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Teledyne M5000B Photo Scanner User Manual

1. eiit rt ere Sene ER nn 5 2 5 4 Suggested Preventive Maintenance Schedule 5 2 5 5 Service Procedures and Adjustments 5 3 SS editat iaio 5 3 5 5 2 Power Supply Test Points 5 3 5 5 3 Setup of the Signal Processing Front End Amplifier 5 3 5 5 4 Oscilloscope Display of the to E Converter Output 5 4 5 5 5 Balancing the Optics for Equal Light Transmission with Zero Fluid in the Sample Cell 5 5 5 5 6 Setup of the Logarithmic Amplifier 5 6 5 5 7 Inverting ala plane 5 6 5 5 8 Integrated Reference and Measuring Signals 5 7 5 5 9 Battery Powered Oscilloscope Synchronization Point 5 7 5 6 Interface Board Terminal Strip 5 7 ii Part Il e Teledyne Analytical Instruments Part Il Analysis Unit Appendix A T utopia A 1 A 2 Recommended 2 Year Spare Parts List A 4 Drawing Listini A 5 Teledyne Analytical Instruments Part 11 iii Model 5000B Photometric Analyzer iv Part Il 49 Teledyne Analytical Instruments Operations Analysis Unit 4 4 0 Operations Before shipment TAI calibrates the analyzer for your application when feasible Calibration data is listed in the Appendix Prior to calibration TAI checks the electronics of the analyzer an
2. Teledyne Analytical Instruments Part Il 5 5 5 Maintenance Model 5000B Photometric Analyzer 7 After the peaks are balanced adjust the gain control until the tallest of the two peaks is 8 to 9 volts The peaks should still be within volt of each other 8 Itisalways good practice to operate the analyzer with as low a gain as possible Therefore with the gain control just barely offits stop once againremove or add screens in the light path to obtain as high a voltage as possible without exceeding 9 volts for the highest peak Read just gain for 8 to 9 volts This concludes the balancing procedure and the instrument is ready for calibration 5 5 6 Setup of the Logarithmic Amplifier The amplifier is inverting and continuously taking the logarithm of the output signal of the second amplifier You can observe the output by connecting the scope probe to TP4 The correct wave shape has a rounded negative going pulse that is the signal and a flat topped positive pulse that depicts saturation of the log amplifier You should not permit distortions or oscillations in the rounded peaks When the positive going pulse is not flat oris distorted adjust trimpot R3 only enough to obtain a flat positive pulse If you over adjust you may lose part of the second decade of absorption and affect the accuracy of analysis for high concentrations of the component of interest where the measuring pulse can become very short The log amplifier
3. Switch P Ref Peak Detector 1 AGC Control Signal tenente Manual Fine Zero y A Manual Span Adjustment E404 la Ho E gt Converter Converter Alarms Canoa Analysis Section 4 Control Section Sample Zero Control lt 4 Ae Auto Signal Zero Figure 4 2 Analyzer System Block Diagram 4 20 x Voltage Signal Output Meter Indication Current Signal Output que TeledyneAnalyticalInstruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 915 Coarse E d gt Zero 0 log Amplifier 2 Control 9 8 El MEAS E _ FE gt lo Meter Driver LL Power 115 VAC to Se mo line Voltage Module mt Regulator 115 VAC t Si 5 Tansformer 4 gt Detector Module 115 VAC 60 Hz Input Preheater Themistor Emp and Heater Control Sample gt Module lt Themistor mp and Heater Control Detector ls Module Themistor Temp and Heater Control Figure 4 3 Power Module Block Diagram que TeledyneAnalyticalInstruments 4 21 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit 4 4 3 Power See Figure 4 3 The power to the analyzer unit enables the switching functions and temperature control for the detector compartment With the microprocessor c
4. Ranges whose limits are entirely within the span of an adjoining range Ranges where the zero is suppressed is 1 10 1 100 etc however 80 100 90 100 is ok where the zero fluid is actually 100 concentration and the calibration is inverted 3 26 Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 Figure 3 2 Examples of Autoranging Schemes Teledyne Analytical Instruments Partl 3 27 3 Operation Control Unit Model 5000B 3 7 The Analyze Function Normally all of the functions automatically switch back to the Analyze function when they have completed their assigned operations Pressing the Escape button in many cases also switches the analyzer back to the Analyze function Alternatively you can press the Analyze button at any time to return to analyzing your sample The Analyze function screen shows the impurity concentration and the application fluides in the first line and the range in the second line In the lower right corner the abbreviation Anlz indicates that the analyzer is in the Analyze mode If there is an before the Anlz it indicates that the range is linearized 1 95 ppm S02 R1 0 10 Anlz If the concentration detected is overrange the first line of the display blinks continuously 3 8 Programming CAUTION The programming functions of the Set Range and Curve Algorithm screens are configured at the factory to the users application specification The
5. scale setting until amplifier saturation is reached Below amplifier saturation the overrange readings are accurate UNLESS the application uses linearization over the selectedrange To program the ranges you must first perform the four steps indicated at the beginning of section 3 8 Programming You will then be in the second System menu screen ALGORITHM APPLICATION MORE OUTPUT 4MA Use the lt gt arrow keys again to move the blinking to APPLICATION and press Enter Sel rng to set appl 01 02 03 CAL lt Use the DN arrow keys to increment decrement the range number to 01 02 03 or CAL and press Enter Fluid Name Me oe sk ste se te oko a K ok FR TO 10 Use the arrow keys to move to Fluid Name FR from lower end of range TO to upper end of range and PPM or Use the DN arrow keys to increment the respective parameters as desired Press Enter to accept the values and return to Analyze mode See note below Repeat for each range you want to set Note The ranges must be increasing from low to high for example if Range 1 is set to 0 10 and Range 2 is set to 0 100 then Range 3 cannot be set to 0 50 since that makes Range 3 lower than Range 2 Ranges alarms and spans are always set in either percent or ppm units as selected by the operator even though all concentration data outputs change from ppm to percent when the concentration is above 9999 ppm Note When performing analy
