personal injury always use two persons to lift and carry the T204 ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Printed Circuit Assemblies PCAs are sensitive to electro static discharges ESD too small to be felt by the human nervous system Failure to use ESD protection when working with electronic assemblies will void the instrument warranty For information on preventing ESD damage refer to the manual Fundamentals of ESD PN 04786 which can be downloaded from our website at http www teledyne api com under Help Center gt Product Manuals in the Special Manuals section CAUTION Do not operate this instrument until you ve removed dust plugs from SAMPLE and EXHAUST ports on the rear panel Note Teledyne API recommends that you store shipping containers materials for future use if when the instrument should be returned to the factory for repair and or calibration service See Warranty section in this manual and shipping procedures on our Website at http www teledyne api com under Customer Support Return Authorization 07889A DCN6900 23 Getting Started Teledyne API T204 Analyzer Manual Verify t
300. librates the high range Applies RANGE TO CAL only to auto and remote range modes this property is not available in single and independent range modes IMPORTANT IMPACT ON READINGS OR DATA For US EPA controlled related applications For analyzers used in US EPA controlled applications that have internal span gas generators option installed the CALIBRATE attribute must always be set to OFF Calibration of instruments used in US EPA related applications should only be performed using external sources of zero air and span gas with an accuracy traceable to EPA or NIST standards and supplied through the 07889A DCN6900 179 Calibration Procedures Teledyne API T204 Analyzer Manual The following example sets sequence 2 to do a zero span calibration every other day starting at 1 00 AM on September 4 2011 lasting 15 minutes without calibration This will start 2 hour later each iteration Table 9 3 Example AutoCal Sequence MODE AND ATTRIBUTE VALUE COMMENT SEQUENCE p 38 1 Define Sequence 2 Select Zero and ZERO SPAN TIMER ENABLE Enable the timer Start after STARTING DATE Sept 4 2011 Sept 4 2011 First Span starts at DELTA DAYS Do Sequence 2 every other day DELTA TIME Do Sequence 2 75 hr later each day DURATION Operate Span valve for 15 min Sequence IMPORTANT IMPACT ON READINGS OR DATA The programmed STARTING TIME must be a minimum of 5 minutes later than the real time clock for settin
301. licable the new setting EXIT ignores the new setting gt SETUP X X INITIALIZING INET 0 INITIALIZATION process proceeds automatically INITIALIZATION SUCCEEDED i INITIALIZATION FAILED SETUP X X COMMUNICATIONS MENU ID ADDR INET EXIT Contact your IT Network Administrator Figure 6 6 COMM Change Hostname 07889A DCN6900 125 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 6 USB PORT FOR REMOTE ACCESS The analyzer can be operated through a personal computer by downloading the TAPI USB driver and directly connecting their respective USB ports 1 Install the Teledyne T Series USB driver on your computer downloadable from the Teledyne API website under Help Center gt Software Downloads www teledyne api com software Run the installer file TAPIVCPInstaller exe 25 Teledyne API USB COM Port Driver Driver Installer JB Teledyne Advanced Pollution Instrumentation Teledyne API USB COM Port Driver Installation Location Driver Version 6 1 C Program 5 _ Change Install Location f j Cancel Connect the USB cable between the USB ports on your personal computer and your analyzer The USB cable should be a Type A Type B cable commonly used as a USB printer cable Determine the Windows XP Com Port number that was automatically assigned to the USB connection Start Control Panel System Hardw
302. line 7 into the blank next to letter A on line 11 amp put the number from line 10 into the blank next to letter B on line 11 18 Divide A by B amp multiply it by 100 19 Write this value it into the blank next to letter C on lines 11 and 12 248 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 20 Subtract that value from 100 amp write it in the blank next to the letter D on line 12 21 This is the converter efficiency e This value should be gt 96 12 7 11 14 SIMPLIFIED GPT DATA SHEET Line TEST 1 LEAK CHECK WHEN HOT RESULT YES NO 2 RESPONSE MOLY BYPASSED 3 NO RESPONSE MOLY IN LINE 4 OUT GASSING NO NOx 7 5 ppb lt 5 ppb 5 mode off ppb 6 NO rem NO mode ppb 7 NO LOSS A lt 4 of oni for 450PP 4 is 18 ppb 8 NO NO mode O3 off ppb 9 NO rem NO mode O3 on ppb 10 NO B gt 300ppb 11 Efficiency LOSS A B x100 _ __A ___B x100 C 12 Total Conv Eff 100 C 21005 C D gt 96 07889A DCN6900 249 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 12 PHOTOMULTIPLIER TUBE PMT SENSOR MODULE The PMT detects the light emitted by the reaction of NO with ozone It has a gain of about 500000 to 1000000 It is not possible to test the detector outside of the instrument in the field The basic method to diagnose
303. lways delete all current channels and stored data 07889A DCN6900 147 Data Acquisition System DAS and APICOM Teledyne API T204 Analyzer Manual To modify add or delete a parameter follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU DAS EDIT Touchscreen Functions SETUP X X 0 ATIMER 5 800 FUNCTION PREV NEXT INS DEL EDIT PRNT EXIT PREV Selects the previous data channel or parameter NEXT Selects the next data channel or parameter SETUP X X NAME CONC SET Selects the previous property to be edited SETUP X E SET SET EDIT EXIT SET Selects the next property to be edited Inserts a new data channel or parameter into the list BEFORE the selected channel DEL Deletes the currently selected data channel or Conti SET or SET paramere ontinue pressin or until g lt EDIT Enters EDIT mode Exports the configuration of all data channels to the PRINT RS 232 interface Buttons only appear when applicable PARAMETER 5 EDIT SETUP X X EDIT PARAMS DELETE DATA YES deletes all data YES NO NO retains the currently stored for data and returns to the previous menu this data channel and continues into EDIT mode SETUP X X 0 PARAM NXCNC1 MODE AVG PREV NEXT INS DEL EDIT EXIT EXIT discards the new setting Toggle these buttons to select a different parameter ENTR accepts the new setting SETUP X X PARAMETE
304. mand type one letter that defines the type of command Allowed designators are listed in Table 8 2 and Appendix A ID is the machine identification number Section 5 7 1 Example the Command 200 followed by a carriage return would print the list of available commands for the revision of software currently installed in the instrument assigned ID Number 200 160 07889A DCN6900 Teledyne API T204 Analyzer Manual Remote Operation COMMANDis the command designator This string is the name of the command being issued LIST ABORT NAME EXIT etc Some commands may have additional arguments that define how the command is to be executed Press lt CR gt or refer to Appendix A for a list of available command designators lt CR gt is a carriage return All commands must be terminated by a carriage return usually achieved by pressing the ENTER button on a computer Table 8 2 Teledyne API s Serial Command Types COMMAND COMMAND TYPE Calibration Diagnostic Logon Test measurement Variable S lt Aalri o0joa Warning 8 2 1 3 DATA TYPES Data types consist of integers hexadecimal integers floating point numbers Boolean expressions and text strings Integer data are used to indicate integral quantities such as a number of records a filter length etc They consist of an optional plus or minus sign followed by one or more digits For example 1 1
305. me warning was displayed Gas leak across AZERO Valve ports Dirty Reaction Cell Os flow problem to RCELL BOX TEMP WARNING Box Temp is 7 C or gt 48 C Box Temperature typically runs 7 C warmer than ambient temperature Poor blocked ventilation to the analyzer Stopped Exhaust Fan Ambient Temperature outside of specified range CANNOT DYN SPAN Dynamic Span operation failed Measured concentration value is too high or low Concentration Slope value to high or too low CANNOT DYN ZERO Dynamic Zero operation failed Measured concentration value is too high Concentration Offset value to high CONFIG INITIALIZED Configuration and Calibration data reset to original Factory state Failed Disk on Module User erased data CONV TEMP WARNING gt NO Converter temperature lt 305 C or gt 325 C Heater configured for wrong voltage type Failed converter Temperature Sensor Relay controlling the Heater is not working Failed Relay Board DATA INITIALIZED Data Storage in DAS was erased Failed Disk on Module User cleared data HVPS WARNING High voltage power supply output outside of warning limits No 15 VDC power supply to Preamplifier PCA Drive voltage not adjusted properly Failed PMT Preamplifier PCA Dirty reaction cell Bad pneumatic flow OZONE FLOW WARNING gen flow rate is lt 50 cc min or gt 150 cc min Failed Sample Pump Blocked drye
306. measurement path NO measurement path Auto Zero Path Based on which path is active the CPU interprets the sensor output to derive raw data representing concentrations for NO NO and zero dark condition accesses the operational data stored in memory then calculates final concentrations for NO NO and The CPU communicates with the user and the outside world in several ways e Through the analyzer s front panel LCD touch screen interface e Through the serial I O channels e Various analog voltage and current outputs e Several sets of Digital I O channels e Ethernet 07889A DCN6900 287 Principles of Operation Teledyne API T204 NO OS3 Analyzer Manual 13 4 2 CPU The unit s CPU card installed on the motherboard located inside the rear panel is a low power 5 VDC 720mA max high performance Vortex86SX based microcomputer running Windows CE Its operation and assembly conform to the PC 104 specification Disk on Module LVDS DOM transmitter board located CPU below LVDS transmitter board IDE active green Power active red CPU oOo0000000000000000000 ngaagogoogoooooogooogoogoogoogoogoogoooodog COM J11 J15 USB M RS 232 only COM2 J12 J2 for LCD RS 232 or Screen RS 485 Figure 13 12 Board The CPU includes two types of non volatile data storage
307. min to measure the gas flow rate though the analyzer Do not use the built in flow measurement viewable from the front panel of the instrument Sample flow checks are useful for monitoring the actual flow of the instrument as the front panel display shows only a calculated value A decreasing actual sample flow may point to slowly clogging pneumatic paths most likely critical flow orifices or sintered filters To perform a sample flow check 1 2 Disconnect the sample inlet tubing from the rear panel SAMPLE port Attach the outlet port of a flow meter to the sample inlet port on the rear panel e Ensure that the inlet to the flow meter is at atmospheric pressure The sample flow measured with the external flow meter should be 500 cm min 1096 e f a combined sample ozone air sample gas dryer is installed optional equipment the flow will be 640 cm min 10 500 cm min for the sample and 80 cm min for the ozone generator supply air and 60 cm min for the purge flow Low flows indicate blockage somewhere in the pneumatic pathway 210 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 11 3 11 OZONE SENSOR MAINTENANCE CAUTION HOT SURFACE HAZARD Do not handle the UV assembly until it has cooled Labs CAUTION GENERAL SAFETY HAZARD Do not look at the UV lamp while the unit is operating UV light can cause eye damage Always use safety glasses made f
308. minescence Federal Register 41 232 52688 52692 December 1976 as amended at 48 FR 2529 Jan 20 1983 2 Ellis Elizabeth C Technical Assistance Document for the Chemiluminescence Measurement of Nitrogen Dioxide U S Environmental Protection Agency Research Triangle Park NC 83 pages December 1975 Available online at http www epa gov ttn amtic files ambient criteria reldocs 4 75 003 pdf 3 Environmental Protection Agency Title 40 Code of Federal Regulations Part 58 Appendix A Measurement Principle and Calibration Procedure for the Measurement of Nitrogen Dioxide in the Atmosphere Gas Phase 07889A DCN6900 187 EPA Protocol Calibration Teledyne API T204 NO 03 Analyzer Manual Chemiluminescence Federal Register 41 232 52688 52692 December 1976 as amended at 48 FR 2529 Jan 20 1983 4 Mavrodineanu R and Gills T E Standard Reference Materials Summary of Gas Cylinder and Permeation Tube Standard Reference Materials Issued by the National Bureau of Standards Document SP260 108 May 1987 And Taylor J K Standard Reference Materials Handbook for SRM Users Document number SP260 100 February 1993 Available online at http patapsco nist gov srmcatalog sp_publications publications htm 5 Quality Assurance Handbook for Air Pollution Measurement Systems Volume A Field Guide to Environmental Quality Assurance EPA 600 R 94 038a April 1994 Available online at http www epa g
309. mmunication Parameters for Hessen Protocol PARAMETER STANDARD HESSEN Baud Rate 300 19200 1200 To change the baud rate of the T204 s COMM ports See Section 6 2 2 To change the remaining COMM port parameters listed in the table above see Section 6 2 1 Table 6 1 Ensure that the communication parameters of the host computer are also properly set Also the instrument software has a 200 ms latency period before it responds to commands issued by the host computer This latency should present no problems but you should be aware of it and not issue commands to the instrument too frequently ACTIVATING HESSEN PROTOCOL Once the COMM port has been properly configured the next step in configuring the T204 in order to operate over a Hessen protocol network is to activate the Hessen mode for COMM ports and configure the communication parameters for the port s appropriately 130 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation To activate the Hessen Protocol press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID COM1COM2 Combined Mode ID COM1 MODE 0 displayed here SET SET EDIT EXIT COM1 QUIET MODE OFF PREV NEXT OFF EXIT Use the PREV and
310. mp downstream from the analyzer s reaction cell several problems are avoided e First the pumping process heats and compresses the sample air complicating the measurement process e Additionally certain physical parts of the pump itself are made of materials that might chemically react with the sample gas e Finally in certain applications where the concentration of the target gas might be high enough to be hazardous maintaining a negative gas pressure relative to ambient means that should a minor leak occur no sample gas would be pumped into the atmosphere surrounding the analyzer 274 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation 13 3 1 1 VACUUM MANIFOLD The vacuum created by the analyzer s pump is supplied to all of the gas streams for the T204 analyzer through the vacuum manifold also called the exhaust manifold Connector Ozone Scrubber Exit Connector Pressure Sensor or Dryer es Connector O3 Sensor Exhaust O ini Connector AutoZero Exit with Critical Orifice Assy at Elbow Exit to Pump Pressure Sensor or Dryer Figure 13 5 Vacuum Manifold Standard Configuration Configurations will vary depending on the optional equipment that is installed For example e optional sample gas dryer will add a tee fitting so that two 74 tubes can be connected to the same port 13 3 1 2 SAMPLE GAS FLOW VALVES AND ROUTING As di
311. mperature and Pressure Compensation TPC 97 Terminal Mode 162 Command Syntax 162 Computer mode 118 Test Channel 36 237 Test Functions 62 73 74 197 220 238 AZERO 73 BOX TEMP 61 73 75 139 HVPS 73 MOLY TEMP 73 NO OFFSET 74 NO SLOPE 74 NORM PMT 73 NOX OFFSET 74 OFFSET 195 316 OZONE FL 73 PMT 73 PMT TEMP 73 RANGE 73 136 RANGE 1 73 136 AUTO 86 IND 83 RANGE2 73 136 AUTO 86 IND 83 RANGES 73 83 RCEL 74 RCELL TEMP 73 SAMP 74 SAMP FLW 73 SLOPE 195 316 STB Stability 73 97 TESTE 74 TIME 74 182 TESTE 74 Thermistors 293 300 Thermocouples 205 223 243 244 300 301 Inputs 301 Thermo Electric Cooler 273 302 304 306 307 See TIME 74 182 TPC_ENABLE 97 U Units of Measurement 64 88 89 Volumetric Units vs Mass Units 88 UV light absorption 275 V vacuum manifold 204 209 210 224 260 273 276 277 278 Vacuum Manifold 74 210 315 Valve Options 32 177 178 Ambient Zero Span Valve Option 55 Flow Diagram 58 INTERNAL PNEUMATICS 58 Rear Panel 55 Valve States 59 Internal Span Gas Generator AutoCal 181 182 Hessen Flags 139 Pressurized Span Gas Inlet Option Flow Diagram 59 Pressurized Zero Air Inlet Flow Diagram 59 Zero Span and AutoCal 180 Calibration 63 177 with Remote Contact Closure 180 VARS MENU 78 90 91 92 94 97 156 VARIABLE DEFAULT VALUES 97 Variable Names CLOCK_ADJ 97 CONC_PRECISION 97 DAS_HOLD_OFF 97 DYN_SP
312. mponents requires electrostatic discharge protection i e ESD grounding straps mats and containers Failure to use ESD protection when working with electronic assemblies will void the instrument warranty For information on preventing ESD damage refer to the manual Fundamentals of ESD PN 04786 which can be downloaded from our website at http www teledyne api com under Help Center Product Manuals in the Special Manuals section 34 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started J19 J21 J23 Analog Output Setup For voltage output of any one two or all 1 Jumper two leftmost pins 2 Jumper next two leftmost pins 3 Calibrate per Analog Configuration menu J19 J21 J23 For current output of any one two or all 1 Remove jumper shunts 2 Install Current Loop option 3 Calibrate per Analog Configuration menu CPU Current Loop option 19 installed on J21 Example setup install jumper shunts for voltage output on J19 and J23 remove jumper shunts and install Current Loop option for current output on J21 Figure 3 8 Current Loop Option Installed on the Motherboard CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation 1 Turn off power to the analyzer 2 If a recording device was connected to the output being modified disconnect
313. n The sample gas dryer used in the T204 is capable of adequately drying ambient air to a dew point of lt 5 C 4000 ppm residual H5O at a flow rate of 1 standard liter per minute slpm or down to lt 15 C 1600 ppm residual H20 at 0 5 slpm The sample gasdryer is also capable of removing ammonia from the sample gas up to concentrations of approximately 1 ppm OZONE SUPPLY AIR FILTER The T204 uses ambient air as the supply gas for the generator and may produce a variety of byproducts Small amounts of water ammonia and various sulfur oxides can combine to create ammonium sulfate ammonium nitrate nitric acid and other compounds Whereas sulfates and nitrates can create powdery residues inside the reaction cell causing sensitivity drift nitric acid is a very aggressive compound which can deteriorate the analyzer s components In order to remove these chemical byproducts from the gas stream the output of the generator flows through a special filter between the generator and the reaction cell 282 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation The small amount of NOx produced in the generator from the reaction of or O and in the air will not affect the T204 s ability to measure NO NO and NO as it is accounted for and removed from the concentration calculations by the analyzer s Auto Zero feature see Section 13 1 4 13 3 3 4 OZONE DESTRUCT Even
314. n examples provide an illustration of each 395 4 PPB 0 0 PPB 395 4 PPB 123 0 PPB 394 8 PPB 0 0 PPB 394 8 PPB 123 0 PPB The analyzer will also alert the user via the Serial I O COMM port s To view or clear the various warning messages press NOTE If a warning message persists after S h SAMPLE WARNING several attempts to clear it the message uppresses the TEST CAL MSG CLR SETUP may indicate a real problem and not an warning messages artifact of the warm up period I SAMPLE 03 GEN WARNING TEST CAL MSG CLR SETUP MSG returns the active warnings to the message field SAMPLE 03 GEN WARNING TEST CAL MSG CLR SETUP Press CLR to clear the current message If more than one warning is active the next message will take SYSTEM O3 GEN WARNING its place TEST CLR SETUP Once the last warning has been cleared the analyzer s display will return to its standard Sample Mode STANDBY RANGE 500 0 PPB OX XXXX The display will continually cycle between showing the TEST CAL MSG SETUP current NOx NO and NO2 concentrations configuration 07889A DCN6900 215 Troubleshooting amp Service Teledyne API T204 Analyzer Manual Table 12 1 Front Panel Warning Messages WARNING FAULT CONDITION POSSIBLE CAUSES AZERO valve not working Auto zero reading above 200 mV BR EUR Ted AZERO WARN Value shown in message indicates auto Faileq 12 VDC power supply XXX X MV zero reading at ti
315. n gas cross port leaks or leaks in supply tubing or user not waiting long enough to flush pneumatic systems 07889A DCN6900 227 Troubleshooting amp Service Teledyne API T204 Analyzer Manual e f the response offset test functions for NO NO OFFS or NOx NOx OFFS are greater than 150 mV a reaction cell contamination is indicated e Clean the reaction cell as described in Section 11 3 7 12 5 1 2 NEGATIVE CONCENTRATIONS For measurements negative concentrations e Asslight negative signal is normal when the analyzer is operating under zero gas and the signal is drifting around the zero calibration point 12 5 2 NO RESPONSE If the instrument shows no response display value is near zero even though sample gas is supplied properly and the instrument seems to perform correctly 1 Carry out an electrical test with the ELECTRICAL TEST procedure in the diagnostics menu see Section 12 7 12 2 e If this test produces a concentration reading the analyzer s electronic signal path is correct 2 Carry out an optical test using the OPTIC TEST procedure in the diagnostics menu see Section 12 7 12 1 e If this test results in a concentration signal then the PMT sensor and the electronic signal path are operating properly e If the T204 passes both ETEST and OTEST the instrument is capable of detecting light and processing the signal to produce a reading e Therefore the problem must be in the p
316. n gas the flow problem is not internal to the analyzer but likely caused by the gas source such as calibrators generators empty gas tanks clogged valves regulators and gas lines e Zero Span valve option is installed in the instrument press CALZ CALS If the sample flow increases suspect a bad Sample Cal valve If none of these suggestions help carry out a detailed leak check of the analyzer as described in Section 11 3 10 2 12 4 1 2 OZONE GENERATOR FLOW IS ZERO OR LOW If there is zero or a low 50 cm min ozone flow the unit displays an OZONE FLOW WARNING message on the front panel and a value between 0 0 and 50 cm min for the actual ozone flow as measured by the internal mass flow meter In this case carry out the following steps 1 Check the actual flow rate through the ozone dryer by using an external flow meter to the inlet port of the dryer e This inlet port is inside the analyzer at the end of the plastic particle filter Section 11 3 2 for illustration e f there is nominal flow about 160 cm min from 80 cm min flow and 80 cm min purge flow consult customer service as there is a problem with the firmware or electronics 2 If the actual flow is low or zero check if the pump operates properly The RCEL pressure should be below 10 in Hg A at sea level If itis above 10 rebuild the pump Section 11 3 4 1 Check the spare parts list in Appendix B on how to order pump rebuild kits
317. nce of the molecule The Model 465L uses a mercury lamp constructed so that a large majority of the light emitted is at the 254nm wavelength Light from the lamp shines down a hollow quartz tube that is alternately filled with sample gas then filled with gas scrubbed to remove ozone The ratio of the intensity of light passing through the scrubbed gas to that of the sample forms a ratio I Ig This ratio forms the basis for the calculation of the ozone concentration The Beer Lambert equation shown below calculates the concentration of ozone from the ratio of light intensities 9 V es 10 T ye 29 92inHg I axl 2723 K P I Where Intensity of light passed through the sample lo Intensity of light through sample free of ozone absorption coefficient path length concentration of ozone in ppb T sample temperature in degrees Kelvin pressure in inches of mercury As can be seen the concentration of ozone depends on more than the intensity ratio Temperature and pressure influence the density of the sample The density changes the number of ozone molecules in the absorption tube which impacts the amount of light removed from the light beam These effects are addressed by directly measuring temperature and pressure and including their actual values in the calculation The absorption coefficient is a number that reflects the inherent ability of ozone to absorb 254 nm light Most current measurements plac
318. ncentration values automatically defaults to 400 0 PPB and span concentration defaults to 80 0 PPB It is recommended that calibration gases of that concentration be used for the initial calibration of the unit To verify that the analyzer concentration settings are set for their default values press SAMPLE NO value NOX value all gases lt TST TST gt CAL SETUP ECT CAL GAS M P CAL NO value NOX value NO gases CAL NO value NOX value 123 0 PPB lt TST_TST gt SPAN CONC EXIT M P CAL CONCENTRATION MENU NOX NO CONV O3 SPAN CONC 80 00PPB 0 0 ENTR EXIT M P CAL GAS TYPE SPAN CONC 400 0 Conc EXIT ignores the new setting and returns to the previous display ENTR ENTR EXIT accepts the new setting and returns to the CAL MP menu The NOx amp NO span concentration EXIT ignores the new setting and values automatically default to returns to the previous display 400 0 PPB ENTR accepts the new setting and returns to the CONCENTRATION MENU If this is not the the concentration of the span gas being used toggle these buttons to set the correct concentration of the NOx and NO calibration gases If using NO span gas in addition to NOx repeat previous step ge 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started INITIAL ZERO SPAN CALIBRATION PROCEDURE To perform an initial Calibration of the T204 analyzer press 5 SAMPLE RANG
319. ne supply DIAG FCAL Front Panel MANUAL Mode Indicator SECTION 2 A 6 7 7 5 9 5 9 5 9 5 9 9 96 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu To access the various DIAG submenus press the following buttons SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT SETUP X X ENTER PASSWORD 818 8 1 8 ENTR EXIT DIAG SIGNAL I O PREV NEXT ENTR EXIT DIAG ANALOG OUTPUT PREV NEXT ENTR EXIT DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT EXIT returns to the SECONDARY SETUP DIAG TEST CHAN OUTPUT MENU PREV NEXT ENTR EXIT ENTR Activates the currently displayed DIAG submenu 7 DIAG OPTIC TEST PREV NEXT ENTR DIAG PREV NEXT ELECTRICAL TEST ENTR DIAG OZONE GEN OVERRIDE PREV NEXT ENTR DIAG FLOW CALIBRATION PREV NEXT ENTR Figure 5 4 Accessing the DIAG Submenus 07889A DCN6900 97 Setup Menu Teledyne API T204 Analyzer Manual 5 9 1 SIGNAL I O The signal I O diagnostic mode allows a user to review and change the digital and analog input output functions of the analyzer Refer to Appendix A for a complete list of the parameters available for review under this menu IMPORTANT IMPACT ON READINGS OR DATA Any changes of signa
320. neumatics or the ozone generator 3 Check if the ozone generator is turned on e Usually the analyzer issues a warning whenever the ozone generator is turned off e Goto SETUP MORE DIAG ENTR then scroll to the OZONE GEN OVERRIDE and see if it shows ON e If it shows OFF turn it ON and EXIT the DIAG menu e If this is done and the ozone flow is correct the analyzer should be properly supplied with ozone unless the generator itself is broken 4 Confirm the lack of response by supplying NO or NO2 span gas of about 80 of the range value to the analyzer 5 Check the sample flow and ozone flow rates for proper values 6 Check for disconnected cables to the sensor module 7T f NO signal is zero while NO signal is correct check the NO NOx valve and the NO converter for proper operation 228 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 5 3 UNSTABLE ZERO AND SPAN Leaks in the T204 or in the external gas supply and vacuum systems are the most common source of unstable and non repeatable concentration readings 1 2 Check for leaks in the pneumatic systems as described in Section 11 3 10 Consider pneumatic components in the gas delivery system outside the T204 such as a change in zero air source ambient air leaking into zero air line or a worn out zero air scrubber or a change in the span gas concentration due to zero air or ambient air leaking into the span
321. nfigured through a terminal emulation program such as HyperTerminal see Figure 7 4 for example It is best to start by downloading the default DAS configuration getting familiar with its command structure and syntax conventions and then altering a copy of the original file offline before uploading the new configuration Instrument HyperTerminal DER Ele Edt View Call Transfer Help Die 3 soie al 2 SETUP PROPERTIES FOR ENGDAT ENGDAT EVENT ATIMER REPORT PERIOD 000 00 02 NUMBER OF RECORDS 2000 RS 232 REPORT ON CHANNEL ENABLED CAL HOLD OFF OFF PARAMETERS 4 1 PARAMETER RCTEMP MODE AVG PRECISION 4 STORE SRMPLES OFF PRRAMETER CNVTMP MODE RVG PRECISION 4 STORE SRMPLES OFF PARAMETER PMTTMP MODE fiV6 PRECISION 4 STORE SRQMPLES OFF PARAMETER BOXTMP MODE RVG PRECISION 4 STORE SRMPLES OFF PARAMETER O3FLOW MODE RVG PRECISION 4 STORE SRMPLES OFF PRRRMETER SMPFLW MODE RVG PRECISION 4 STORE SAMPLES OFF PARAMETER SMPPRS MODE RVG PRECISION 4 STORE SRMPLES OFF PARAMETER RCPRES MODE RV6 PRECISION 4 amp STORE SAMPLES OFF PARAMETER AZERO MODE RVG PRECISION amp STORE_SAMPLES OFF PRRRMETER HVPS MODE AVG PRECISION 4 STORE SAMPLES 0FF PARAMETER PMTDET MODE AVG PRECISTON 4 STORE_SAMPLES OFF PARAMETER RF4096 MODE RVG PRECISION 4 STORE_SAMPLES OFF PARAMETER REFGND MODE AVG PRECISION amp STORE_SAMPLES OFF Connected 00 01 32 auto detect TCP IP SCROU URS NUM rii Figure 7 4
322. ns to move between gas types Toggle this button to set the concentration range for the list entry Toggle these buttons to set the appropriate GAS ID For new list entries this number will be displayed Toggle this button turn ON OFF the REPORT attribute Concentration field displays all gases HESSEN GAS LIST SET SET EDIT SETUP 0 211 REPORTED PREV NEXT INS DEL EDIT PRNT EXIT S SETUPX X GAS TYPE NOX PREV NEXT ENTR EXIT EXIT sets the Lepel gas type to NONE SETUP X X CONC RANGE 0 0 ENTR EXIT pre SETUP X X GASID ID Number 7 EXIT discards the 0 0 0 ENTR EXIT new setting Ep E ENTR accepts the new setting 7 SETUP X X REPORTED ON ON ENTR EXIT SETUP X X 0 200 REPORTED PREV MEXT INS DEL EDIT PRNT EXIT 07889A DCN6900 135 Communications Setup and Operation Teledyne API T204 Analyzer Manual DELETING HESSEN Gas LIST ENTRIES To delete an entry from the Hessen Gas list press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID HESN COM1 COM2 EXIT HESSEN VARIATION TYPE1 SET SET gt EDIT EXIT Continue pressing SET until HESSEN GAS LIST SET SET EDIT EXIT SETUP 0 211 REPORTE
323. ntrol option External analog input option O3 option N N BE on NF N w APPENDIX A 5 Trigger Events and DAS Parameters Table A 5 DAS Trigger Events Nme Beso conciws concaw AZEROW 07889A DCN6900 A 21 APPENDIX A 5 Trigger Events and DAS Parameters Teledyne API T200 T204 and 200E Series 05295F DCN6900 OFLOWW RPRESW RTENPW SIE osTMPW S OaLMPW OPRSW CTENPW PTEMPW SFLOWM STENPW Low span option Factory option option option Concentration alarm option O3 option Table A 6 DAS Parameters Name Description mV mV mV mV mV mV yo A 22 07889A DCN6900 Teledyne 200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version NXZSC1 NOx concentration for range 1 during zero span calibration just before computing new slope and offset NXZSC2 NO concentration for range 2 during zero span calibration just before computing new slope and offset NXZSC3 NO concentration for range 3 during zero span calibration just before computing new slope and offset NOZSC1 NO concentration for range 1 during zero span calibration just before computing new slope and offset NOZSC2 NO concentration for range 2 during zero span calibration just before computing new slope and offset NO
324. nts throughout this procedure TST TST gt CAL SETUP Allow zero gas to enter the sample port at the rear of the analyzer Wait until NOX STB falls below 0 5 PPB This may take several minutes SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL CALZ CALS SETUP SAMPLE RANGE TO CAL LOW i LOW HIGH ENTR EXIN Only appears if the AUTO range mode is selected Press to select the appropriate range Press ENTR to changes Repeat entire procedure for M P CAL NOX STB XXX X PPB NOX XXX X the OFFSET amp SLOPE each range LU lt TST TST gt ZERO CONC EXIT ha NO Press EXIT to leave the calibration unchanged and M P CAL NOX STB XXX X PPB NOX X XXX return to the previous lt TST TST gt ENTR CONC EXIT Allow span gas to enter the sample port at the rear of the analyzer SAMPLE RANGE 500 0 PPB XXXX Wait until NOX STB falls below 0 5 PPB This may take several minutes lt TST TST gt CAL CALZ CALS SETUP SAMPLE RANGE TO CAL LOW i 1 ENTR EXI n Only appears if the AUTO range mode is selected Press to select the appropriate range Repeat entire procedure for each range Press ENTR to changes the OFFSET amp SLOPE values for both the NO and NO measurements Press EXIT to leave the calibration unchanged and return to the previous L NOXSTB XXX X PI TST gt ZERO SPAN CO NOX X XXX
325. nual 13 8 1 2 AC CONFIGURATION STANDARD HEATERS JP2 Power configuration for the AC the standard heaters is set using Jumper set JP2 see Figure 13 26 for the location of JP2 Table 13 6 Power Configuration for Standard AC Heaters JP2 JUMPER JUMPER LINE VOLTAGE HEATER S BETWEEN FUNCTION COLOR PINS 1to 8 Common Reaction Cell Sample Chamber Heaters 110 VAC 115 VAC 50Hz amp 60 Hz Moly Converter 220 VAC 240 VAC 50Hz amp 60 Hz Reaction Cell Heaters NO gt NO Converter Heaters 4 gt 110 VAC 115 VAC Figure 13 26 Typical Set Up of AC Heater Jumper Set JP2 Reaction Cell Sample Reaction Cell Heaters NO gt NO 10 Converter Heaters 220 VAC 240 VAC 310 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation 13 9 FRONT PANEL TOUCHSCREEN DISPLAY INTERFACE Users can input data and receive information directly through the front panel touchscreen display The LCD display is controlled directly by the CPU board The touchscreen is interfaced to the CPU by means of a touchscreen controller that connects to the CPU via the internal USB bus and emulates a computer mouse Back Light Supply PAM Touch Screen Controller mote Local Utility USB amp 5V Controller TFT BIAS Supply 10 4 7 0 16 4V LVDS Transmitter Pairs Board LAN COM4 USB4 SB Master Ethernet Front Panel Interfa
326. nuous self checking with alarms e Permeation dryer on ozone generator and catalytic ozone destruct for NOx sensor e Converter efficiency correction software e Bi directional RS 232 optional USB and RS 485 and 10 100Base T Ethernet ports for remote operation e Front panel USB ports for peripheral devices and firmware upgrades e Digital outputs to provide instrument operating status e Adaptive signal filtering to optimize response time e Comprehensive internal data logging with programmable averaging periods e Ability to log virtually any combination of operating parameters e 8 analog inputs optional e Internal zero and span check optional 07889A DCN6900 17 Introduction Features and Options Teledyne API T204 Analyzer Manual 1 3 DOCUMENTATION In addition to this operation manual part number 07889 supplemental manuals are available for download from our website at http www teledyne api com under Help Center gt Product Manuals in the table of Special Manuals e Communications APICOM DAS Software Manual PN 07463 e Electro static discharge ESD damage prevention Fundamentals of ESD PN 04786 18 07889A DCN6900 2 SPECIFICATIONS APPROVALS amp COMPLIANCE This section presents specifications for the T204 Agency approvals EPA designation and CE mark and safety compliance 2 1 SPECIFICATIONS Error Reference source not found presents the instrument s parameters and th
327. o the values recorded on the printed record of the Final Test and Validation Data Sheet The following table can be used as a basis for taking action as these values change with time recommend weekly check The internal data acquisition system DAS is a convenient way to record and track these changes Use APICOM Section 8 1 1 to download and review this data from a remote location Table 11 2 Predictive Uses for Test Functions FUNCTION EXPECTED ACTUAL INTERPRETATION amp ACTION Fluctuatin Developing leak in pneumatic system Check for leaks RCEL Constant to within 3 5 5 P EE 2 z ressure 0 5 in Ho A ump performance is degrading Rebuild pump when pressure p 9 Slowly increasing is above 10 in Hg A Fluctuating Developing leak in pneumatic system Check for leaks SAMP Slowly increasing Flow path is clogging up Replace orifice filters pressure changes Developing leak in pneumatic system to vacuum developing Slowly decreasing valve failure Check for leaks OZONE FL iater within Slowly decreasing Flow path is clogging up Replace orifice filters Developing AZERO valve failure Replace valve Constant within P PMT cooler failure Check cooler circuit and power supplies AZERO 20 of check out Significantly increasing value Developing light leak air filter cartridge is exhausted Change chemical NO poen d Slowly oe Converte