6. 1 7 1 Introduction Model 5000B Alphanumeric Interface Screen The backlit VFD screen is an easy to use interface between operator and analyzer It displays values options and messages for immediate feedback to the operator 1 5 Control Section Interface Panel The Control Section interface panel shown in Figure 1 2 contains the electrical terminal blocks for external inputs and outputs The input output functions are described briefly here and in detail in the Installation chapter of this manual e Power Connection Analog Outputs e Alarm Connections e RS 232 Port e Remote Bench Remote Span Zero e Calibration Contact Range ID Contacts e Network I O AC power source 115VAC 50 60 Hz 0 1 V dc concentration and 0 1 V de range ID Isolated 4 20 mA dc and 4 20 mA dc range ID 2 concentration alarms and 1 system alarm Serial digital concentration signal output and control input Provides all electrical interconnect to the Analysis Section Digital inputs allow external control of analyzer calibration To notify external equipment that instrument is being calibrated and readings are not monitoring sample Four separate dedicated range relay contacts Serial digital communications for local network access For future expansion Not implemented at this printing Note If you require highly accurate Auto Cal timing use external Auto Cal control where possible The internal clock
7. OPERATING INSTRUCTIONS Model 5000B Photometric Analyzer AN 1 lesa L Ir Il Es US TT ns Q E LA HIGHLY TOXIC AND OR FLAMMABLE LIQUIDS OR GASES MAY BE PRESENT IN THIS MONITORING SYSTEM PERSONAL PROTECTIVE EQUIPMENT MAY BE REQUIRED VVHEN SERVICING THIS SYSTEM HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FORA 5 TIME EVENAFTER THE POWERIS TURNED OFF AND DISCONNECTED ONLY AUTHORIZED PERSONNEL SHOULD CONDUCT MAINTENANCE AND OR SERVICING BEFORE CONDUCTINGANY MAINTENANCE OR SERVICING CONSULT WITH AUTHORIZED SUPERVISOR MANAGER 1 1 02 2006 Teledyne Analytical Instruments Model 5000B Copyright 1999 Teledyne Analytical Instruments Rights Reserved No part of this manual may be reproduced transmitted transcribed stored in a retrieval system or translated into any other language or computer language in whole or in part in any form or by any means whether it be electronic mechanical magnetic optical manual or otherwise without the prior written consent of Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Warranty This equipment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction and that our
8. 3 Operation Control Unit Model 5000B This function andthe TRACK HOLD feature will prevent false alarms while performing remote or autoscheduled calibrations These functions are not applicable if the calibration is initiated through the front panel To enter the Calibration Hold Timer function you must 1 Press the System key to start the System function DIG_FILT SELF TEST PWD LOGOUT MORE 2 Using the Right or Left arrow keys select and press Enter The Second System screen appears AUTOCAL FILSOL TRACK CAL HOLD TIMER MORE or AUTOCAL FILSOL HOLD CAL HOLD TIMER MORE 3 Select with the Right or Left keys CAL HOLD TIMER and press the Enter key to access this function menu Calbrt hold 3 min Sample hold 1 min The calibration hold time is set on the first row while the sample hold time is set on the second row To select one or the other use the Right or Left keys To modify the time of either timer use the Up or Down keys The time is in the minutes 3 3 11 Analog 4 to 20 mA Output Calibration This function will let the operator calibrate the 4 to 20 mA analog output to match the display reading A DMM configure as a DC ammeter is needed The DMM should be connected across the output terminals of the 4 to 20 mA output to monitor the output current To enter the 4 to 20 mA output adjust function you must 1 Press the System key to start the System function DIG_FILT SELF TEST PWD LOGOUT MORE 2
9. 46 C As noted previously the filter wheel is driven by asynchronous AC chop per motor which operates at 1800 RPM The filter wheel performs two func tions 1 switching filters and 2 chopping the optical signal to give pulses whichcan be amplified for high quality processing 4 22 Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Part Il Maintenance Analysis Unit Maintenance 5 Maintenance 5 0 Routine Maintenance 5 1 Automatic operation and routine operational duties The system operates continuously without adjustment Under normal condi tions after you program the system for automatic operation only routine maintenance procedures are necessary The most common failure condition is a temporary interruption of the power serving the instrument Ifthe power service is interrupted the source lamp in the analyzer will restart automatically as long as there is no defect in the lamp circuit or its starter Youcan detect a lamp off condition with the signal failure alarm circuit but you mustconnect the relay contacts from the alarm to your indicating device In addition you willexperience an alarm condition when the cell windows are extremely dirty or the electronics fail in the detector converter log amplifier or inverter circuits When the alarm circuit is powered independently from the analyzer power source the alarm circuit is fail safe and will detect power failure A messag
10. Auto Mode Zeroing above It calculates the differences between successive samplings and displays the rate of change as Slope a value in parts per million per second ppm s HHL 802 Slope S Zero Generally you have a good zero when Slope is less than 0 05 ppm s for about 30 seconds Once zero settling completes the information is stored in the analyzer s memory and the instrument automatically returns to the Analyze mode 3 4 1 3 Cell Failure Detector failure in the 5000BF is usually associated with inability to zero the instrument with a reasonable voltage differential between the refer ence and measure voltages If this should ever happen the 5000BF system alarm trips and the LCD displays a failure message Detector cannot be balanced Check your zero fluid Before optical balancing a Check your zero fluid to make sure it is within specifications b Check for leaks downstream from the Sample Cell where con tamination may be leaking into the system c Check flowmeter to ensure that the flow is no more than 200 SCCM d Check temperature controller board e Check fluid temperature f Check the Sample Cell for dirty windows If none of the above proceed to perform an optical balance as described in section 5 3 18 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 3 4 2 Span Cal The Span function on the menu is used to span calibrate the analyzer Spa
11. LOGOUT Prevents an unauthorized tampering with analyzer settings AUTOCAL Set the automatic calibrated timer schedule for Zero and Span cycling FILSOL Select Span Zero flag filter or Span Zero solenoid valve for calibration method TRACK Set the system reading to be held or followed by the concentration fluid or filter during calibration CAL HOLD TIMER Set the timing for calibration holding and timing for the sample reading after return to analyze mode ALGORITHM Linearize the output for nonlinear characteristic APPLICATION Used to define the analysis ranges and application fluid used MODEL Displays model number and software version OUTPUT 4 20 MA Adjust 4 and 20 mA output SHOW_NEG Whether to display negative readings or not affects analog output too No negative readings is the default 3 3 1 Setting up an AUTO CAL When proper automatic valving is connected the Analyzer can cycle itself through a sequence of steps that automatically zero and span the instru ment 3 4 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 Note Before setting up an AUTO CAL be sure you understand the Zero and Span functions as described in section 4 4 and follow the precautions given there Note If you require highly accurate AUTO CAL timing use external AUTO CAL control where possible The internal clock in the Model 5000BF is accurate to 2 3 Accordingly internally sc
12. This is the Teledyne Analytical Instruments Part 3 21 3 Operation Control Unit Model 5000B offsetto be entered 4 Do a manual run to check Reintroduce the zero calibration fluid Start a zero on the analyser but this time enter the offset value 5 At the end of the zero function check that the instrument reads the entered offset 6 Reintroduce the process background fluid mix to the 5000BF sample cell in the Analyse mode It should read close to zero once the reading is stable 1 error of full scale Spanning the 5000 Since the instrument might be spanned with background fluid the same as the zero calibration fluid the span value to be entered should be the span concentration plus the offset value if the offset value has a minus sign then algebraically itbecomes a subtraction 3 5 The A arms Function The Model 5000BF is equipped with two fully adjustable set points concentration with two alarms and a system failure alarm relay Each alarm relay has a set of form C contacts rated for 3 amperes resistive load at 250 V ac See Figure in Chapter 2 Installation and or the Interconnection Dia gram included at the back of this manual for relay terminal connections The system failure alarm has a fixed configuration described in chapter 2 Installation The concentration alarms can be configured from the front panel as either high or low alarms by the operator The alarm modes can be set as latching or no
13. lt gt arrow keys again to move the blinking to the SELF TEST and press Enter The screen will follow the running of the diagnostic RUNNING DIAGNOSTIC Testing Preamp Cell When the testing is complete the results are displayed Power OK Analog OK Cell 2 Preamp 3 The module is functioning properly if it is followed by OK A number indicates a problem in a specific area of the instrument Refer to Chapter 5 Maintenance and Troubleshooting for number code information The results screen alternates for a time with Press Any Key To Continue Then the analyzer returns to the initial System screen Teledyne Analytical Instruments Part 3 9 3 Operation Control Unit Model 5000B 3 3 5 The Model Screen Move the lt gt arrow key to MORE and press Enter With MODEL blinking press Enter The screen displays the manufacturer model and software version information 3 3 6 Checking Linearity with ALGORITHM Fromthe System Function screen select ALGORITHM and press Enter sel rng to set algo gt 01 02 03 lt Use the lt gt keys to select the range 01 02 or 03 Then press Enter Fluid Use SO2 Range 10 Press Enter again Algorithm setup VERIFY SET UP Select and Enter VERIFY to check whether the linearization has been accomplished satisfactorily Dpt INPUT OUTPUT 0 00 0 00 The leftmost digit under Dpt is the number of the data point being monitored Use the DN key
14. manually Select span mode MANUAL Teledyne Analytical Instruments Part 3 19 3 Operation Control Unit Model 5000B Use the DN keys to toggle between AUTO and MAN span settling Stop when MAN appears blinking on the display Press Enterto move to the next screen Span Val 20 00 lt ENT gt To begin span Use the lt gt arrow keys to toggle between the span concentration value and the units field ppm Use the DN arrow keys change the value and or the units as necessary When you have set the concentration of the span fluid you are using press Enter to begin the Span calibration Press Enter to enter the span value into the system and begin the span calibration Once the span has begun the microprocessor samples the output at a predetermined rate It calculates the difference between successive samplings and displays this difference as Slope on the screen It takes several seconds for the first Slope value to display Slope indicates rate of change of the Span reading Itis a sensitive indicator of stability HHHH HH Co S02 Slope Span When the Span value displayed on the screen is sufficiently stable press Enter Generally when the Span reading changes by 1 or less of the range being calibrated for a period of ten minutes it is sufficiently stable Once Enter is pressed the Span reading changes to the correct value The instrument then automatically enters the Analyze function 3 4 3 Offse