328. o which the CPU is mounted the motherboard The motherboard is directly mounted to the inside rear panel and collects data performs signal conditioning duties and routes incoming and outgoing signals between the CPU and the analyzer s other major components Data are generated by the sensor module which outputs an analog signal corresponding to the amount of chemiluminescence present in the reaction cell This signal is converted into digital data by a unipolar analog to digital converter located on the motherboard A variety of sensors report the physical and operational status of the analyzer s major components again through the signal processing capabilities of the motherboard These status reports are used as data for the various concentration calculations and as trigger events for certain warning messages and control commands issued by the CPU This information is stored in memory by the CPU and in most cases can be viewed by the user via the front panel display The CPU issues commands via a series of relays and switches also over the bus located on a separate printed circuit assembly called the relay PCA to control the function of key electromechanical devices such as heaters and valves It also issues some commands directly to the Sensor module e g initiate Electric Test or Optical Test By controlling the state of various valves the CPU directs the flow of sample gas through the various gas paths of the analyzer NO
329. ode for as long as the contacts remain closed If contact closures are being used in conjunction with the analyzer s AutoCal Section 9 3 feature and the AutoCal attribute CALIBRATE is enabled the T204 will not re calibrate the analyzer UNTIL when the contact is opened At this point the new calibration values will be recorded before the instrument returns to SAMPLE mode If the AutoCal attribute CALIBRATE is disabled the instrument will return to SAMPLE mode leaving the instrument s internal calibration variables unchanged 9 3 AUTOMATIC ZERO SPAN CAL CHECK AUTOCAL The AutoCal system allows unattended periodic operation of the ZERO SPAN valve options by using the T204 s internal time of day clock AutoCal operates by executing SEQUENCES programmed by the user to initiate the various calibration modes of the analyzer and open and close valves appropriately It is possible to program and run up to three separate sequences SEQ1 SEQ2 and SEQ3 Each sequence can operate in one of three modes or be disabled Table 9 1 AUTOCAL Modes DISABLED Disables the Sequence ZERO Causes the Sequence to perform a Zero calibration check Causes the Sequence to perform a Zero point ZERO SPAN calibration check followed by a Span point calibration check Causes the Sequence to perform a Span concentration calibration check only 178 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Calibration Proced
330. of the decimal AUTO 1 2 E RONG PRECISION point display of concentration and stability values 3 4 AUTO Adjusts the speed of the analyzer s clock Choose sign if 60 to 60 CLOCK ADJ the clock is too slow choose sign if the clock is too fast s day Resets the service timer Pressing OFF turns the setting to a SERVICE CLEAR ON ENTR resets the timer to 0 and returns the setting to OFF Mere OFF Displays number of hours since last service since 9 TIME SINCE SVC SERVICE_CLEAR was reset dd 10 SVC INTERVAL Sets the number of hours between service reminders 0 100000 0 1 Use of the DYN ZERO and SPAN features are not allowed for applications requiring EPA equivalency There is a 2 second latency period between inputting a change to a VARS value and storing it into the analyzer s memory DO NOT turn the analyzer off during this period or the new setting will be lost Note 07889A DCN6900 95 Setup Menu Teledyne API T204 Analyzer Manual 5 9 SETUP gt DIAG DIAGNOSTICS FUNCTIONS A series of diagnostic tools is grouped together under the SETUPS gt MORESDIAG menu The parameters are dependent on firmware revision see Appendix A These tools can be used in a variety of troubleshooting and diagnostic procedures and are referred to in many places of the maintenance and troubleshooting sections of this manual The various operating modes available under the DIAG menu are Table
331. old block to create a light signal that can be measured with the PMT If zero air is supplied to the analyzer the entire measurement capability of the sensor module can be tested including the PMT and the current to voltage conversion circuit on the PMT preamplifier board See Section 12 7 12 1 for instructions on performing this test 13 6 2 PMT COOLING SYSTEM The performance of the analyzer s PMT is significantly affected by temperature Variations in PMT temperature are directly reflected in the signal output of the PMT Also the signal to noise ratio of the PMT output is radically influenced by temperature as well The warmer the PMT is the noisier its signal becomes until the noise renders the concentration signal useless To alleviate this problem a special cooling system exists utilizing a type of electronic heat pump called a thermo electric cooler TEC A TEC is a solid state active heat pump which transfers heat from a heat absorbing cool side to a heat releasing hot side via a series of DC powered semiconductor junctions The effectiveness of the pump at moving heat away from the cold side is reliant on the amount of current flowing through the semiconductor junctions and how well the heat from the hot side can be removed HEAT ABSORBING COLD JUNCTION ELECTRICA CONDUCTOR LEE SST HEAT RELEASING HOT JUNCTION AY KLELECTRICAL INSULATOR DC POWER SOURCE Figur
332. ollows If desired assign an alias for each 128 07889A DCN6900 Teledyne API T204 Analyzer Manual Communications Setup and Operation Read Write Definition Slave ID Function Cancel Address 0 Quantity 52 Scan Rate 1000 Read Write Enabled View Rows 10 O20 Ot100 04 Read Input Registers 3x Apply ms Read Write Once C Hide Alias Columns C Address in Cell Display Float inverse Example Read Write Definition window Connection Setup Connection CIPLC Addresses Base 1 OK A V Port 4 _ v 8 Data bis 115200 Baud None Parity L Mode RTU OASCI Response Timeout 1000 ms Delay Between Polls 1 Stop Bit v Remote Server IP Address 100 ms Connect Timeout 3000 ms Example Connection Setup window Modbus Poll Mbpoll1 Eile Edit Connection Setup Functions Display View Window Help amp 1 o 06 15 16 22 22 101 E Mbpoll1 3103 Err 0 ID 1 F 04 SR 1000ms Alias CO REF Type Parameter name here 00000 00030 00040 2825 489 0 000000 0 000000 1 000000 4646 791 4096 228 0 114132 0 000000 0 000000 25 474514 4636 899 0 000000 0 000000 30 966089 0 511390 30 960850 1 000000 0 000000 1 000000 29 772381 30 960850 1 000000 0 000000 30 960850
333. on Note Optical Test Optical Test Control Generator from CPU Electric Test Control From CPU HI Range Select From CPU Electric Test Generator PMT Output Gain Adjustment Physical Range Select Circuitry Amp gt Volts Low Pass Converter s LED MUX and Noise High T Filter Voltage Amplifier Power Supply PMT HVPS Fine Gain Rotary To PMT HVPS DA Motherboard Drive Voltage Converter HVPS Coarse Gain PMT Temp Adjustment Sensor Baam Thermistor PMT Temperature Feedback TEC Control Circuit PCA Adjustment 1 Le PMT Temp Analog Signal To Motherboard PMT Output Signal PMT DET to Motherboard Figure 13 20 PMT Preamp Block Diagram 07889A DCN6900 303 Principles of Operation Teledyne API T204 Analyzer Manual The PMT preamplifier PCA also operates two different tests used to calibrate and check the performance of the sensor module e electrical test ETEST circuit generates a constant electronic signal intended to simulate the output of the PMT after conversion from current to voltage By bypassing the detector s actual signal it is possible to test most of the signal handling and conditioning circuitry on the PMT preamplifier board See section 12 7 12 2 for instructions on performing this test e The optical test OTEST feature causes an LED inside the PMT c
334. on for range 1 during zero span calibration just before computing new slope and offset NOx concentration for range 2 during zero span calibration just before computing new slope and offset NO concentration for range 1 during zero span calibration just before computing new slope and offset NO concentration for range 2 during zero span calibration just before computing new slope and offset concentration for range 1 during zero span calibration just before computing new slope and offset Auto zero offset range de normalized Pre React Manifold temperature fe Converter efficiency ER LN NOy concentration for range 1 Converter efficiency factor for range 2 Converter temperature 07889A mV mV mV mV mV mV PPB PPB PPB PPB PPB PPB PPB PPB PPB PPB PPB PPB PPB mV C C 28 concentration for range 2 during zero span calibration just before computing new slope and offset Teledyne 200 T204 and 200E Series 05295F DCN6900 Appendix Wamings and Test Measurements Software Version MODBUS Register Description Address decimal 0 based e s Samepemwe 6 memetoxtempeue Henvotagepowersupiyouput w REF_GND 2 406mvreerene REE4096 MV 74 Diagnostic test input TEST INPUT I3 76 Biagnostc temperature input TEMP INPUT 5 iseme OOO OOOO
335. oncentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X TIME OF DAY CLOCK TIME DATE EXIT SETUP X X TIME 12 00 SETUP X X DATE 01 JAN 11 1 2 0 0 ENTR EXIT 0 1 JAN 1 1 ENTR EXIT Toggle these these 99 buttons to enter HOUR MINUTE keys to enter current day month current hour gt TIME 22 30 1 ENTR EXIT ENTR EXIT 0 SETUP X X TIME OF DAY CLOCK EXIT returns to TIME DATE SAMPLE MODE 07889A DCN6900 91 Setup Menu Teledyne API T204 Analyzer Manual 5 6 2 ADJUSTING THE INTERNAL CLOCK S SPEED In order to compensate for CPU clocks that run fast or slow you can adjust a variable called CLOCK_ADJ to speed up or slow down the clock by a fixed amount every day The CLOCK_ADJ variable is accessed via the VARS submenu To change the value of this variable press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Concentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT SETUP X X ENTER SETUP PASS 0 8 1 8 ENTR EXIT SETUP X X 0 DAS HOLD OFFz15 0 Minutes PREV NEXT JUMP Continue pressing NEXT until SETUP X X 8 CLOCK_ADJUST 0 Sec Day EDIT ENTR EXIT PREV NEXT EDIT ENTR EXIT SETUP X X 8 CLOCK_ADJUST 0 Sec Day 0 0 EDIT ENTR EXIT Pt
336. oncentration field displays all gases SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP X X RANGE MODE SNGL SNGL IND AUTO ENTR EXIT SETUP X X RANGE MODE SNGL SNGL IND AUTO SETUP X X RANGE MODE MENU MODE SET UNIT DIL SETUP RANGE 500 0 Conc Toggle these 5 0 0 10 ENTR EXIT buttons to select the upper SPAN limit for the shared NOx NO and NO2 reporting range SETUP RANGE 100 00 1 0 0 0 0 ENTR EXIT EXIT discards the new E setting Toggle these buttons to select the upper SPAN limit for the O3 ENTR accepts the new setting reporting range I 5 4 3 2 SETUP gt RNGE gt MODE gt IND CONFIGURING THE T204 ANALYZER FOR INDEPENDENT RANGE MODE The independent range mode IND assigns the four NO NO NO and O concentrations to individual analog output channels In IND range mode the RANGE test function displayed on the front panel will then be replaced by four separate functions Table 5 1 IND Mode Analog Output Assignments TEST CONCENTRATION ANALOG OUTPUT FUNCTION REPORTED CHANNEL RANGE1 NO A1 RANGE2 NO A2 RANGE3 NO2 A3 RANGE4 4 07889A DCN6900 81 Setup Menu Teledyne API T204 Analyzer Manual Each can be configured with a different reporting range upper limit and analog signal span EXAMPLE
337. one generator Unplug the electrical connection on the rear side of the brick Unscrew the two mounting screws that attach the ozone generator to the chassis and take out the entire assembly If you received a complete replacement generator with circuit board and mounting bracket attached simply reverse the above steps to replace the current generator Ensure to carry out a leak check 11 3 10 and a recalibration after the analyzer has warmed up for about 60 minutes 12 8 3 SAMPLE AND OZONE DRYER S REPLACEMENT The T204 standard configuration is equipped with a dryer for the ozone supply air An optional dryer is available for the sample stream and a combined dryer for both gas streams can also be purchased To change one or both of these dryers 1 Turn off power to the analyzer and pump remove the power cord and the analyzer cover Locate the dryers in the center of the instrument between sensor and NO2 converter see Figure 3 5 e They are mounted to a bracket which can be taken out when unscrewing the two mounting screws if necessary 258 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 11 12 13 Disconnect all tubing that extends out of the dryer assembly e Take extra care not to twist any of the white plastic fittings on the dryer e These connect the inner drying tube to the outer purge tube and are delicate See Sections 13 3 1 and 11 3 2 Note th
338. or 98 199 200 218 282 284 286 295 Option 07889A DCN6900 317 INDEX Teledyne API T204 Analyzer Manual Relay PCA Status LED s 222 223 Offset 109 218 316 OFFSET 195 316 ON OFF Switch 235 308 Operating Modes 98 Calibration Mode 76 139 Diagnostic Mode DIAG 98 M P CAL Mode 139 Sample Mode 29 SAMPLE mode 71 72 97 180 SAMPLE Mode 59 Secondary Setup 78 SPAN CAL 59 Warm Up Mode 139 ZERO CAL 59 Optic Test 98 Optical Test 251 OTEST 264 Ozone 19 61 75 98 116 196 200 201 207 208 209 212 218 224 226 227 228 229 230 231 234 248 251 255 259 269 270 281 282 284 285 286 287 OZONE FL 73 OZONE FLOW WARNING 61 75 139 OZONE GEN OFF 61 75 139 218 286 Ozone Generator 61 OZONE FLOW 239 287 292 P Particulate Filter 198 218 219 266 Photometer Sensor Flow 242 PRessure 241 Physical Range 73 80 High Range 80 Low Range 80 PMT 61 241 251 257 260 261 271 282 286 291 292 302 303 307 TEC 216 254 262 293 302 306 307 308 Sensor Control 257 AZERO 197 228 Calibration 260 Electric Test 98 Electrical Test 252 Gain Voltage 304 Housing 207 210 HVPS 253 262 264 302 Light Leaks 210 Maintenance 196 210 Noise 228 273 NORM PMT 73 261 291 Offset 273 Optic Test 98 251 306 Output 273 291 304 306 PMT TEMP 73 257 292 PMT TEMP WARNING 75 139 218 PMTDET 291 304 315 Preamplifie
339. or configuration and operation details 5 4 SETUP D gt RNGE ANALOG OUTPUT REPORTING RANGE CONFIGURATION Use the SETUP gt RNGE menu to configure output reporting ranges including scaled reporting ranges to handle data resolution challenges This section describes configuration for Single Dual and Auto Range modes 5 4 1 T204 PHYSICAL RANGES The T204 analyzer measures NO NO and NO concentrations from 2 to 20 000 ppb e ALOW range that measures concentration from 0 ppb to 2 000 ppb with a resolution of 0 27 ppb per count e AHIGH range that measures the full 20 000 ppb range of the analyzer The analyzer s CPU chooses the appropriate range based on how the user sets up the reporting ranges for the instrument s analog outputs when an analog range is selected with a lower limit between 0 and 2000 ppb the analyzer will utilize its low physical range When an analog range is in use that has a reporting range with an upper limit set between 2001 and 20 000 ppb the instrument will operate in its high physical range Once both ranges have been using the same span gas values the analyzer s front panel will accurately report concentrations between 0 and 20 000 ppb seamlessly switching between the low and high physical ranges regardless of the selected analog reporting range The T204 analyzer measures concentrations from 0 to 1 000 ppb default range 0 500 ppb 5 4 2 T204 ANALOG OUTPUT REPORTING RANGES For applications u
340. ose Diameter nominal Sample gas inlet of reaction cell a He of flow of sample gas into the 0 010 0 25 mm 500 cm min O supply inlet of reaction cell abbas Lr of flow of ozone gas into o 004 0 10 mm 80 cm min Controls flow rate of dry air return purge ini Dry air return of sample gas dryer air of the dryer 0 004 0 10 mm 80 cm min Controls rate of sample gas flow when Vacuum manifold Auto Zero port bypassing the reaction cell during the Auto 0 010 0 25 mm 500 cm min Zero cycle Vacuurmimanifold Controls rate of flow of zero purge gas pan g through the optional Internal span gas 0 003 0 10 mm 60 cm min generator exhaust port Tae generator when it is installed O3 sensor exhaust line Controls sample flow through O3 sensor 0 012 0 3 mm 900 cm min The necessary 2 1 ratios across the critical flow orifices is largely exceeded by the pumps supplied with the analyzer which are designed to accommodate a wide range of possible variability in atmospheric pressure and age related degradation of the pump itself Once the pump does degrade the ratio between sample and vacuum pressures may fall to less than 2 1 At this point the instrument will display an invalid sample flow rate measurement XXXX The diameter of a critical flow orifice may change with temperature POE because of expansion of the orifice material and hence the most crucial
341. ot successful in which case you may have to configure the analyzer s Ethernet properties manually See your network 124 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation 6 5 2 1 CHANGING THE ANALYZER S HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network The initial default Hostname is blank To assign or change this name particularly if you have more than one T204 analyzer on your network where each must have a different Hostname enter the SETUP gt COMMS gt INET men and scroll to the HOSTNAME menu as in Figure 6 5 make the changes as shown in Figure 6 6 SETUP X X HOSTNAME lt SET SET gt EDIT EXIT SETUP X X HOSTNAME BUTTON FUNCTION lt CH Moves the cursor one character to the left CH CH INS DEL ENTR EXIT CH Moves the cursor one character to the right bama INS Inserts a character before the cursor location DEL Deletes a character at the cursor location Press this button to cycle through th e range of m numerals and chara cters available for Use these buttons to edit the HOSTNAME i insertion 0 9 A Z space 7 amp FHIOA ENTR Accepts the new setting and returns to the revious menu SETUP HOSTNAME T200 STATION 2 example name EXIT Ignores the new setting and returns to the previo us menu CH CH INS DEL ENTR EXIT ENTR accepts Some buttons only appear as app
342. ound that set point To check the operation of the PMT temperature control system 1 Turn off the analyzer and let its internal components cool heat to ambient temperature Turn on the analyzer Set the front panel to show the PMT TEMP test function see Section 4 1 1 e The temperature should fall steadily to 6 10 C e f the temperature fails to reach this point after 60 minutes there is a problem in the cooler circuit e f the control circuit on the preamplifier board is faulty a temperature of 1 C will be reported 256 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service 12 8 SERVICE PROCEDURES Note This section contains some procedures that may need to be performed when a major component of the analyzer requires repair or replacement To service O3 sensor related items see Section 11 3 11 Maintenance procedures e g replacement of regularly changed expendables are discussed in Section 11 Instrument Maintenance and are not listed here Also there may be more detailed service notes for some of the below procedures Contact Teledyne API s Customer Service Department WARNING ELECTRICAL SHOCK HAZARD Unless the procedure being performed requires the instrument be operating turn it off and disconnect power before opening the analyzer and removing adjusting or repairing any of its components or subsystems LN e CAUTION QUALI