15. 3 Checkthe solenoid valves 5 2 Part Teledyne Analytical Instruments Part Il Maintenance Analysis Unit Maintenance 5 5 5 Service Procedures and Adjustments 5 5 1 Electronics TAI aligns the system s electronics However you may need to touch up the circuitry using the following procedure Equipment Required Oscilloscope dual trace is preferred but not required To observe oscilloscope test points switch the vertical input selector of the scope to DC Switch to AC to observe the demodulator switch signals DVM Digital Voltmeter PC Board Extender Use the PC board extender whenever you need to adjust trimpot Because all PC board connectors are keyed to avoid wrong positioning in the connectors you must remove the key and after testing you need to replace the key with long nosed pliers Turn off the power during this operation Never disconnect or connect the PC boards with the power on because you may damage the PC board C MOS devices 5 5 2 Power Supply Test Points Measure 15 volt 1 volt DC and 15 volt 1 volt DC on the differential power supply PC board in the control unit Refer to the power supply schematic in the back of the manual to identify the power supply test points 5 5 3 Setup of the Signal Processing Front End Amplifiers the sample cell with air ora stable fluid such that the photo energy that strikes the detector is constant A stable fluid is distilled or tap water This step may
16. 4 to 20 mA output is tied to the 0 to 1 volt output this function can be used to calibrate the 0 to 1 volt output if the 4 to 20 mA output is not used By using a digital Volt meter on the 0 1 Volt output 3 3 12 Model This selection in the System menu flashes for a few seconds the model number and the software version installed in this instrument Teledyne Analytical Instruments Partl 3 15 3 Operation Control Unit Model 5000B 3 3 13 Show Negative The analyzer defaults to not to show negative readings on the analyze mode only This affects the analog outputs too by pressing the UP or DOWN key the analyzer can be set to display negative readings on the SHOW NEG field of thesystem menu 3 4 The Zero and Span Functions The Model 5000BF can have as many as three analysis ranges plus a special calibration range Cal Range Calibrating any one of the ranges will automatically calibrate the other ranges CAUTION Always allow 4 5 hours warm up time before calibrating if your analyzer has been disconnected from its power source This does not apply if the analyzer was plugged in but was in STANDBY The analyzer is calibrated using zero and span fluides Note Shut off the fluid pressure before connecting it to the analyzer and be sure to limit pressure to 40 psig or less when turning it back on Readjust the fluid pressure into the analyzer until the flowrate through the Sample Cell settles between 50 to 200 cc min appr
17. Using the Right or Left arrow keys select and press Enter The second System screen appears AUTOCAL FILSOL TRACK CAL HOLD TIMER MORE 3 14 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 or AUTOCALFILSOL HOLD CAL HOLD TIMER MORE 3 Using the Right or the Left arrow keys select MORE and press Enter The third System screen appears ALGORITHM APPLICATION MODEL OUTPUT 4MA Or ALGORITHM APPLICATION MODEL OUTPUT 20 MA OUTPUT 4 MA and OUTPUT 20 MA can be toggled by moving on that field and pressing the Up or Down key 4 mA output should be calibrat ed first and 20 mA output afterwards 4 Select OUTPUT 4 MA and press the Enter key Use UP DOWN arrow to Adjust 4 ma 250 The number on the second row is the setpoint of the 4 mA output It is analogous to a potentiometer wiper The number can be set anywhere from 0 to 500 The default is 250 in the middle At the default setting the output should be very close to 4 mA If not slowly adjust the number using the Up or the Down keys until DMM reads 4 00 mA Press the Enter key when done Now select OUTPUT 20 MA and press Enter key screen similar to the one above will appear and the DMM should read close to 20 mA If not slowly adjust the number using the Up or Down key until DMM reads 20 0 mA Press the Enter key when done The range of adjustment is approximately 10 of scale 1 6 ma Since the
18. Value selected Enters the value into the analyzer as data Advances cursor on to the nextoperation In the Analyze mode it calls the main menue Functions called out by the main menue System This function is a menu that calls a number of functions that regulate the analyzer Operation Span This function spans the instrument Zero This function zeros the instrument Alarms This functions sets the alarm preferences 1 6 Partl Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit Range Thisfunctionselectswhetheranalyzeris autoranging or locked on one range Standby Places the analyzer in a sleep mode WARNING The power cable must be disconnected to fully remove power from the instrument Em N a 9 eer N Rae 1111 n H aE imm n L i E a Q 5 Q Figure 1 1 Model 5000B Controls Indicators and Connectors Digital Meter Display The meter display is a Light Emitting Diode LED device that produces large bright 7 segment numbers that are legible in any lighting It is accurate across all analysis ranges The 5000B models produce continuous readout from 0 10 000 ppm and then switch to continuous percent readout from 1 100 Teledyne Analytical Instruments Part
19. a possibility that your sample stream may have some background materials not in the makeup of the calibration fluid 13 From time to time re check the zero setting If it is found that there is no zero drift re checking the zero setting may become unnecessary or may be performed only on an occasional basis 14 Some optical filters used in some applications will be so temperature sensitive that screening must be performed with the filters near the operating temperature DIRECTIONS FOR USING TELEDYNE CALIBRATION OPTIONS FOR ON LINE PROCESS PHOTOMETRIC ANALYZERS General These calibration options consists of procedures for calibrating analyzers on line These techniques are offered when process conditions high pressures temperatures sample phase changes are extremely difficult to deal with and calibration standards are impossible difficult to obtain are too expensive to use due to volume consumption into the system are unstable or are difficult to introduce into the analyzer or sample system because of toxicity pressure etc Also many times the sample stream composition is difficult to match with a calibration fluid In one case an optical absorbing filter s is inserted into the light path of the analyzer The absorber is actuated by a switch s located on the readout panel of the control unit The option functions by pre senting a calibrated and reproducible absorbance or fluid into the light path of the analyzer que Teledyn
20. be configured as high actuates when concentration is above threshold or low actuates when concentration is below thresh old e Can be configured as fail safe or non fail safe e Can be configured as latching or nonlatching e Can be configured out defeated Can be configured as high actuates when concen tration is above threshold or low actuates when concentration is below threshold e Can be configured as fail safe or non fail safe Can be configured as latching or nonlatching e Can be configured out defeated Actuates when DC power supplied to circuits is unacceptable in one or more parameters Permanently configured as fail safe and latching Cannot be de feated Actuates if self test fails To reset a System Alarm during installation discon nect power to the instrument and then reconnect it Further detail can be found in chapter 3 section 3 5 Digital Remote Cal Inputs Remote Zero and Span Inputs The REMOTE SPAN and RE MOTE ZERO inputs are on the DIGITAL INPUT terminal block They 2 6 Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit accept 0 V OFF or 24 V dc ON for remote control of calibration See Remote Calibration Protocol below Zero Floating input 5 to 24 V input across the and terminals puts the analyzer into the ZERO mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows ZERO mode
21. be omitted when the system is stable in its present state Teledyne Analytical Instruments Part Il 5 3 5 Maintenance Model 5000B Photometric Analyzer If you open the detector module keep stray light out by covering the opening with a dense black cloth If you do not take this precaution the result is a misinterpretation of the scope patterns On general purpose systems the scope test points are in the bottom of the detector module and are accessible withoutopening the module 5 5 4 Oscilloscope Display of the I to E Converter Output The output of the I to E Converter is observed at the output of the second amplifier The objective of this operation 1s to set up the optical system and the gain of the second amplifier in such a way that the analyzer keeps operating within 1ts dynamic range Connect the oscilloscope to TP3 The oscilloscope displaysthe measur ing and reference pulses in an alternating pattern The display is created by the light passing through the reference and measuring filters as they are brought in and out of the light beam by the rotating filter wheel These light pulses are converted to electronic energy which is amplified and brought to TP2 The base line represents the blocking of the light beam by the opaque part of the filter wheel To identify which of the pulses is the measuring peak insert the span filter when present ora piece of flat glass or clear plastic in the light beam The peak that bec
22. for ordering information To enter data From the System Functions Screen 1 Use lt gt to select ALGORITHM and Enter 2 Select and Enter SETUP 3 Enter MANUAL from the Calibration Mode Select screen Dpt INPUT OUTPUT 0 00 0 00 The data entry screen resembles the verify screen but the fluid values can be modified and the data point number cannot Use the lt gt keys to toggle between the INPUT and OUTPUT fields Use the D keys to set the value for the lowest concentration into the first point Then press Enter After each point is entered the data point number increments to the next point Moving from the lowest to the highest concentration use the DN keys to set the proper values at each point Dpt INPUT OUTPUT 0 0 00 0 00 Teledyne Analytical Instruments Partl 3 31 3 Operation Control Unit Model 5000B Repeat the above procedure for each of the data points you are setting up to nine points 0 8 Set the points in unit increments Do not skip numbers The linearizer will automatically adjust for the number of points entered When you are done Press ESCAPE The message Completed Wait for calculation appears briefly and then the main System screen returns Toendthe session send st lt enter gt st lt enter gt to the analyzer from the computer 3 8 2 2 Auto Mode Linearization To linearize in the Auto Mode you must have on hand a separate calibration fluid for each of the data points you
23. in back of this manual for details 4 4 Part Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 5000B Photometric Analyzer Part ll Analysis Unit NEC or ATEX Type 5000 GP Rack Panel Integral or Remote 5000 GP Bulkhead Z Purged in Div Il or Zone 2 areas I II B C D Integral 5000B X Purged 1 1 B C D Integral 5000B Purged Zone 1 Integral Teledyne Analytical Instruments Model 5000B Photometric Analyzer Table of Contents 4 OperationalTheory 4 0 O e ia M 4 1 4 1 Control Function al died 4 2 4 1 1 Analysis SECUON sd 4 2 4 1 2 Explosion Proof Version Control Module 4 2 4 22 Stat UE Sco ture bett adi as 4 3 4 2 1 Preliminary Inspection 4 3 4 2 2 Pre Start Up Electrical Checkout 4 4 4 2 3 Power On Observations 4 4 amp 8 SC QUAL One a met 4 6 4 4 Operational Theory Continued 4 17 4 4 1 Source ModuUle ii 4 17 4 4 2 Sample iii 4 19 dd ga OW OE oe oto dut nA 4 22 4 4 4 Detector 4 22 5 Routine Maintenance 5 0 Routine Maintenance oerte ncs 5 1 5 1 Automatic Operation and Routine Operational Duties 5 1 5 2 System Visual Check and Response Procedure 5 1 5 3 Routine