343. ov ttn amtic qabook html 6 Quality Assurance Handbook for Air Pollution Measurement Systems Volume ll Ambient Air Specific Methods EPA 600 4 77 027a December 1986 US EPA Order Number 454R98004 available at the National Technical Information Service NTIS 5285 Port Royal Rd Springfield VA 22151 Portions are also available at http www epa gov ttn amtic qabook html 7 Environmental Protection Agency Title 40 Code of Federal Regulations Part 58 Appendix B Measurement Principle and Calibration Procedure for the Measurement of Nitrogen Dioxide in the Atmosphere Gas Phase Chemiluminescence Federal Register 41 232 52688 52692 December 1976 as amended at 48 FR 2529 Jan 20 1983 8 Quality Assurance Guidance Document Reference Method for the Determination of Nitrogen Dioxide in the Atmosphere Chemiluminescence Draft document 58 pages February 2002 Office of Air Quality Planning and Standards Research Triangle Park NC 27711 draft document available at http www epa gov ttn amtic qabook html Guidelines about the measurement of in this document replace those in the old QA Handbook and should be consulted as the latest reference 10 2 REFERENCES RELATING TO MONITORING 1 Calibration of Ozone Reference Methods Code of Federal Regulations Title 40 Part 50 Appendix D 2 Technical Assistance Document for the Calibration of Ambient Ozone Monitors EPA publication available from EPA Department E M
344. ow the analyzer to respond more quickly Two conditions must be simultaneously met to switch to the short filter First the instantaneous concentration must differ from the average in the long filter by at least 50 ppb Second the instantaneous concentration must differ from the average in the long filter by at least 1096 of the average in the long filter 13 10 2 TEMPERATURE PRESSURE COMPENSATION TPC The T204 software includes a feature that compensates for some temperature and pressure changes that might affect measurement of NO and NOx concentrations When the TPC feature is enabled default setting the analyzer divides the value of the PMT output signal PMTDET by a value called FACTOR which is calculated using the following four parameters e BOX TEMP The temperature inside the analyzer s case measured in K This is typically about 5 K higher than room temperature e RCELL TEMP The temperature of the reaction cell measured in K e RCEL The pressure of the gas in the vacuum manifold measured in in Hg A e SAMP The pressure of the sample gas before it reaches the reaction cell measured in in Hg A This measurement is 1 in Hg A lower than atmospheric pressure As RCEL TEMP BOX TEMP RCELL and SAMP pressure increase the value of TP FACTOR increases and hence the PM TDET value decreases These adjustments are meant to counter act changes in the concentrations caused by these parameters e The current value of these
345. ower right hand side of the board If this is true removing U57 from its socket will allow the instrument to start up but the measurements will be invalid e the analyzer stops during initialization the front panel display shows a fault or warning message it is likely that the DOM the firmware or the configuration and data files have been corrupted 07889A DCN6900 241 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 9 RS 232 COMMUNICATIONS 12 7 9 1 GENERAL RS 232 TROUBLESHOOTING Teledyne API s analyzers use the RS 232 communications protocol to allow the instrument to be connected to a variety of computer based equipment RS 232 has been used for many years and as equipment has become more advanced connections between various types of hardware have become increasingly difficult Generally every manufacturer observes the signal and timing requirements of the protocol very carefully Problems with RS 232 connections usually center around 4 general areas e Incorrect cabling and connectors See Section 3 3 1 8 Figure 3 12 for connector and pin out information e The BAUD rate and protocol are incorrectly configured See Section 6 2 2 e If a modem is being used additional configuration and wiring rules must be observed See Section 8 3 e Incorrect setting of the DTE DCE Switch See Section 6 1 to set correctly e Verify that cable P N 03596 that connects the serial COMM ports o
346. pen circuit or failed op amp on control PCA itself e voltage between T2 T3 0 VDC and the voltage measured between T1 to T2 is some voltage other than 0 VDC the TEC is most likely shorted e T4 is tied directly to ground To determine the absolute voltage on any one of the other test points make a measurement between that test point and T4 07889A DCN6900 253 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 15 12 7 15 1 GENERATOR The ozone generator can fail in two ways electronically printed circuit board functionally internal generator components Assuming that air is supplied properly to the generator the generator should automatically turn on 30 minutes after the instrument is powered up or if the instrument is still warm See Section 13 3 3 for ozone generator functionality Accurate performance of the generator can only be determined with an ozone analyzer connected to the outlet of the generator However if the generator appears to be working properly but the sensitivity or calibration of the instrument is reduced suspect a leak in the ozone generator supply air A leak in the dryer or between the dryer and the generator can cause moist ambient air to leak into the air stream which significantly reduces the ozone output The generator will produce only about half of the nominal concentration when run with moist ambient air instead of dried ai
347. port testing for correct connection If using a USB option communication connection setup requires configuring the COM2 baud rate Section 6 2 2 07889A DCN6900 115 Communications Setup and Operation Teledyne API T204 Analyzer Manual 6 2 1 COMMUNICATION MODES Each of the analyzer s serial ports can be configured to operate in a number of different modes listed in Table 6 1 As modes are selected the analyzer sums the mode ID numbers and displays this combined number on the front panel display For example if quiet mode 01 computer mode 02 and Multi Drop Enabled mode 32 are selected the analyzer would display a combined MODE ID of 35 Table 6 1 COMM Port Communication Modes MODE ID DESCRIPTION Quiet mode suppresses any feedback from the analyzer such as warning messages to the remote device and is typically used when the port is communicating with a QUIET 1 computer program where such intermittent messages might cause communication problems Such feedback is still available but a command must be issued to receive them COMPUTER 2 Computer mode inhibits echoing of typed characters and is used when the port is communicating with a computer operated control program HESSEN 16 The Hessen communications protocol is used in some European countries TAPI P N PROTOCOL 02252 contains more information on this protocol E 8 1 8192 When turned on this mode
348. pressing SET gt until you reach the output to be configured DIAG AIO AIN CALIBRATED NO lt SET CAL DIAG AIO CALIBRATING A D ZERO Firmware automatically performs a zero point calibration of the Motherboard s analog Inputs DIAG CALIBRATING A D SPAN Firmware automatically performs a span point calibration of the Motherboard s analog Inputs A D CALIBRATION ERROR AIN CALIBRATED YES AIN CALIBRATED NO CAL 112 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu 5 9 3 11 EXTERNAL ANALOG INPUTS XIN1 XIN8 OPTION CONFIGURATION To configure the analyzer s optional external analog inputs define for each channel e gain number of units represented by 1 volt e offset volts e engineering units to be represented in volts each press of the touchscreen button scrolls the list of alphanumeric characters from A Z and 0 9 e whether to display the channel in the Test functions These parameters can also be captured in the internal Data Acquisition System DAS refer to Appendix A for Analog In DAS parameters To adjust settings for the Analog Inputs option parameters press DIAG ANALOG CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO Press SET to scroll to the first CAL channel Continue pressing SET gt to view each of 8 channels lt SET SET DIAG AIO XIN1 1 00 0 00 V OFF Press EDIT at any channel to to c
349. pt the changed settings and ensure that COM1 MODE now shows 35 Press select SET to go to the COM1 BAUD RATE menu and ensure it reads the same for all instruments edit as needed so that all instruments are set at the same baud rate The communication Host instrument can address only one instrument at a Note time each by its unique ID see step 7 above MS Teledyne API recommends setting up the first link between the Host and the first analyzer and testing it before setting up the rest of the chain 07889A DCN6900 45 Getting Started Teledyne API T204 Analyzer Manual RS 485 CONNECTION As delivered from the factory COM2 is configured for RS 232 communications This port can be reconfigured for operation as a non isolated half duplex RS 485 port Using COM2 for RS 485 communication will disable the USB port To reconfigure this port for RS 485 communication please contact the factory 3 3 2 PNEUMATIC CONNECTIONS This section provides not only pneumatic connection information but also important information about the gases required for accurate calibration Section 3 3 2 1 it also illustrates the pneumatic layouts for the analyzer in its basic configuration and with options Before making the pneumatic connections carefully note the following cautionary and additional messages CAUTION A GENERAL SAFETY HAZARD Do not vent calibration gas or sample gas into enclosed areas
350. r Blocked inlet outlet to purifier Dirty dryer DFU Leak downstream of RCELL Failed Flow Sensor OZONE GEN OFF Ozone generator is off This is the only warning message that automatically clears itself It clears itself when the ozone generator is turned on generator override is turned ON Electrical connection between motherboard and generator is faulty Bad 15VDC power supply PMT TEMP WARNING Sample temperature is lt 5 C or gt 12 C PMT fan not operating Failed PMT Temperature Sensor TEC not functioning Failed PMT Preamp PCA RCELL PRESS WARN Sample Pressure is 15 in Hg or gt 35 in Hg Normally 29 92 in Hg at sea level decreasing at 1 in Hg per 1000 ft of altitude with no flow pump disconnected If Sample Pressure is 15 in HG e Blocked Particulate Filter e Blocked Sample Inlet Gas Line eFailed Pressure Senor circuitry If Sample Pressure is gt 35 in HG e Bad Pressure Sensor circuitry ePressure too high at Sample Inlet RCELL TEMP WARNING RCELL temperature is lt 45 C or gt 55 C Heater configured for wrong voltage type Failed RCELL Temperature Sensor Relay controlling the heater is not working Failed Relay Board Bus REAR BOARD NOT DET Motherboard not detected on power up This WARNING only appears on Serial I O COMM Port s Front Panel Display will be frozen blank or will not respond Failure of Motherboard
351. r 218 253 293 295 304 305 PReamplifier 260 Reaction Cell 271 Replacement 262 TEMP 292 Temperature 61 263 301 304 307 Test Function 73 210 234 Theory of Operation 303 304 Thermistors 293 Troubleshooting 218 228 229 230 233 With Zero NO 73 PMT Preamp PCA 98 PMT TEMP 73 PMT TEMP WARNING 61 139 Pneumatic Sensors Os Flow 286 Sample Gas Flow 286 Sample Pressure 285 287 Vacuum Pressure 286 Pneumatic Setu Basic T204 Bottled Gas 52 Pneumatic Setup Basic 51 Preamplifier 218 253 293 302 304 Predictive Diagnostics 19 141 143 161 Using DAS 143 PTEF 52 53 56 57 Pump Sample 218 219 311 R RANGE 73 136 HIGH 73 LOW 73 Range Mode AUTO 86 IND 83 85 SNGL 64 82 RANGE1 73 136 AUTO 86 IND 83 RANGE2 73 136 AUTO 86 IND 83 RANGE3 73 83 RCEL 74 RCELL PRESS WARN 61 75 139 RCELL TEMP 73 RCELL TEMP WARNING 61 75 139 Reaction Cell 74 202 208 209 210 255 262 264 276 278 281 282 284 289 292 309 Auto Zero 273 Auto Zero Valve 277 298 AutoZero 281 AZERO 278 Chemiluminescence 271 278 Cleaning 207 229 233 234 Contamination 228 Critical Flow Orifice Cleaning 209 Critical Flow Orifices 279 281 Dirty 207 218 229 231 233 234 318 07889A DCN6900 Teledyne API T204 Analyzer Manual INDEX Dwell Time 278 Gas Flow Troubleshooting 227 Gas Flow Caclulation 286 Gas Inlets 281 Heater 257 Interferents
352. r In addition moist supply air will produce large amounts of nitric acid in the generator which can cause analyzer components downstream of the generator to deteriorate and or causes significant deposit of nitrate deposits on the reaction cell window reducing sensitivity and causing performance drift Carry out a leak check as described in Section 11 3 10 O GENERATOR OVERRIDE This feature allows the user to manually turn the ozone generator off and on This should be done before disconnecting the generator to prevent ozone from leaking out or after a system restart if the user does not want to wait for 30 minutes during warm up time To access this feature press the following buttons Also note that the ozone generator does not turn on if the ozone flow conditions are out of specification e g if there is no flow through the system or the pump is broken 254 07889A DCN6900 Teledyne API T204 Analyzer Manual Troubleshooting amp Service SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP Continue pressing lt TST or TST gt until Concentration display shows all gasses SAMPLE PMT 2750 MV NOX XXXX lt TST TST gt CAL SETUP ENTER PASSWORD 8 1 8 ENTR SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SIGNAL I O PREV NEXT SETUP X X SECONDARY SETUP MENU DIAG OZONE GEN OVERRIDE PREV NEXT ENTR EXIT DIAG OZONE OZONE GEN OVERIDE Toggling this button OFF EXIT turns O
353. r Range Analog Output Resolution 1 part in 4096 of selected full scale voltage 07889A DCN6900 19 Specifications Approvals amp Compliance Teledyne API T204 Analyzer Manual 2 2 2 3 PARAMETER SPECIFICATION Recorder Offset 10 Standard I O 1 Ethernet 10 100Base T 2 RS 232 300 115 200 baud 2 USB device ports 8 opto isolated digital status outputs 7 defined 1 spare 6 opto isolated digital control inputs 4 defined 2 spare 4 analog outputs Optional I O 1 USB com port 1 RS485 8 analog inputs 0 10V 12 bit 4 digital alarm outputs Multidrop RS232 3 4 20mA current outputs Dimensions H x W x D 7 x 17 x 23 5 178mm x 432 mm x 597 mm Weight Analyzer 40 Ibs 18 kg External Pump Pack 15 Ibs 7 kg Operating Temperature Range 5 40 C with EPA equivalency Humidity Range 0 95 RH non condensing Environmental Conditions Installation Category Over voltage Category II Pollution Degree 2 Intended for Indoor Use Only Maximum Operating Altitude 2000 meters 1 As defined by the US EPA Defined as twice the zero noise level by the US EPA EPA EQUIVALENCY DESIGNATION Teledyne Advanced Pollution Instrumentation s Model T204 NOx analyzer is officially designated as an equivalent method EQOA 0514 214 for measurement as defined in 40 CFR Part 53 when the T204 is operated under t
354. r efficiency may be degrading Replace converter Concentration M components concentrations concentration NO Constant for Drift of instrument response clean RCEL window Check for Concentration constant Decreasing over time flow leaks or irregularities concentration 1 Ozone Generator Flow 07889A DCN6900 195 Instrument Maintenance Teledyne API T204 NO 03 Analyzer Manual 11 3 MAINTENANCE PROCEDURES The following procedures are to be performed periodically as part of the standard maintenance of the T204 11 3 1 REPLACING THE SAMPLE PARTICULATE FILTER The particulate filter should be inspected often for signs of plugging or contamination We recommend that when you change the filter handle it and the wetted surfaces of the filter housing as little as possible Do not touch any part of the housing filter element retaining ring glass cover or the o ring with your bare hands Teledyne API recommends using gloves or PTFE coated tweezers or similar handling to avoid contamination of the sample filter assembly To change the filter 1 Turn OFF the analyzer to prevent drawing debris into the instrument 2 Open the T204 s hinged front panel and unscrew the filter nut on the filter assembly N FILTER NUT NE WINDOW a O RING a TM 7 IBI i TEFLON RETAINING RING C x NOTE NOTCHES FACING UP FILTER ELEMENT C 7 FRON PAN T EL Figure 11 1 Replacing th
355. r of the same ID model a unique Slave ID must be assigned to each Using the front panel menu go to SETUP MORE COMM ID The MACHINE ID default is the same as the model number Toggle the menu buttons to change the ID Reboot analyzer For the settings to take effect power down the analyzer wait 5 seconds and power up the analyzer Make appropriate cable connections Connect your analyzer either via its Ethernet or USB port to a PC this may require a USB to RS232 adapter for your PC if so also install the sofware driver from the CD supplied with the adapter and reboot the computer if required or via its COM2 port to a null modem this may require a null modem adapter or cable Specify MODBUS software settings for MODBUS Poll software examples used here are what you wish to read from the analyzer 1 Click Setup Read Write Definition a In the Read Write Definition window see example that follows select a Function b Input Quantity based on your firware s register map c In the View section of the Read Write Definition window select a Display typically Float Inverse d Click OK 2 Next click Connection Connect a In the Connection Setup window see example that follows select the options based on your computer b Press OK Read the Modbus Poll Register Use the Register Map to find the test parameter names for the values displayed see example that f
356. r the ozone flow over time for predictive diagnostics and maintenance evaluation 13 3 4 5 O3 SENSOR CELL PRESSURE An absolute pressure transducer connected to the exhaust manifold of the O3 sensor is used to measure the pressure of the O3 sensor cell The actual pressure value is viewable through the analyzer s front panel display as the test function O3CEL PR 07889A DCN6900 285 Principles of Operation Teledyne API T204 Analyzer Manual 13 4 ELECTRONIC OPERATION 13 4 1 OVERVIEW Figure 13 11 shows a block diagram of the major electronic components of the analyzer Concentration Aout 4 NO Concentration Aout 3 NO 1 Aout 2 NO Aout 1 Analog Outputs Flow Pressure Sensor PCA Sample Pressure Sensor Os Gen Flow Sensor Reaction Cell Pressure Sensor j0sueg PMT Output PMT DET High Voltage Power Supply Level PMT Temperature PMT Temperature Reaction Cell Temperature PMT PREAMP PCA Thermistor Interface Electric Test Control Preamp Range HI ANALOG USBCOM RS232 Ethemet IN Female port ale A I C Bus Status Control Outputs