24. liability shall be limited to replacing or repairing at our factory without charge except for transportation or at customer plant at our option any material or construction in which defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements provide for a shorter period Components manufactured by others bear the warranty of their manufacturer This warranty does not cover defects caused by wear accident misuse neglect or repairs other than those performed by Teledyne or an autho rized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the instrument or its interface with the process being measured be properly trained in the process itself as well as all instrumen tati
25. of the radiation between the source and the detector modules Each com pound in the sample path exhibits its own characteristic absorption spectrum Cell spacer thicknesses will vary depending upon the absorbance of the compo nent of interest at the measuring wavelength Due to the possible variation of absorption with temperature itis either necessary to maintain the sample ata constant temperature during analysis or to compensate for the minor frequency shifts of the water bonding which can change due to sample temperature varia tions To achieve this two separate methods of temperature control are em ployed for constant temperature control 1 A preheater heat exchanger coil is used on the incoming sample stream to raise or lower it to the desired temperature controlled level que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit 2 Theentire sample module is separately controlled to maintain the sample temperature during analysis 3 The sample is temperature compensated for by software while inputing the temperture value at the sample cell Control Signals to M Co i Tea switch Electronic Switch and aa cn Position Sensor Driver Peak Detectors Manual Peak 20 Balance v Y Electrical Signal PIS Electronic from Detector amp pes gt Signal
26. representative of the sample fluid incomposition like the zero fluid and contain a measured quantity of the component of interest The component of interest content of the fluid should be in the region of 75 to 100 of the range of measurement As with the zero fluid the accuracy of the system is dependent upon the your knowledge of the span fluid composition Ideally the span sample should contain at least 75 of whatever the instrumentis set up to analyze Procedure Introduce zero fluid see above into the sample cell Flow liquid samples into the cell at a flow rate of about 50 cc minute to allow the sample to completely flush to a steady state concentration Make certain that bubbles are not introduced or formed in the cell Some back pressure may help avoid this Gas samples can be introduced at about 200 500 cc minute The digital meter should be capable of adjusting the zero level to an on scale reading Consult section for zero functioning If the reading cannot be adjusted then the signals will require rebalancing for your particular process fluid The filter wheel located inside the detector module must be removed and balanced optically with screens See section b Ifthe measuring peak is so far out of balance with the reference peak that it can no longer be adjusted with potentiometer R3 the optical filters require re screening If the analyzer has been in use for some time it is possible that the sample cell w
27. shut the instrument off By entering LOGOUT you effectively log off the instrument leaving the system protected against use until the password is reentered To log out press the System button to enter the System function DIG_FILT SELF TEST PWD LOGOUT MORE Use the lt gt arrow keys to position the blinking over the LOGOUT function and press Enter to Log out The screen will display the message Protected until password entered 3 8 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 3 3 4 System Self Diagnostic Test The Model 5000BF has a built in self diagnostic testing routine Pre programmed signals are sent through the power supply output board preamp board and sensor circuit The return signal is analyzed and at the end of the test the status of each function is displayed on the screen either as OK as a number between 1 and 1024 See System Self Diagnostic Test in chapter 4 for number code If any of the functions fails the System Alarm is tripped Note The sensor will always show failed unless Zero fluid is present in the sampling cell at the time of the SELF TEST The self diagnostics are run automatically by the analyzer whenever the instrument is turned on but the test can also be run by the operator at will To initiate a self diagnostic test during operation Press the System button to start the System function DIG_FILT SELF TEST PWD LOGOUT MORE Use the
28. to terminate when done A synchronous signal must open and close the external zero valve appropriately See Remote Probe Connector at end of section 3 3 With the C option the internal valves automati cally operate synchronously Span Floating input 5 to 24 V input across the and terminals puts the analyzer into the SPAN mode Either side may be grounded at the source of the signal 0 to 1 volt across the terminals allows SPAN mode to terminate when done A synchronous signal must open and close the external span valve appropriately See Remote Probe Connector at end of section 3 3 With the C option the internal valves automati cally operate synchronously Cal Contact This relay contact is closed while analyzer is spanning and or zeroing See Remote Calibration Protocol below Remote Calibration Protocol To properly time the Digital Remote Cal Inputs to the Model 5000B Analyzer the customer s controller must monitor the Cal Relay Contact When the contact is OPEN the analyzer is analyzing the Remote Cal Inputs are being polled and a zero or span command can be sent When the contact is CLOSED the analyzer is already calibrating It will ignore your request to calibrate and it will not remember that request Once a zero or span command is sent and acknowledged contact closes release it If the command is continued until after the zero or span is complete the calibration will repeat and the Cal Relay Conta
29. void the instrument performance should they interfere particulates assumed none If compounds are found present such as moisture acid gases or corrosive solvents etc the sample system materials may be compromised for corrosion resistance integrity We assume that the sample will not polymerize clog or react in any 1 4 sample line filter or sample cell when transporting through the sample systems for all inlet ambient or sample pressures and temperatures from takeoff or derived from sample conditioning Special materials may be required for stability corrosion protection coalesc ing filtering hazardous protection or due to heating or cooling We recommend when ambient temperatures exceed outside a 1 50 C range that the instrument and sample system be conditioned appropriately for heating cooling without condensation crystallizing coating polymerization etc Should the general purpose or explosion proof instrument be supplied on a back panel or as a bulk mount housing the customer must install to protect the instrument to meet harsh ambient conditions for dust water snow wind corrosion etc Teledyne is not responsible for applying a general purpose instrument in a hazardous area or where a flammable or toxic gas or liquid is brought to an analyzer above its lower explosive limit and the area has been classified as general purpose and safe The internal calibration features using optical filters are optimized and used when the
30. whether or not a password has been previously installed Enter password TAI or Enter password AAA The screen prompts you to enter the current password If you are not using password protection press Enter to accept TAl as the default pass word If a password has been previously installed enter the password using the lt gt arrow keys to scroll back and forth between letters and the D 3 6 Partl Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 arrow keys to change the letters to the proper password Press Enter to enter the password In a few seconds you will be given the opportunity to change this pass word or keep it and go on Change Password lt ENT gt Yes lt ESC gt No Press Escape to move on or proceed as in Changing the Password below 3 3 2 2 Installing or Changing the Password If you want to install a password or change an existing password proceed as above in Entering the Password When you are given the oppor tunity to change the password Change Password lt ENT gt Yes lt ESC gt No Press Enter to change the password either the default TAI or the previously assigned password or press Escape to keep the existing pass word and move on If you chose Enter to change the password the password assignment screen appears Select new password TAI Enter the password using the lt gt arrow keys to move back and forth between the existing pass
31. 2 on the detector PC board When this cannot be done because both peaks are too short or too long search for screens mounted in the light path usually located inaholder on the light pipe which interconnects the detector and sample module and remove or add screens as necessary 2 When balancing is needed identify the peaks as outlined under Section di For example if the reference peak is the shorter one stop the filter wheel with your hand and see if screens are located behind the reference filter The reference filter is identified by the letter engraved on the filter wheel 4 If screens are found remove them after taking the filter wheel off the shaft with the special Allen wrench supplied in the tool kit 5 Afterremoval of the screens and remounting the filter mount the filter wheel back on the shaft Position it correctly on the shaft by lining up the two paint marks on shaft and wheel 6 Turn on the instrument and observe the balance on the oscillo scope a Ifthe reference peakis now too tall remove the filter wheel and add a screen of lesser density behind the reference filter Repeat this procedure until the peaks are within 1 volt of each other b Ifthe measuring peak is equal to or within 1 voltofthereference peak the system is optically balanced and ready for calibration If the peak is still too short repeat the procedure but thistime put a screen behind the measuring filter to shorten its peak
32. 57 Fuse 5A Slo Blo 5 F 14 Fuse 10A Slo Blo 1 D3 PbS detector standard 2 C128 Sample Cell Window sapphire 1 16776 Accessory Kit 2 F1268 Fuse 6 3 A Fast blo 1 F1092 Filter 1 9 WB 1 F850 Filter 1 94 NB H2O in Acetic Acid etc 1 F1216 Filter 1 90 NB H20 in EDC etc Note Orders for replacement parts should include the part number if available and the model and serial number of the instrument for which the parts are intended Orders should be sent to TELEDYNE Analytical Instruments A 4 Teledyne Analytical Instruments Photometric Analyzer 5000B Appendix 16830 Chestnut Street City of Industry CA 91749 1580 Phone 626 934 1500 Fax 626 961 2538 TWX 910 584 1887 TDYANYL COID Web www teledyne ai com or your local representative A 3 Drawing List 5000B SEE MANUAL ADDENDUM OF Q FOR COMPLETE DRAWING LIST Teledyne Analytical Instruments A 5 Appendix Models 5000B A 6 Teledyne Analytical Instruments
33. Analyzer Part I Control Unit 0 3 0 4 0 5 0 6 0 7 0 8 0 9 10 1 0 O 0 tA A Q 8 8 10 4 12 0 13 6 15 2 16 8 18 4 20 0 To provide an indication of the range a second pair of analog output terminals are used They generate a steady preset voltage or current when using the current outputs to represent a particular range Table 2 2 gives the range ID output for each analysis range Table 2 2 Analog Range ID Output Example Range Voltage V Range 1 0 25 Range 2 0 50 Range 3 0 75 Alarm Relays Current mA 8 12 16 There are three alarm circuit connectors on the alarm relays block under RELAY OUTPUTS for making connections to internal alarm relay contacts Each provides a set of Form C contacts for each type of alarm Each has both normally open and normally closed contact connections The contact connections are indicated by diagrams on the rear panel They are capable of switching up to 3 ampers at 250 V AC into a resistive load Figure 2 6 Teledyne Analytical Instruments Part 2 5 1 Introduction Model 5000B Ya Normally closed Normally open Moving contact e Normally open e e Moving contact p THRESHOLD CE 1 D ALARM CONTACT 2 6 Types of Relay Contacts The connectors are Threshold Alarm 1 Threshold Alarm 2 System Alarm e Can