357. rgoes the chemiluminescence reaction described in Equation 13 1 and Equation 13 2 By converting the NO in the sample gas into NO the analyzer can measure the total NOX content of the sample gas i e the NO present the converted NO present By switching the sample gas stream in and out of the moly converter every 6 10 seconds the T204 analyzer is able to quasi continuously measure both the NO and the total NOx content Finally the NO concentration is not directly measured but calculated by subtracting the known NO content of the sample gas from the known NOx content 13 1 4 AUTO ZERO Inherent in the operation of any PMT is a certain amount of noise This is due to a variety of factors such as black body infrared radiation given off by the metal components of the reaction cell unit to unit variations in the PMT units and even the constant universal background radiation that surrounds us at all times In order to reduce this amount of noise and offset the PMT is kept at a constant 7 C 45 F by a Thermo Electric Cooler TEC While this intrinsic noise and offset is significantly reduced by cooling the PMT it is not eradicated To determine how much noise remains once every minute for about 8 seconds the T204 diverts the sample gas flow directly to the vacuum manifold without passing the reaction cell During this time only is present in the reaction cell effectively turning off the chemiluminescence reaction Once
358. ring operation for the NO converter to function properly the NO converter assembly can fail in two ways e An electrical failure of the band heater and or the thermocouple control circuit and e A performance failure of the converter itself 12 7 10 1 gt NO CONVERTER ELECTRICAL SYSTEM converter heater failures can be divided into two possible problems e Temperature is reported properly but heater does not heat to full temperature e In this case the heater is either disconnected or broken or the power relay is broken e Disconnect the heater cable coming from the relay board and measure the resistance between any two of the three heater leads with a multi meter e The resistance between A and B should be about 1000 Q That between A and C should be the same as between B and C about 500 each If any of these resistances is near zero or without continuity the heater is broken e Temperature reports zero or overload near 500 C e This indicates a disconnected or failing thermocouple or a failure of the thermocouple circuit e Check that the thermocouple is connected properly and the wire does not show signs of a broken or kinked pathway e Ifit appears to be properly connected disconnect the yellow thermocouple plug marked K from the relay board and measure the voltage not resistance between the two leads with a multi meter capable of measuring in the low mV range The voltage should be about 12 mV
359. rm 1 amp Alarm 1 will both be associated with the Alarm 2 relay on the rear panel This allows you do have multiple alarm levels for individual gases A more likely configuration for this would be to put one gas on the Alarm 1 relay and the other gas on the Alarm 2 relay NO Alarm 1 20 PPM NO Alarm 2 Disabled Alarm 1 Disabled Alarm 2 100 PPM ALARM 4 RELAY This relay is connected to the range bit If the instrument is configured for Auto Range and the instrument goes up into the high range it will turn this relay on 3 3 1 8 CONNECTING THE COMMUNICATIONS INTERFACES The T Series analyzers are equipped with connectors for remote communications interfaces Ethernet USB RS 232 RS 232 Multidrop and RS 485 each described here In addition to using the appropriate cables each type of communication method must be configured using the SETUP gt COMM menu see Sections 5 7 and 6 ETHERNET CONNECTION For network or Internet communication with the analyzer connect an Ethernet cable from the analyzer s rear panel Ethernet interface connector to an Ethernet port Although the analyzer is shipped with DHCP enabled by default Section 6 5 2 it should be manually assigned a static IP address Configuration manual i e static Section 6 5 1 07889A DCN6900 39 Getting Started Teledyne API T204 Analyzer Manual Note IMPORTANT USB CONNECTION The USB op
360. rmat DD MON YY CONTINUE NEXT PAGE With STARTING TIME 07889A DCN6900 181 Calibration Procedures Teledyne API T204 Analyzer Manual Toggle buttons to set time Format HH MM This is a 24 hr clock PM hours are 13 24 Example 2 15 PM 14 15 Toggle buttons to set number of days between procedures 1 365 Toggle buttons to set delay time for each iteration of the sequence HH MM 0 24 00 CONTINUED FROM PREVIOUS PAGE STARTING DATE SETUP X X STARTING DATE 04 SEP 03 SET SET EDIT EXIT SETUP X X STARTING TIME 00 00 SET SET EDIT EXIT ES SETUP STARTING TIME 00 00 1 4 24 5 ENTR EXIT SETUP X X STARTING TIME 14 15 SET SET EDIT EXIT o SETUP X X DELTA DAYS 1 SET SET EDIT EXIT e SETUP DELTA DAYS 1 0 0 2 EXIT SETUP DELTA DAYS 2 lt SET SET gt EDIT EXIT SETUP DELTA ina lt SET SET gt EDIT EXIT SETUP X X DELTA TIME 00 00 0 0 3 0 ENTR EXIT SETUP X X DELTA TIME 00 30 SET SET EDIT EXIT CONTINUE NEXT PAGE With DURATION TIME 182 07889A DCN6900 Teledyne API T204 Analyzer Manual Calibration Procedures CONTINUED FROM PREVIOUS PAGE DELTA TIME SETUP DURATION 15 0 MINUTES lt SET SET gt EDIT EXIT
361. rmistor interface AID Converter VIF RELAY PCA Preamplifiers and Signal Conditioning THERMOCOUPLE CONFIGURATION Cold Junction JUMPER Compensation JP5 Solid State AC Relays J type Thermocouple NO NO converter NO NO Converter Heater Reaction Cell Heater Figure 13 16 Heater Control Loop Block Diagram 298 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation The PMT temperature is maintained by a separate control loop that does not involve the relay PCA see Section 13 6 2 Note 13 4 4 5 THERMOCOUPLE INPUTS AND CONFIGURATION JUMPER JP5 Although the relay PCA supports two thermocouple inputs the current T204 analyzers only utilize one It is used to sense the temperature of the NO gt NO converter e This single thermocouple input is plugged into the TC1 input J15 e TC2 J16 is currently not used see Figure 13 13 for location of J15 and J16 The type and operating parameters of this thermocouple are set using a jumper plug JP5 The default configuration for this thermocouple is e Type K e Temperature compensated for Type K e Isolated Table 13 4 Thermocouple Configuration Jumper JP5 Pin Outs TC INPUT ERE DESCRIPTION FUNCTION Selects preamp gain factor for J or K TC Gain Selector OUT K TC gain factor IN J TC gain factor Selects preamp gain factor for J or K TC Output Scale Selector OUT 10m
362. roken stuck valve driver chip broken D13 Green Pressurized Zero shutoff valve Valve broken or stuck valve driver chip broken Note D4 D6 and D14 16 are not indicated as they are not used 12 4 GAS FLOW PROBLEMS The T204 has three main flow paths the NOx sample flow sample flow and the flow of the ozone generator supply air With zero span valve option installed there is a fourth zero air and a fifth span gas flow path but either one of those is only controlled by critical flow orifices and not displayed on the front panel or stored to the DAS Additionally the sensor sample flow is not measured or reported e Flow is too high e Flow is greater than zero but is too low and or unstable e Flow is zero no flow When troubleshooting flow problems it is essential to confirm the actual flow rate without relying on the analyzer s flow display The use of an independent external flow meter to perform a flow check as described in Section 11 3 10 3 is essential Refer to the pneumatic flow diagrams as needed for reference 222 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 12 4 1 ZERO OR LOW FLOW PROBLEMS 12 4 1 1 NOx SAMPLE FLOW IS ZERO OR LOW The T204 does not actually measure the NO sample flow but rather calculates it from a differential pressure between sample and vacuum manifold On flow failure the unit will display a SAMPLE FLOW W
363. rom UV blocking material Generic plastic glasses are not adequate O Detector Sample Inlet Exhaust Outlet Potentiometer 15V RS232 UV Lamp pot Connector Connector Housing Figure 11 7 Sensor Detail 11 3 11 1 ADJUSTING THE UV LAMP OF Pe Ooi Instrument should be running and warmed up for at least 20 minutes With instrument running remove the top cover from the chassis Scroll the lt TST TST gt menu to the REF reading REF XXXX MV Locate the UV Detector adjustment pot on the forward end of the sensor module While observing the REF value on the display slowly turn the pot to adjust the value The target adjustment range is as high as possible within the range of 800 1150 mV If the required adjustment cannot be achieved by adjusting the UV Detector pot alone then additional adjustment can be made by loosening the two UV lamp setscrews on the UV lamp housing and rotating the lamp Rotate the lamp very slowly while observing the REF value on the display Make sure the lamp does not pull out and remains seated in the housing while it is being rotated Re tighten the two setscrews when a desired point has been reached If necessary additional fine tuning can now be done with the UV Detector adjustment pot per step 5 Re Install instrument cover and observe REF value on display for a couple minutes to verify it does not drift out of the adjustment range
364. rs subject to the distance limitations of the RS 232 standard 6 Onthe rear panel of each analyzer adjust the DCE DTE switch so that the green and the red LEDs RX and TX of the COM1 connector labeled RS232 are both lit Ensure you are using the correct RS 232 cables internally wired specifically for RS 232 communication see Section 3 3 1 8 Connecting the Communications Interfaces RS 232 Connection 44 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started Analyzer COM2 Female DB9 Male DB9 Analyzer Analyzer Last Analyzer COM2 COM2 COM2 Ensure jumper is installed between JP2 pins 21 22 in last instrument of multidrop chain Figure 3 15 RS 232 Multidrop PCA Host Analyzer Interconnect Diagram BEFORE communicating from the host power on the instruments and check that the Machine ID code is unique for each Section 5 7 1 a In the SETUP Mode menu go to SETUP MORE COMNPID The default ID is typically the model number or 0 b to change the identification number press the button below the digit to be changed c Press select ENTER to accept the new ID for that instrument Next in the SETUP gt MORE gt COMM gt COM1 menu do not use the COM2 menu for multidrop edit the COM1 MODE parameter as follows press select EDIT and set only QUIET MODE COMPUTER MODE and MULTIDROP MODE to ON Do not change any other settings Press select ENTER to acce
365. rs if one of the voltage ranges is selected Manual adjustment menu only appears if either the Auto Cal feature is OFF or the range is set for CURR SET SAMPLE DAS RNGE PASS CLK COMM VARS ANALOG CONFIGURATION SET EDIT CAL ions CALIBRATED CONC OUT 1 CONC OUT 2 CONC OUT 3 TEST OUTOUT AIN CALIBRATED SETUP MORE DIAG ENTER PASSWORD 818 PREV NEXT TEST CHANNEL OPTICS OZONE GEN OUPUT TEST OVERIDE Press ENTR r3 to start Calibration ON OFF ELECTRICAL FLOW NONE TEST CALIBRATION DETECTOR OZONE FLOW Press ENTR Press ENTR SAMPLE FLOW to start to start Calibration Calibration SAMPLE PRESSURE RCELL PRESSURE RCELL TEMP MANIFOLD TEMP IZS TEMP CONV TEMP PMT TEMP BOX TEMP HVPS VOLTAGE RANGE OVER RANGE AUTO CALIBRATED OUTPUT i OFFSET CAL i 1 ON ON ON 1 OFF J J Sets the degree of offset 1 Manual Caf 01V 1V 5 10V CURR U100 UP10 UP DOWN DN10 D100 Figure A 5 Secondary Setup Menu DIAG 07889A DCN6900 APPENDIX 1 Software Menu Trees and Index Version 1 1 0 T200 T204yKb7 200E Teledyne API T200 T204 and 200E Series 05295F DCN6900 CFG TEN LM EW SAMPLE SETUP ACAL DAS RNGE PASS CLK MORE E EDIT eng NEXT ENTER _ A 818 CALDAT PREV NEXT EDIT CALCHECK cono DIA HIRE NO lt SET SET gt NEXT NX10 E
366. rument readings or cause loss of data Pertinent information associated with the proper care operation or maintenance of the analyzer or its parts Note 07889A DCN6900 vii TABLE OF CONTENTS satety Messages ooi e ee e ES e Lt a e e s Lune iii Warranty udo edet edo tet dst o V About This Marital M OC DRM P ee vii PART I GENERAL 15 1 INTRODUCTION FEATURES AND OPTIONS nnns 17 1 1 eI MT M 17 1 2 ccm E 17 Juris EE 18 2 SPECIFICATIONS APPROVALS amp LO 2 9peciflCatlons csi ce eite isti ute deu metu dede e tL I Me Lin uet SO 19 2 2 EPA Equivalency DesigriatiOn 1 ort ihe pee te tH Reo PEE e re ee p 20 2 3 Apptovals and Certifications iie Tete Rc E t te e ede ce as eae 20 2 3 1 Safety rni ed LEE de abt dabat med ees 21 2 3 2 EMG 1n ree deg erm LL Ld rud 21 3 GETTING STARTED w nuum o E EE RM VR 3 1 Unpacking and Inspecting the T204 Analyzer ennemi nnns 23 3 1 1 Proper Clearance for Ventilation and Access 24 ESAME 25 3 2 1 Front Panel 25 3 2 2 Rear Panel
367. s fail to appear see Section 11 for troubleshooting tips lt TST TST ZERO SPAN CONC EXIT M P CAL NOX STB XXX X PPB NOX X XXX lt TST TST gt ENTR CONC EXIT M P CAL NOX X XXX PPB EXIT at this point lt TST TST gt ENTR CONC EXIT returns to the SAMPLE menu The T204 Analyzer is now ready for operation Note Once you have completed the above set up procedures please fill out the Quality Questionnaire that was shipped with your unit and return it to Teledyne API This information is vital to our efforts in continuously improving our service and our products THANK YOU 07889A DCN6900 65 Getting Started Teledyne API T204 Analyzer Manual This page intentionally left blank 66 07889A DCN6900 PART Il OPERATING INSTRUCTIONS 07889A DCN6900 67 68 07889A DCN6900 4 OVERVIEW OF OPERATING MODES Note To assist in navigating the analyzer s software a series of menu trees is available for reference in Appendix A of this manual Some control buttons on the touch screen do not appear if they are not applicable to the menu that you re in the task that you are performing the command you are attempting to send or to incorrect settings input by the user For example the ENTR button may disappear if you input a setting that is invalid or out of the allowable range for that parameter such as trying to set the 24 hour clock to 25 00 00 Once
368. s mode are listed in Table 8 1 and in Appendix A 8 2 1 1 HELP COMMANDS IN INTERACTIVE MODE Table 8 1 Terminal Mode Software Commands COMMAND Oio Control T Switches the analyzer to terminal mode echo edit If mode flags 1 amp 2 are OFF the interface can be used in interactive mode with a terminal emulation program Control C Switches the analyzer to computer mode no echo no edit CR A carriage return is required after each command line is typed into the terminal computer carriage return The command will not be sent to the analyzer to be executed until this is done On personal computers this is achieved by pressing the ENTER button BS Erases one character to the left of the cursor location backspace ESC Erases the entire command line escape ID CR This command prints a complete list of available commands along with the definitions of their functionality to the display device of the terminal or computer being used The ID number of the analyzer is only necessary if multiple analyzers are on the same communications line such as the multi drop setup Control C Pauses the listing of commands Control P Restarts the listing of commands 8 2 1 2 COMMAND SYNTAX Commands are not case sensitive and all arguments within one command i e ID numbers key words data values etc must be separated with a space character All Commands follow the syntax X ID COMMAND CR Where X is the com
369. s or digital control inputs SETUP SETUP mode is being used to configure the analyzer The gas measurement will continue during setup SPAN CAL A Unit is performing SPAN calibration initiated automatically by the analyzer s AUTOCAL feature SPAN CAL M Unit is performing SPAN calibration initiated manually by the user 1 1 SPAN CAL R Unit is performing SPAN calibration initiated remotely through the COM ports or digital control inputs 1 ZERO CAL A Unit is performing ZERO calibration procedure initiated automatically by the AUTOCAL feature ZERO CAL M Unit is performing ZERO calibration procedure initiated manually by the user ZERO CAL R Unit is performing ZERO calibration procedure initiated remotely through the COM ports or digital control inputs 4 1 SAMPLE MODE This is the analyzer s standard operating mode In this mode the instrument is a calculating NO NO NO and O concentrations These values are displayed in the CONC field of the analyzer s front panel display While the instrument is in SAMPLE mode this field provides a readout of all the gas concentrations being measured by the T204 NO NO NO and Os When the analyzer is in sample mode the PARAM field will display warning messages and test functions that give the user information about the operational status of the analyzer 70 07889A DCN6900 Teledyne API T204 NO 03 Analyzer Manual Overview of Operating Modes 4 1 1 TEST FUNCTIONS These fun
370. s pertinent information regarding communication equipment describes the instrument s communications modes presents configuration instructions for the communications ports and provides instructions for their use including communications protocol Data acquisition is presented in Section 0 6 1 DATA TERMINAL COMMUNICATION EQUIPMENT DTE DCE RS 232 was developed for allowing communications between data terminal equipment DTE and data communication equipment DCE Basic terminals always fall into the DTE category whereas modems are always considered DCE devices The difference between the two is the pin assignment of the Data Receive and Data Transmit functions e DTE devices receive data on pin 2 and transmit data on pin 3 e DCE devices receive data on pin 3 and transmit data on pin 2 To allow the analyzer to be used with terminals DTE modems DCE and computers which can be either a switch mounted below the serial ports on the rear panel labeled DCE DTE Figure 3 4 allows the user to set the RS 232 configuration for one of these two data devices This switch exchanges the Receive and Transmit lines on RS 232 emulating a cross over or null modem cable The switch has no effect on COM2 6 2 COMMUNICATION MODES BAUD RATE AND PORT TESTING Use the SETUP gt MORE gt COMM menu to configure COMI labeled RS232 on instrument rear panel and or COM2 labeled COM2 on instrument rear panel for communication modes baud rate and or
371. screw the NPT fitting 07889A DCN6900 207 Instrument Maintenance Teledyne API T204 Analyzer Manual Note 7 Take out the components of the assembly e spring e sintered filter e two O rings e orifice For the vacuum manifold only you may need to use a scribe or pressure from the vacuum port to get the parts out of the manifold 8 Discard the two O rings and the sintered filter and install new ones 9 Reassemble the parts as shown in Figure 11 6 10 Reinstall the critical flow orifice assembly into the reaction cell manifold or the vacuum manifold 11 Reconnect all tubing power up the analyzer and pump After a warm up period of 30 minutes carry out a leak test as described in Section 11 3 10 11 3 9 CHECKING FOR LIGHT LEAKS When re assembled or operated improperly the T204 can develop small gaps around the PMT which let stray light from the analyzer surrounding into the PMT housing To find such light leaks follow the procedures below CAUTION QUALIFIED PERSONNEL ONLY This procedure is carried out with the analyzer running and its cover removed 1 Scroll the front panel display to show then test function to PMT 2 Supply zero gas to the analyzer 3 With the instrument still running carefully remove the analyzer cover LN WARNING ELECTRICAL SHOCK HAZARD Do NOT touch any of the inside wiring with the metal cover or with your body Do NOT drop
372. screws or tools into a running analyzer Note 4 Shine a powerful flashlight or portable incandescent light at the inlet and outlet fitting and at all of the joints of the reaction cell as well as around the PMT housing e The PMT value should not respond to the light the PMT signal should remain steady within its usual noise floor 5 If there is a PMT response to the external light symmetrically tighten the reaction cell mounting screws or replace the 1 4 vacuum tubing with new black PTFE tubing this tubing will fade with time and become transparent Often light leaks are also caused by O rings being left out of the assembly 6 Replace the five desiccant bags in the PMT housing if the PMT housing end plate Figure 12 9 was removed during this procedure Table 11 1 7 Carefully replace the analyzer cover If tubing was changed carry out a pneumatic leak check 208 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 11 3 10 CHECKING FOR PNEUMATIC LEAKS A CAUTION TECHNICAL INFORMATION Do not exceed 15 psi when pressurizing the system during either Simple or Detailed checks 11 3 10 1 SIMPLE VACUUM LEAK AND PUMP CHECK Leaks are the most common cause of analyzer malfunction This section presents a simple leak check whereas the next section details a more thorough procedure The method described here is easy fast and detects but does not locat
373. scussed in Section 13 1 the measurement of NO NO and NO requires that the sample gas flow cycles through different routes that include and exclude various scrubbers and converters There are several valves that perform this function e The NO NOx valve directs the sample gas either directly to the reaction cell or through the unit s NO converter alternating every 8 sec e The Auto Zero valve directs the sample gas stream to completely bypass the reaction cell for dark noise measurement once every minute which is then subtracted as a measurement offset from the raw concentration signal 07889A DCN6900 275 Principles of Operation Teledyne API T204 Analyzer Manual Table 13 1 T204 Valve Cycle Phases NO NOx Auto Zero Time Phase Valve Valve index Activity Figure Status Status Open to _ Wait period NO dwell time Ensures reaction cell has NO Auto Zero Open to Ones been flushed of previous gas Figure Measure reaction cell 13 3 valve 2 4s Analyzer measures chemiluminescence in reaction cell 4 6 Wait period NOx dwell time Ensures reaction cell has NOx rs Open to been flushed of previous gas Figure Measure converter l eactioncel 5 Analyzer measures NO chemiluminescence in 13 3 reaction cell Cycle repeats every 8 seconds Wait period AZERO dwell time Ensures reaction cell Aute Open to Open to 0 45 has been flushed of sample gas and chemi
374. sed triggering events are e ATIMER Sampling at regular intervals specified by an automatic timer Most trending information is usually stored at such regular intervals which can be instantaneous or averaged e EXITZR EXITSP and SLPCHG exit zero exit span slope change Sampling at the end of irregularly occurring calibrations or when the response slope changes These triggering events create instantaneous data points e g for the new slope and offset concentration response values at the end of a calibration Zero and slope values are valuable to monitor response drift and to document when the instrument was calibrated e WARNINGS Some data may be useful when stored if one of several warning messages appears such as WTEMPW GFC wheel temperature warning This is helpful for troubleshooting by monitoring when a particular warning occurred To edit the list of data parameters associated with a specific data channel follow the instruction shown in Section 7 1 3 then press Starting at the EDIT CHANNEL MENU SETUP X X 0 CONC ATIMER 5 800 DEL EDIT PRNT EXIT INS PREV NEXT NAME CONC SETUP X X SET SET EDIT PRNT NAME CONC C SETUP X X C N EXIT discards the new setting ENTR accepts the new setting Press each button repeatedly to cycle through the available character set 0 9 A Z space amp _ lt gt 146
375. sing chart recorders or other analog recording devices the T204 s 20 000 ppb physical range for NO NO and NO can cause resolution problems For example in an application where the expected concentrations of NO and NO are typically less than 500 ppb the full scale of expected values is only 2 5 of the instrument s 20 000 ppb physical range The corresponding output signal would then only be recorded across 2 5 of the range of the recording device The T204 solves this problem by allowing the user to select a reporting range for the analog outputs that only includes that portion of the physical range that covers the specific application This increases the reliability and accuracy of the analyzer by avoiding additional gain amplification circuitry 78 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Setup Menu Note Only the reporting range of the analog outputs is scaled Both the DAS values stored in the CPU s memory and the concentration values reported on the front panel are unaffected by the settings chosen for the reporting range s of the instrument 5 4 2 1 ANALOG OUTPUT RANGES FOR NOx NO AND CONCENTRATION The analyzer has three active analog output signals related to NO NO and concentration accessible through a connector on the rear panel ANALOG OUT NO Concentration NO Concentration NO Concentration IMPORTANT P d Os Concentration A3 4 Figur
376. sist after the 30 minutes warm up period is over investigate their cause using the troubleshooting guidelines in Section 12 1 58 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started To view and clear warning messages press Pressing the TEST button suppresses the warning messages and the CLR button disappears Once the last warning has been cleared the analyzer will automatically switch to SAMPLE mode NOTE If a warning message persists after several attempts to clear it the message SAMPLE SYSTEM RESET T qs may indicate a real problem and not an TEST CAL MSG CLR SETUP artifact of the warm up period SAMPLE NO 399 8 NOX 399 8 lt TST TST gt CAL MS SETUP MSG returns the active warnings to the message field SAMPLE SYSTEM RESET Press CLR to clear the current TEST CAL MSG CLR SETUP message If more than one warning is active the next message will take SYSTEM SYSTEM RESET its place until all warning messages have been cleargd TEST CLR SETUP STANDBY RANGE 500 0 PPB NOX XXXX TEST CAL MSG SETUP Concentration field displays all gases Table 3 8 lists brief descriptions of the warning messages that may occur during start up Table 3 8 Possible Warning Messages at Start Up SYSTEM RESET ANALOG CAL WARNING BOX TEMP WARNING CANNOT DYN SPAN CANNOT DYN ZERO CONFIG INITIALIZED DATA INITIALIZED OZONE FLOW WARNING OZONE GEN OFF RCELL PRESS WARN RCELL TEM
377. ss to cycle through the range of ID INET EXIT numerals and available characters 0 9 amp SAMPLE ENTER SETUP PASS 818 Moves the cursor one character left or right DEL Deletes a character at the cursor location Accepts the new setting and returns to the previous menu ENTR EXIT Ignores the new setting and returns to the previous menu DHCP ON is default setting DHCP ON Skip this step Some buttons appear only when relevant if it has been EDIT setto OFF DHCP OFF SET INST IP 000 000 000 000 SET SET EDIT Cursor location is indicated by brackets INST IP 0 00 000 000 CH CH DEL 0 ENTR EXIT GATEWAY IP 000 000 000 000 lt SET SET gt EDIT GATEWAY IP 0 00 000 000 lt CH CH gt DEL ENTR EXIT SUBNET MASK 255 255 255 0 lt SET SET gt EDIT 4 SUBNET MASK 2 55 255 255 0 TCP PORT 3000 lt CH CH gt DEL ENTR EXIT The PORT number must remain at 3000 Do not change this setting unless instructed to by Pressing EXIT from Teledyne Instruments Customer Service personnel any of the above display menus causes the Ethernet option to reinitialize its internal interface firmware 0 e INITIALIZING INET 100 INITIALIZATION SUCCEEDED INITIALIZATION FAILED M SETUP COMMUNICATIONS MENU Conta
378. stics operations according to user needs 5 1 SETUP gt CFG CONFIGURATION INFORMATION Press NEXT of PREV to move back and SETUP Pressing the CFG button displays the instrument configuration information This display lists the analyzer model serial number firmware revision software library revision CPU type and other information Use this information to identify the software and hardware when contacting customer service Special instrument or software features or installed options may also be listed here NOX XXXX SETUP RANGE 500 0 PPB CAL SAMPLE lt TST TST gt Concentration field displays all gases PRIMARY SETUP MENU SETUP CFG DAS RNGE PASS CLK MORE Press exit at any time to return to the Sample display LT T200 NOX O2 Analyzer Press exit at any forth through the following list of PREV NEXT time to return to Configuration information MODEL NAME PART NUMBER e SERIAL NUMBER e SOFTWARE REVISION LIBRARY REVISION CPU TYPE amp OS REVISION the SETUP menu 07889A DCN6900 77 Setup Menu Teledyne API T204 Analyzer Manual 5 2 SETUP gt ACAL AUTOMATIC CALIBRATION OPTION The menu button for this option appears only when the instrument has the zero span option See Section 9 3 for details 5 3 SETUP gt DAS INTERNAL DATA ACQUISITION SYSTEM Use the SETUP gt DAS menu to capture and record data Refer to Section 0 f
379. sually unaffected Specifically the gases of interest for the T204 NO and do not get absorbed and pass the dryer unaltered On the other hand other small polar gases that are capable of hydrogen bonds such as ammonia NH3 can be absorbed this way too This is an advantage since gases such as NH can cause interference for the measurement of NO NO and 07889A DCN6900 281 Principles of Operation Teledyne API T204 Analyzer Manual Note 13 3 3 3 TO GENERATOR DRY AIR RETURN OUTER TUBE PURGE OUTER TUBE TO EXHAUST MANIFOLD Dry Air i Ambient Air in j INNER schmitt 1 NAFION TUBE Wet Air FILTER Figure 13 10 T204 Sample Gas Dryer To provide a dry purge gas for the outer side of the Nafion tube the T204 returns some of the dried air from the inner tube to the outer tube This means that any time the analyzer is turned on after having been OFF for 30 minutes or more the humidity gradient between the inner and outer tubes is not very large and the dryer s efficiency is low Since it takes a certain amount of time for the humidity gradient to become large enough for the sample gas dryer operate efficiently in such cold start cases the Generator is not turned on until 30 minutes has passed in order to ensure that it is not operating until its air supply is properly dry During this 30 minute duration the O3 GEN OVERRIDE menu displays TMR on the front panel scree
380. t LAN USB RS 232 and RS 485 eee eee eer th 3 3 1 1 CONNECTING POWER Attach the power cord to the analyzer and plug it into a power outlet capable of carrying at least 10 A current at your AC voltage and that it is equipped with a functioning earth ground WARNING ELECTRICAL SHOCK HAZARD e High Voltages are present inside the analyzer s case e Power connection must have functioning ground connection e Ensure easy access to disconnect power from instrument AN e Do not defeat the ground wire on power plug e Turn off analyzer power before disconnecting or connecting electrical subassemblies e Ensure that installation provides access to disconnect power from the instrument e Do not operate with cover off CAUTION GENERAL SAFETY HAZARD To avoid damage to your analyzer ensure that the AC power voltage matches the voltage indicated on the analyzer s model specs label before plugging the T204 into line power 32 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started 3 3 1 2 CONNECTING ANALOG INPUTS OPTION The Analog In connector is used for connecting external voltage signals from other instrumentation such as meteorological instruments and for logging these signals in the analyzer s internal data acquisition system DAS The input voltage range for each analog input is 0 10 VDC and input impedance is nominally 20 kQ in parallel with 0 luF Figure
381. t air from the analyzer passes a small particle filter Dry Filter Unit DFU filter P N FL3 before entering the pump It should be replaced when It becomes visibly dirty or The pressure differential between the test functions SAMP and RCEL increases significantly 07889A DCN6900 201 Instrument Maintenance Teledyne API T204 Analyzer Manual 11 3 5 1 ATTENTION PROCEDURE FOR REPLACING FILTERS ON EXTERNAL PUMPS 1 9 Power down the analyzer and pump 2 For internally mounted filters skip the next two steps 3 4 Remove the particle filter from the pump by pushing the white plastic ring into the Remove the analyzer exhaust tube from the dust filter fitting and pulling the filter out of the fitting e f necessary use needle nose pliers to pry the filter out of the fittings Push a new filter into the pump fitting and ensure that the arrow on the filter points towards the pump Push the exhaust tubing onto the filter Skip the next two steps For internally mounted filters at the inside rear panel remove the chassis and locate the filter between the vacuum manifold and the exhaust port fitting Disconnect the clear tubing from the filter body and change the filter with the arrow pointing against the gas flow To remove the hose clamps slide the two clamp ends in opposite directions with a needle nose pliers until the clamp comes apart Reconnect the tubing by using the s
382. t from the front It cannot be disconnected to check its resistance Box temperature will vary with but will usually read about 5 C higher than ambient room temperature because of the internal heating zones from the converter reaction cell and other devices To check the box temperature functionality we recommend checking the BOX_TEMP signal voltage using the SIGNAL I O function under the DIAG Menu Section 12 1 3 At about 30 C the signal should be around 1500 mV To check the accuracy of the sensor use a calibrated external thermometer temperature sensor to verify the accuracy of the box temperature by e Placing it inside the chassis next to the thermistor labeled XT1 above connector J108 on the motherboard e Compare its reading to the value of the test function PMT TEMP PMT TEMPERATURE SENSOR CONTROL The temperature of the PMT should be low and constant It is more important that this temperature is maintained at a constant level than it is to be a specific temperature The PMT cooler uses a Peltier thermo electric cooler element supplied with 12 V DC power from the switching power supply PS2 The temperature is controlled by a proportional temperature controller located on the preamplifier board Voltages applied to the cooler element vary from 0 1 to 12 VDC The temperature set point hard wired into the preamplifier board will vary by 2 The actual temperature will be maintained to within 0 1 C ar
383. t measures NO NO and Their ID numbers are as follows NO 211 NO 212 213 REPORT States whether this list entry is to be reported or not reported whenever this gas type or instrument is polled by the HESSEN network If the list entry is not to be reported this field will be blank Its default gas list consists of only reads NOX 0 211 REPORTED NO 0 212 REPORTED NO2 0 213 REPORTED These default settings cause the instrument to report the concentration value of the currently active range If you wish to have just concentration value stored for a specific range this list entry should be edited or additional entries should be added to the list EXAMPLE Changing the above NO gas list entry to read NOX 2 211 REPORTED would only record the last NO reading that occurred while RANGE2 HIGH range was active 134 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Communications Setup and Operation EDITING OR ADDING HESSEN Gas LIST ENTRIES To add or edit an entry to the Hessen Gas List press SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X SECONDARY SETUP MENU COMM VARS DIAG EXIT COMMUNICATIONS MENU ID HESN COM1 2 EXIT HESSEN VARIATION TYPE1 lt SET SET gt EDIT EXIT Continue pressing NEXT until Use the PREV and NEXT button to move between gas list entries Use the PREV and NEXT butto
384. tage is out of range then either pressure transducer 51 is bad the board is bad or there is a pneumatic failure preventing the pressure transducer from sensing the absorption cell pressure properly Replace the PCA 12 7 7 3 VACUUM PRESSURE SENSOR CHECK e Measure the pressure on the inlet side of S2 with an external pressure meter e Measure the voltage across TP5 and TP1 e Evaluate the reading in the same manner as for the sample pressure sensor 12 7 7 4 GENERATOR FLOW SENSOR CHECK e Measure the voltage across and TP1 e With proper flow 80 cc min through the generator this should be approximately 2V x 0 25 this voltage will vary with altitude e With flow stopped photometer inlet disconnected or pump turned OFF the voltage should be approximately 1V e If the voltage is incorrect the flow sensor S3 is bad the board is bad replace the PCA or there is a leak upstream of the sensor 12 7 8 CPU There are two major types of CPU board failures a complete failure and a failure associated with the Disk On Module DOM If either of these failures occurs contact the factory For complete failures assuming that the power supplies are operating properly and the wiring is intact the CPU is faulty if on power on the watchdog LED on the motherboard is not flashing e n some rare circumstances this failure may be caused by a bad IC on the motherboard specifically U57 the large 44 pin device on the l
385. tages 0 5 VDC are output through an optically isolated 8 pin connector located on the rear panel of the analyzer see Figure 3 4 These outputs convey good bad and on off information about certain analyzer conditions They can be used to interface with certain types of programmable devices e For information on setting up the status outputs see Section 3 3 1 4 CONTROL INPUTS By applying 5V DC power to these digital inputs from an external source such as a PLC or Data logger zero point and span point calibrations can be remotely initiated e For information on setting up the status inputs see Section 3 3 1 6 INTERNAL DIGITAL I O There are several internal digital control signals that are generated by the motherboard under CPU control and used to control subsystems of the analyzer ELECTRICAL TEST CONTROL When the CPU sets this control signal to high ON the electric test feature ETEST is initiated see Section 8 3 e The ETEST can be initiated by following the procedure in Section 12 7 12 2 or by setting the SIGNAL I O Function ELEC_TEST to ON OPTICAL TEST OTEST CONTROL When the CPU sets this control signal to high ON the optical test feature is initiated see Section 8 3 e The OTEST can be initiated by following the procedure in 12 7 12 1 or by setting the SIGNAL I O Function OPTIC_TEST to ON 292 07889A DCN6900 Teledyne API T204 Analyzer Manual Principles of Operation Note PMT
386. ted inside the generator The content of the ozone cleanser needs periodical exchange according to Table 11 1 A rebuild kit is available from the factory see Appendix B of this manual lists the part numbers To change the ozone cleanser chemical follow these steps 1 2 Turn of power to the analyzer and pump Remove the analyzer cover and locate the filter in the front of the analyzer next to the generator Use a 7 16 wrench to remove both pieces of 1 8 male nut with tubing from the NPT fittings 198 07889A DCN6900 Teledyne API T204 Analyzer Manual Instrument Maintenance 12 BLACK 1 8 TFE TUBING MALE NUT FERRULE CONNECTOR P N FT9 2 PLACES lt gt NPT FITTING 6 PLUG P N FT349 O GLASS WOOL P N IN6 2 PLACES 2 MANIFOLD SCRUBBER CARULITE SILICA GEL P N 05810 DECAL P N 058980200 4 CHASSIS REFERENCE P N 05823B SCREW P N SN229 d gt 2 PLACES Figure 11 3 Ozone Generator Cleanser Assembly 3 manifold from the chassis Discard the glass wool Pour the contents of the scrubber Remove the integrated screws with a Phillips screw driver and remove the scrubber Using a 9 16 wrench remove both fittings from the cartridge manifold onto a sheet of white paper If necessary remove the plug to ensure that all the contents are poured out
387. ted span Table 5 6 Analog Output Voltage Range Min Max RANGE NAME RANGE SPAN MINIMUM OUTPUT MAXIMUM OUTPUT 0 1V 0 100 mVDC 5 mVDC 105 mVDC 1V 0 1 VDC 0 05 VDC 1 05 VDC 5V 0 5 VDC 0 25 VDC 5 25 VDC 10V 0 10 VDC 0 5 VDC 10 5 VDC The default offset for all VDC ranges is 0 5 VDC CURR 0 20 mA 0 mA 20 mA While these are the physical limits of the current loop modules typical applications use 2 20 mA or 4 20 mA for the lower and upper limits Please specify desired range when ordering this option The default offset for all current ranges is 0 mA To change the output type and range select the ANALOG CONFIGURATION submenu see Figure 5 5 then press From the AIO CONFIGURATION SUBMENU DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO SET gt CAL EXIT Continue pressing SET gt until you reach the output to be configured DIAG AIO CONC_OUT_2 5V OVR NOCAL lt SET SET gt EDIT EXIT DIAG AIO CONC_OUT_2 RANGE 5V Pressing ENTR records lt SET SET gt EDIT EXIT the new setting and These butions returns previous set the signal Pressing EXIT ignores the level and type DIAG AIO CONC_OUT_2 RANGE 5V new setting and returns to ot theselected the previous menu channel 1V 5V 10V CURR ENTR EXIT P UA 07889A DCN6900 101 Setup Menu Teledyne API T204 Analyzer Manual 5 9 3 2 CALIBRATING THE ANAL
388. terminated successfully To log on to the T204 analyzer with SECURITY MODE feature enabled type LOGON 940331 940331 is the default password To change the default password use the variable RS 232 PASS issued as follows V RS 232_PASS NNNNNN Where N is any numeral between 0 and 9 07889A DCN6900 165 Remote Operation Teledyne API T204 Analyzer Manual This page intentionally left blank 166 07889A DCN6900 9 CALIBRATION PROCEDURES Note This section contains information for calibrating a T204 NO Analyzer as well as other supporting information including calibration checks and calibration of the basic analyzer and with valve options calibration quality assessment and gas flow calibration Throughout this Section are various diagrams showing pneumatic connections between the T204 and various other pieces of equipment such as calibrators and zero air sources These diagrams are only intended to be schematic representations of these connections and do not reflect actual physical locations of equipment and fitting location or orientation Contact your regional EPA or other appropriate governing agency for more detailed recommendations 9 1 BEFORE CALIBRATION Note The calibration procedures in this section assume that the range mode analog range and units of measure have already been selected for the analyzer If this has not been done please do so before continuing see Section
389. the Special Manuals section RMA procedures are under Help Center gt Return Authorization when returning parts for repair or calibration may void your warranty For anti ESD 07889A DCN6900 Teledyne API T204 Analyzer Manual This page intentionally left blank Vi 07889A DCN6900 ABOUT THIS MANUAL Presented here is a list of documents comprising this manual and the conventions used STRUCTURE This T204 manual PN 07889 is comprised of multiple documents assembled in PDF format as listed below Part No Rev Name Description 07889 A T204 Operation Manual this manual 05295 F Software Menu Trees Appendix A 07887 A Spare Parts List Appendix B 08156 A Repair Questionnaire Appendix C 06911 C Interconnect Diagram Appendix D Note We recommend that this manual be read in its entirety before any attempt is made to operate the instrument 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 inst
390. the orifice a pressure differential is created This pressure differential created by the analyzer s external pump draws the gas through the orifice As the pressure on the downstream side of the orifice the pump side continues to drop the speed that the gas flows though the orifice continues to rise Once the ratio of upstream pressure to downstream pressure is greater than 2 1 the velocity of the gas through the orifice reaches the speed of sound As long as that ratio stays at least 2 1 the gas flow rate is unaffected by any fluctuations surges or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice The actual flow rate of gas through the orifice volume of gas per unit of time depends on the size and shape of the aperture in the orifice The larger the hole the more gas molecules moving at the speed of sound pass through the orifice In addition to controlling the gas flow rates into the reaction cell the two critical flow orifices at the inlets of the reaction cell also maintain an under pressure inside it effectively reducing the number of molecules in the chamber and the corresponding incidence of third body quenching and therefore increasing the chemiluminescence yield e The T204 reaches its peak sensitivity at about 2 in Hg A below which the sensitivity drops due to t
391. these components requires opening the sensor module This is a delicate assembly and it is recommend that you ensure the PMT HVPS or TEC modules are indeed faulty before unnecessarily opening of the module CAUTION QUALIFIED PERSONNEL While the PMT or HVPS can be removed through the front panel without un mounting the entire sensor module we recommend turning off the instrument opening its top cover and removing the entire assembly so that further repairs can be carried out at an anti ESD workstation Follow the guidelines defined in the Electrostatic Discharge manual for preventing electrostatic damage to electronic components on our website at http www teledyne api com under Help Center gt Product Manuals in the Special Manuals section Turn OFF the analyzer and disconnect the power cord Remove the cover Disconnect all pneumatic and electrical connections from the sensor assembly Remove the sensor assembly If the TEC is to be replaced remove the reaction cell assembly at this point by unscrewing two holding screws ak WN gt e This is necessary only if the repair being performed involves removing the PMT cold block 07889A DCN6900 261 Troubleshooting amp Service Teledyne API T204 Analyzer Manual PMT housing end plate This is the entry for PMT exchange S PMT si M connector Evacuation port fitting PMT supply connector Sensor housing Reaction cell
392. though ozone is unstable and typically reacts to form the break down is not quite fast enough to ensure that it is completely removed from the exhaust gas stream of the T204 by the time the gas exits the analyzer Due to the high toxicity and reactivity of O a highly efficient catalytic converter scrubs or converts all of the O from the gas exiting the reaction cell The conversion process is very safe It only converts ozone to oxygen and does not produce any toxic or hazardous gases The destruct is located just inside the NO converter As this is a true catalytic converter there are no maintenance requirements as would be required for charcoal based ozone destructs A certain amount of fine black dust may exit the catalyst particularly if the analyzer is subjected to sudden pressure drops for example when disconnecting the running pump without letting the analyzer properly and slowly equilibrate to ambient pressure To prevent the dust from entering the reaction cell or the pump the ozone destruct is equipped with a quartz wool filter material 13 3 4 PNEUMATIC SENSORS Note The T204 displays all pressures in inches of mercury absolute in Hg A 1 e absolute pressure referenced against zero a perfect vacuum The T204 uses three pneumatic sensors to verify the flow and pressure levels of its gas streams They are located on a printed circuit assembly called the pneumatic pressure flow sensor board located just
393. ting ranges of the analog output channels are e SNGL mode e Oto 500 0 ppb e Oto5VDC 5 4 8 SETUP gt RNGE gt MODE 5 4 3 1 Note Single range mode SNGL reports all gas concentrations using the same reporting range span see Section 5 4 3 1 Independent range mode IND allows the analog outputs to be set with different reporting range spans see Section 5 4 3 2 Automatic range mode AUTO allows the analyzer to automatically switch the reporting range between two user upper span limits designated LOW and HIGH based on the actual concentrations being measured for each see Section 5 4 3 3 These are not the same as the analyzer s low and high physical ranges SETUP gt RNGE gt MODE gt SNGL CONFIGURING THE T204 ANALYZER FOR SINGLE RANGE MODE When the single range mode is selected SNGL all analog concentration outputs are slaved together and set to the same reporting range limits e g 500 0 ppb This reporting range can be set to any value between 100 ppb and 20 000 ppb Although all outputs share the same concentration reporting range the electronic signal ranges of the analog outputs may still be configured for different values e g 0 5 VDC 0 10 VDC etc see Section 5 9 3 1 To select SNGL range mode and to set the upper limit of the range press 80 07889A DCN6900 Teledyne API T204 Analyzer Manual Setup Menu SAMPLE RANGE 500 0 PPB NOX XXXX lt TST TST gt CAL SETUP C
394. tion 12 10 because it may be possible to recover operation of the analyzer If after 30 60 seconds neither DS5 is flashing nor have any characters been written to the front panel display then the CPU is bad and must be replaced o ofo 200500 B CPU Status LED Figure 12 2 CPU Status Indicator 12 3 2 RELAY PCA STATUS LEDS There are sixteen LEDs located on the Relay PCA Some are not used on this model 12 3 2 1 BUS WATCHDOG STATUS LEDS The most important is D1 see Figure 12 3 which indicates the health of the bus 220 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service Table 12 2 Relay PCA Watchdog LED Failure Indications LED Function Fault Status Indicated Failure s D1 Red 2 or Faulty Connectors Wiring between Motherboard Failed Halted CPU Continuously ON Faulty Motherboard Touchscreen or Relay PCA Continuously OFF Touchscreen or Relay PCA Failed Faulty 5 VDC Power Supply PS1 12 3 2 2 If D1 is blinking then the other LEDs can be used in conjunction with DIAG Menu Signal I O to identify hardware failures of the relays and switches on the Relay PCA RELAY PCA STATUS LEDS D10 Green NO NO Valv D9 Green AutoZero Valve D8 Green Optional Sample Cal Valve D7 Green Optional Zero Span Valve D3 Yellow NO gt NO Converter Heater D2
395. tion can be used for direct communication between the analyzer and a PC connect a USB cable between the analyzer and computer USB ports Baud rates must match check the baud rate on either the computer or the instrument and change the other to match see Section 6 2 2 This USB connection can only be used when the COM2 port is not in use except for RS 232 Multidrop communication Configuration Section 6 6 If this option is installed the rear panel COM2 port cannot be used for anything other than Multidrop communication RS 232 CONNECTION For RS 232 communications with data terminal equipment DTE or with data communication equipment DCE connect either a DB9 female to DB9 female cable Teledyne API part number WR000077 or a DB9 female to DB25 male cable as applicable from the analyzer s rear panel RS 232 port to the device Adjust the DCE DTE switch Figure 3 4 to select DTE or DCE as appropriate Section 6 1 Configuration Section 6 3 and Section 6 7 2 for Hessen protocol IMPACT ON READINGS OR DATA Cables that appear to be compatible because of matching connectors may incorporate internal wiring that makes the link inoperable Check cables acquired from sources other than Teledyne API for pin assignments Figure 3 12 before using 40 07889A DCN6900 Teledyne API T204 Analyzer Manual Getting Started Male DB 9 RS 232 As seen from outside analyzer GND GND DCE mode Figure 3 12 R
396. tion for each screen component ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY Do not use hard surfaced instruments such as pens to touch the control buttons 26 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started Table 3 1 Display Screen and Touch Control Description Description Function Status LEDs indicating the states of Sample Calibration and Fault as follows Off Unit is not operating in sample mode DAS is disabled On Sample Mode active Front Panel Display being updated DAS data SAMPLE Green being stored Blinking Unit is operating in sample mode front panel display being updated DAS hold off mode is ON DAS disabled Off Auto Cal disabled CAL Yellow On Auto Cal enabled Blinking Unit is in calibration mode FAULT Off Wamingsrexist Blinking Warnings exist Conc Displays the actual concentration of the sample gas currently being measured by the analyzer in the currently selected units of measure Displays the name of the analyzer s current operating mode Param Displays a variety of informational messages such as warning messages operational data test function values and response messages during interactive tasks Displays dynamic context sensitive labels on each button Blank menu buttons indicate either non Control Buttons applicability or incorrect input Figure 3 3 shows how the front panel display is mapped to the menu charts illustrated in th
397. to Zero filter may also cause negative concentrations e lf ashort high noise value was detected during the Auto Zero cycle that higher reading will alter the Auto Zero filter value e As the value of the Auto Zero filter is subtracted from the current PMT response it will produce a negative concentration reading e High Auto Zero readings can be caused by e leaking or stuck Auto Zero valve replace the valve by electronic fault the preamplifier causing it to have a voltage on the PMT output pin during the Auto Zero cycle replace the preamplifier e by a reaction cell contamination causing high background gt 40 mV PMT readings clean the reaction cell e by a broken PMT temperature control circuit allowing high zero offset repair the faulty PMT cooler After fixing the cause of a high Auto Zero filter reading the T204 will take 15 minutes for the filter to clear itself or by an exhausted chemical in the ozone cleanser see Section 11 3 3 e Calibration error is the most likely explanation for negative concentration values e If the zero air contained some NO or NO gas contaminated zero air or a worn out zero air scrubber and the analyzer was calibrated to that concentration as zero the analyzer may report negative values when measuring air that contains little or no NO e The same problem occurs if the analyzer was zero calibrated using zero gas that is contaminated with ambient air or spa
398. tor on the front panel to see if the pump needs replacement If this value goes above 10 in Hg A on average the pump head needs to be rebuilt 07889A DCN6900 265 Troubleshooting amp Service Teledyne API T204 Analyzer Manual QUESTION ANSWER Why does my RS 232 serial connection not work There are several possible reasons The wrong cable please use the provided or a generic straight through cable do not use a null modem type cable and ensure the pin assignments are correct Sections 3 3 1 8 and 6 3 The DCE DTE switch on the back of the analyzer is not set properly ensure that both green and red lights are on Section 6 1 e The baud rate of the analyzer s COMM port does not match that of the serial port of your computer data logger Section 6 2 2 How do make the instrument s display and my data logger agree This most commonly occurs when an independent metering device is used besides the data logger recorder to determine gas concentration levels while calibrating the analyzer These disagreements result from the analyzer the metering device and the data logger having slightly different ground levels Use the data logger itself as the metering device during calibration procedures Do the critical flow orifices of my analyzer require regular replacement No The o rings and the sintered filter associated with them require replacement once a ye
399. ue selecting other COM modes you want to enable or disable using the ON or OFF button Figure 6 1 COMM Communication Modes Setup 07889A DCN6900 117 Teledyne API T204 Analyzer Manual Communications Setup and Operation 6 2 2 COM PORT BAUD RATE To select the baud rate of either COMM Port go to SETUP gt MORE gt COMM and select either COMI or 2 as follows use COM2 to view match your personal computer baud rate when using the USB port Section 6 6 Select which COM port to configure COM1 for example Press SET gt until you reach the COM1 BAUD RATE Use PREV and NEXT to move between available baud rates 300 1200 4800 9600 19200 38400 57600 115200 6 2 3 COM PORT TESTING The serial ports can be tested for correct connection and output in the COMM menu This test sends a string of 256 w characters to the selected COMM port While the test is running the red LED on the rear panel of the analyzer should flicker SETUP X X COMMUNICATIONS MENU ID INET COM1 COM2 SETUP X X SET SET SET SETUP X X PREV NEXT SETUP X X NEXT ON Figure 6 2 COM1 MODE 0 EXAMPLE SETUP X X COM1 BAUD RATE 19200 EDIT COM1 BAUD RATE 19200 ENTR COM1 BAUD RATE 9600 ENTR COMM COMM Port Baud Rate ENTR accepts the new setting 07889A DCN6900 118 Teledyne API T204 Analyzer Manual Communications Setup and Operation
400. uminescence Detection in the T204 Reaction 269 13 1 3 NOx and NO Determination 270 13 1 4 Aut aaa edna 271 13 2 Ozone Measurement nennen enne nns 273 13 3 Pneumatic Operatlon deett Ie pat e Ree de Paden deed ade eee peated 274 13 3 1 Sample Gas g 274 13 3 2 Flow Rate Control Critical Flow Orifices c ccccceceeeeeeeeceeeeeeeeeeeeeaeeeeeeeeesesennieeeeeees 276 13 3 3 Ozone Gas Generation and Air 1 eene 279 13 3 4 Prieuimatic Sersors eei rir ipe Fe baie IR eee REDIRET e eae Ce e DRE aedes 283 13 4 Electronic Operatlon eiecit e ettet ere e dor te a a eee Feat ee e HERE e e ERR PARE IRA Fe ua STER dae 286 13 4 1 eau Tr 286 13 4 2 CDU c e eL iu E E 288 13 4 3 MotherbOaEd 45 nce edu etiatn M 289 13 4 4 Relay PORA dcs nuu LU t n UI on EE 294 13 5 Sensor Module Reaction Cell seeesesssssssseseeeeeeesenenenn nene enen nnne rnn nenne sensns r sn nr nsns nnns 300 13 6 Photo Multiplier Tube PMT niente trn nnne tetra itat norat netta ne Herrn 301 13 6 1
401. umn of the analyzer Final Test and Validation Data Sheet P N 04490 shipped with the instrument Values outside these acceptable ranges indicate a failure of one or more of the analyzer s subsystems Functions whose values are still within acceptable ranges but have significantly changed from the measurement recorded on the factory data sheet may also indicate a failure A worksheet has been provided in Appendix C to assist in recording the value of these test functions A value of XXXX displayed for any of these TEST functions indicates an OUT OF RANGE reading Sample Pressure measurements are represented in terms of ABSOLUTE pressure because this is the least ambiguous method reporting gas pressure Absolute atmospheric pressure is about 29 92 in Hg A at sea level It decreases about 1 in Hg per 1000 ft gain in altitude A variety of factors such as air conditioning systems passing storms and air temperature can also cause changes in the absolute atmospheric pressure 12 1 3 DIAG gt SIGNAL I O USING THE DIAGNOSTIC SIGNAL I O FUNCTION The signal I O diagnostic mode allows access to the digital and analog I O in the analyzer Some of the digital signals can be controlled through the touchscreen These signals combined with a thorough understanding of the instrument s principles of operation Section 13 are useful for troubleshooting in three ways e technician can view the raw unprocessed signal level of the
402. unctionality of the analyzer The secondary use is for data analysis documentation and archival in electronic format To support the DAS functionality Teledyne API offers APICOM a program that provides a visual interface for remote or local setup configuration and data retrieval of the DAS Using APICOM data can even be retrieved automatically to a remote computer for further processing The APICOM DAS manual PN 07463 contains a more detailed description of the DAS structure and configuration and is briefly described in this document The T204 is configured with a basic DAS configuration already enabled The data channels included in this basic structure may be used as is or temporarily disabled for later or occasional use The green SAMPLE LED on the instrument front panel which indicates the analyzer status also indicates certain aspects of the DAS status Table 7 1 Front Panel LED Status Indicators for DAS BLINKING N IMPORTANT System is in calibration mode Data logging can be enabled or disabled for this mode Calibration data are typically stored at the end of calibration periods concentration data are typically not sampled diagnostic data should be collected Instrument is in hold off mode a short period after the system exits calibrations DAS channels can be enabled or disabled for this period Concentration data are typically disabled whereas diagnostic should be collected Sampling normally IMPACT ON REA
403. ure and vacuum pressure Ifthe critical flow orifice assembly is partially or completely clogged both the sample and vacuum pressures are still within their nominal ranges the pump keeps pumping the sample port is open to the atmosphere but there is no flow possible through the reaction cell Although measuring the actual flow is the best method in most cases this fault can also be diagnosed by evaluating the two pressure values e Since there is no longer any flow the sample pressure should be equal to ambient pressure which is about 1 in Hg A higher than the sample pressure under normal operation e reaction cell pressure the other hand is significantly lower than under normal operation because the pump no longer has to remove 500 cm min of sample gas and evacuates the reaction cell much better 07889A DCN6900 225 Troubleshooting amp Service Teledyne API T204 Analyzer Manual e Those two indicators taken together with a zero or low actual flow indicate a clogged sample orifice The T204 features a new orifice holder which makes switching sample and ozone flow orifices very easy refer to Section 11 3 8 on how to change the sample orifices and to Appendix B for part numbers of these assemblies Again monitoring the pressures and flows regularly will reveal such problems because the pressures would slowly or suddenly change from their nominal mean values Teledyne API recommends
404. ures For each mode there are seven parameters that control operational details of the SEQUENCE They are Table 9 2 AutoCal Attribute Setup Parameters ATTRIBUTE ACTION TIMER ENABLED Turns on the Sequence timer STARTING DATE Sequence will operate after Starting Date STARTING TIME Time of day sequence will run Number of days to skip between each Sequence execution DELTA DAYS e If set to 7 for example the AutoCal feature will be enabled once every week on the same day Number of hours later each Delta Days Sequence is to be run e If set to 0 the sequence will start at the same time each day Delta DELTA TIME Time is added to Delta Days for the total time between cycles e This parameter prevents the analyzer from being calibrated at the same daytime of each calibration day and prevents a lack of data for one particular daytime on the days of calibration Number of minutes the sequence operates e This parameter needs to be set such that there is enough time for the DURATION concentration signal to stabilize e The STB parameter shows if the analyzer response is stable at the end of the calibration e This parameter is logged with calibration values in the DAS Enable to do a calibration Disable to do a cal check only CALIBRATE e For analyzers with internal span gas generators installed and functioning when used in US EPA applications this setting must be set to OFF LOW calibrates the low range HIGH ca
405. ures its customers that prompt service and support will be available 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 PRODUCT RETURN 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 All units or components returned to Teledyne API should be properly packed for handling and returned freight prepaid to the nearest designated Service Center After the repair the equipment will be returned freight prepaid The complete Terms and Conditions of Sale can be reviewed at http www teledyne api com terms_and_conditions asp CAUTION Avoid Warranty Invalidation Failure to comply with proper anti Electro Static Discharge ESD handling and packing instructions and Return Merchandise Authorization RMA procedures handling and packing instructions please refer to the manual Fundamentals of ESD PN 04786 in its Packing Components for Return to Teledyne API s Customer Service section The manual can be downloaded from our website at http Awww teledyne api com under Help Center gt Product Manuals in
406. use large negative offsets which may take 2 3 weeks to disappear Do not leave this material uncovered for more than a few seconds as it will absorb contaminants from ambient air Always store unused well 9 Seal the silica gel desiccant with 1 cm of glass wool on each well e Ensure that the plug is large enough and compressed into the cartridge so that the chemical is securely held in place 10 Add new Teflon tape P N HN000036 to the NPT fittings 11 Screw the NPT fittings back into the scrubber manifold 12 Screw the cartridge back onto the chassis orientation is not important 13 Evaluate the ferrules on the tubing e Ifthe ferrules are too old we recommend replacing them with new ferrules 14 Reconnect the tubing using 7 16 and 9 16 wrenches e Donotover tighten the fittings 15 If the service interval for this item has been exceeded it may also be necessary to clean the reaction cell as described in Section 11 3 7 16 Leak check the system using the pressurized approach described in Section 11 3 10 2 e f necessary tighten the fittings some more but do not over tighten 17 Restart the analyzer and pump and continue operation 18 Recalibrate the analyzer after one hour Section 9 e f Auto Zero is high or is changing not constant you may have to wait a day until the silica gel is conditioned before recalibrating the instrument 200 07889A DCN6900 Teledyne API T204 Analyzer
407. ven the molecules of the reaction cell walls and transfers its excess energy to this collision partner represented by M in the Equation 13 3 below without emitting any light at all In fact by far the largest portion of the excited NO returns to the ground state this way leaving only a few percent yield of usable chemiluminescence Equation 13 3 NO M NO The probability of a collision between the NO5 molecule and a collision partner increases proportionally with the reaction cell pressure This non radiating collision with the NO5 molecules is usually referred to as third body quenching Even under the best conditions only about 20 of the NO that is formed by the reaction described in Equation 13 1 is in the excited state In order to maximize chemiluminescence the reaction cell is maintained at reduced pressure thereby reducing the amount of available collision partners and is supplied with a large constant excess of ozone about 3000 5000 ppm from the internal ozone generator 268 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Principles of Operation 13 1 2 CHEMILUMINESCENCE DETECTION IN THE T204 REACTION CELL 13 1 2 1 THE PHOTO MULTIPLIER TUBE PMT The T204 uses a special kind of vacuum tube called a photo multiplier tube PMT to detect the amount of light created by the NO and O reaction in the reaction cell Photons enter the PMT and strike a negatively charged photo cathode
408. volts for OFF Table 12 8 Status Outputs Check PIN LEFT TO RIGHT STATUS ST_SYSTEM_OK ST_CONC_VALID ST_HIGH_RANGE ST ZERO CAL ST SPAN CAL ST DIAG MODE Not Used on T204 AJOJ NJ gt ST_O2_CAL 12 7 6 4 CONTROL INPUTS The control input bits can be tested by applying a trigger voltage to an input and watching changes in the status of the associated function under the SIGNAL submenu EXAMPLE to test the A control input 1 Ox Qu Under the DIAG Signal I O menu see Section 12 1 3 scroll through the inputs and outputs until you get to the output named EXT ZERO CAL Connect a jumper from the pin on the appropriate connector to the U on the same connector Connect a second jumper from the V on the connector to the A pin The status of EXT ZERO CAL should change to read Connect a second jumper from the V on the connector to the B pin The status of EXT ZERO CAL should change to read Table 12 9 1204 Control Input Pin Assignments and Corresponding Signal I O Functions INPUT CORRESPONDING I O SIGNAL C D E amp F NOT USED 07889A DCN6900 239 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 7 7 PRESSURE FLOW SENSOR ASSEMBLY The flow and pressure sensors of the T204 are located on a PCA just behind the PMT sensor see
409. w from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA At 50 mA the transistor will drop approximately 1 2V from its collector to emitter The status outputs are accessed via a 12 pin connector on the analyzer s rear panel labeled STATUS Figure 3 4 Pin outs for this connector are STATUS 1 2 3 4 5 67 8 D 5 to external device SYSTEM OK ZERO CAL SPAN CAL DIAG_MODE CONC VALID HIGH RANGE Figure 3 9 Status Output Connector Table 3 5 Status Output Pin Assignments OUTPUT STATUS DEFINITION CONDITION SYSTEM OK On if no faults are present On if concentration measurement is valid CONC VALID If the concentration measurement is invalid this bit is OFF 1 2 3 4 5 HIGHRANGE On if unit is in high range of DUAL or AUTO Range Modes 5 SPANCAL OnwnmeremsmeninONSmok 5 DIAG MODE on wheneverthe instrumentis in DIAGNOSTIC mode Fd EmierBUS The emitters ofthe transistor on pins 1 to 8 are bussed together a L Diaital Ground The ground level from the analyzer s internal DC power supplies This 9 connection should be used as the ground return when 5VDC power is used 36 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Getting Started 3 3 1 6 CONNECTING THE CONTROL INPUTS The analyzer is equipped with three
410. will appear at various points of this process Wait until NOX STB falls below 0 5 PPB This may take several minutes It is not necessary to press them Record NOx NO span point readings DO NOT PRESS THE ENTR button 07889A DCN6900 175 Calibration Procedures Teledyne API T204 Analyzer Manual 9 2 7 9 2 7 1 Note Only appears if the AUTO range mode is selected Repeat entire procedure for M P CAL 2 The NOx amp NO span concentration 0 values automatically default to MANUAL CALIBRATION USING VALVE OPTIONS The following section describes the basic method for manually calibrating the T204 NOx analyzer If the analyzer s reporting range is set for the AUTO range mode a step will appear for selecting which range is to be calibrated LOW or HIGH Each of these two ranges MUST be calibrated separately SETTING THE EXPECTED SPAN GAS CONCENTRATION The expected concentrations for both NOx and NO are usually set to the same value unless the conversion efficiency is not equal to 1 000 or not entered properly in the conversion efficiency setting When setting expected concentration values consider impurities in your span gas source e g NO often contains 1 396 NO and vice versa The NO NO and O span gas concentrations should be 80 of range of concentration values likely to be encountered in your application The default factory reporting range setting is
411. wipe and do not touch it after cleaning 14 If the cold block or TEC is to be changed e Disconnect the TEC driver board from the preamplifier board remove the cooler fan duct 4 screws on its side including the driver board e Disconnect the driver board from the TEC and set the sub assembly aside 262 07889A DCN6900 Teledyne API T204 NO OS3 Analyzer Manual Troubleshooting amp Service 15 16 17 Remove the end plate with the cooling fins 4 screws and slide out the PMT cold block assembly which contains the TEC Unscrew the TEC from the cooling fins and the cold block and replace it with a new unit Reassemble this TEC subassembly in reverse order e Ensure to use thermal grease between TEC and cooling fins as well as between TEC and cold block and that the side opening in the cold block will face the reaction cell when assembled e Evenly tighten the long mounting screws for good thermal conductivity CAUTION QUALIFIED PERSONNEL The thermo electric cooler needs to be mounted flat to the heat sink A If there is any significant gap the TEC might burn out Ensure to apply heat sink paste before mounting it and tighten the screws evenly and cross wise 18 19 20 21 22 23 24 25 26 27 Reinsert the TEC subassembly in reverse order e Ensure that the O ring is placed properly and the assembly is tightened evenly Insert the LED and thermistor into the cold block insert n
412. y be necessary to get the analyzer back into its proper range of expected values e possible indicator of this scenario is a slope or offset value that is outside of its allowed range 0 7 1 3 for slope 20 to 150 for offsets See Section 12 8 4 on how to carry out a low level hardware calibration 07889A DCN6900 229 Troubleshooting amp Service Teledyne API T204 Analyzer Manual 12 5 5 INABILITY TO ZERO NO ZERO BUTTON CALZ In general the T204 will not display certain buttons whenever the actual value of a parameter is outside of the expected range for that parameter If the calibration menu does not show a ZERO button when carrying out a zero calibration the actual gas concentration must be significantly different from the actual zero point as per last calibration which may be for any of several reasons 1 Confirm that there is a good source of zero air Check any zero air scrubber for performance It may need to be replaced Section 11 3 4 2 Check to ensure that there is no ambient air leaking into zero air line Check for leaks in the pneumatic systems as described in Section 11 3 10 12 5 6 NON LINEAR RESPONSE The T204 was factory calibrated to a high level of NO and should be linear to within 196 of full scale Common causes for non linearity are Leaks in the pneumatic system e Leaks can add a constant of ambient air zero air or span gas to the current sample gas stream which
413. zero span point calibrations on analyzers with these options installed is similar to the methods discussed in the previous sections The primary differences are e instruments with the Z S valve option zero air and span gas is supplied to the analyzer through other gas inlets besides the sample gas inlet e zero and span calibration operations are initiated directly and independently with dedicated buttons CALZ amp CALS 9 2 5 SETUP FOR CALIBRATION USING VALVE OPTIONS Each of the various calibration valve options requires a different pneumatic setup that is dependent on the exact nature and number of valves present Refer to the following diagrams for information on each or these valve sets 9 2 6 MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS INSTALLED SAMPLE RANGE 500 0 PPB NOX XXXX Set the Display to show lt TST TST gt CAL CALZ CALS SETUP the NOX STB test function This function calculates the stability of the NO NO Analyzer display continues to cycle through all of the Toggle TST gt button until measurement available gas measurements throughout this procedure SAMPLE NOX STB XXX X PPB NOX XXXX lt TST TST gt CAL CALZ CALS SETUP Wait until NOX STB falls below 0 5 PPB This may take several minutes Record NOx NO or NO2 zero point readings DO NOT PRESS THE ENTR KEY SAMPLE NOX STB XXX X PPB NOX XXXX lt TST TST gt CAL CALZ CALS SETUP The ZERO and or SPAN buttons

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