34. Cenelec Purging functions 1 2 Typical Applications A few typical applications of the Model 5000B are WATERMONITORING Background Typical Range Acids including 0 4000 PPM Acetic Formic Sulfuric Acetaldehyde 0 1000 PPM Air 0 2 Alcohols including 0 400 ppm Butanol Teledyne Analytical Instruments Part 1 1 1 Introduction Model 5000B Ethanol Isopropanol Methanol Alkanes including 0 500 ppm Heptane Hexane Ammonia 0 1000 ppm and up Aromatics including 0 500 ppm Benzene Cumene Toluene Xylene Chlorinated Hydrocarbons including 0 200 ppm Carbon Tetrachloride Ethyl Chloride Ethylene Dichloride Methyl Chloride Perchloroethylene Propylene Dichloride Trichloroethylene Vinyl Chloride Chloroprene 0 200 ppm Chloropicrin 0 200 ppm Deuterium Oxide 0 200 ppm Epichlorohydrin 0 2000 ppm Ethylene Glycol 0 500 ppm Freons 0 500 ppm Gasoline 0 500 ppm 1 2 Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit HydrogenFluoride 0 10 Hydroperoxides 0 5 Kerosene 0 500 ppm Ketones 0 1000 ppm Methyl Acetate 0 1000 ppm Methyl Methacrylate 0 1000 ppm Oils 0 1 Olefins 0 500 ppm Pentane 0 300 ppm o Picolene 0 300 ppm Phenol 0 1000 ppm Polyols 0 500 ppm Propylene Glycol 0 500 ppm Propylene Oxide 0 200 ppm Sulfinol 0 15 Sulfur Dioxide 0 1000 ppm Vinyl Acetate 0 2 NOTE Range may be higher or lower per application OTHER NIR ABSORBERS that can be
35. M SOS SERIES NI 0 or ppm H20 in solvents DESIGN BY ENGINEER 316SS VITONORKALREZ TEFLON MATERIALS SALES ORDER NO que Teledyne Analytical Instruments 4 15 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit ATTACHMENT 5000B 5020NIR ANALYZER Quote Exceptions and LIQUID PHASE Conditions for this application 1 Response Time is proportional to sample system design for take off distance process pressure line size sequencing and bypass by pass analyzer flow design dead volumes tee s sample cell volume and instrument electronics Maximum cell operation pressure to be 175 psig based upon standard Sapphire window cell design Higher pressures available The sample flow through the analyzer should be regulated to within 5 of its recommended absolute nominal set point flow value typically 20 60ccm This will avoid any pressure drops across any orifices or poor temperature control of the sample The temperature of the sample from the take off thorough the sample cell must be non freezing non crystallizing non coating as provided by customer The sample temperature should not vary at the inlet more than 15 C of the calibration temperature nor exceed the design operating specifications typically 5 45 C Assume sample below 45 C and requires no cooling Any background components later found to be present and not specified in the original application feasibility may
36. Range 1 0 5 Range 2 0 75 V Range 3 4 20 mA dc Range Currentincreases linearly with increasing sample concentration from 4 mA at 0 to 20 mA at full scale 100 Full scale 100 of programmed range Teledyne Analytical Instruments Part 2 3 1 Introduction Model 5000B 4 20 mA dc Range ID 8 mA Range 12 mA Range 2 16 mA Range 3 ANALOG OUTPUTS VOLTAGE CURRENT 1 Negative dress Floating ground e e e e Turn to hold ccw to N loosen wire Insert wire gt here 0 1 O P RANGE ID N 4 20MA O P RANGE ID Figure 2 5 Analog Output Connections Examples The analog output signal has a voltage which depends on the sample concentration AND the currently activated analysis range To relate the signal output to the actual concentration it 1s necessary to know what range the instrument is currently on especially when the analyzer is in the autoranging mode The signaloutput for concentration is linear over currently selected analysis range For example if the analyzer is set on a range that was defined as 0 10 then the output would be as shown in Table 2 1 Table 2 1 Analog Concentration Output Examples Concentration Voltage Signal Current Signal Output V dc Output MA dc 0 0 0 4 0 0 1 5 6 2 0 2 7 2 2 4 Partl Teledyne Analytical Instruments Photometric
37. _FILT SELF TEST PWD LOGOUT MORE 2 DIG_FILT will flash press the ENTER key Weight of digital Filter 9 S The number on the second row will flash and can be set by using the Up or Down arrow keys The settings go from zero no digital filtering to 10 maximum digital filtering The default setting is 8 and that should suffice for most applica tions In some applications where speeding the response time with some trade off in noise is of value the operator could decrease the number of the digital filter In applications where the signal is noisy the operator could switch to a higher number the response time is slowed down though 90 response time on the different settings to a step input is shown below This response time does not include the contributions of the bench sampling system and the preamplifier near the detector Setting 90 Response time seconds 0 4 5 1 4 5 2 5 0 3 5 0 4 5 5 5 7 0 Teledyne Analytical Instruments Part 3 11 3 Operation Control Unit Model 5000B 6 9 0 7 14 0 8 25 0 9 46 0 10 90 0 Atasetting of zero the response time is purely set by the electronics to 4 5 seconds The numbers above can and will change depending on application and they merely serve to illustrate the effectofthe digital filter 3 3 8 Filter or Solenoid Setup The 5000BF can be spanned or zeroed by calibration fluids or by optical filters The proper calibration method should be set at the factory To acc
38. alytical Instruments Part 3 5 3 Operation Control Unit Model 5000B 3 3 2 Password Protection Before a unique passwordis assigned the system assigns TAI by default This password will be displayed automatically The operator just presses the Enter key to be allowed total access to the instrument s features Ifapasswordis assigned then setting the following system parameters can be done only afterthe password is entered alarm setpoints assigning anew password range application selections and curve algorithm linearization APPLICATION and ALGORITHM are covered inthe programming section However the instrumentcan still be used for analysis or for initiating a self test withoutentering the password To defeat security the password must be changed backto TAI NOTE If you use password security it is advisable to keep a copy of the password in a separate safe location 3 3 2 1 Entering the Password To install a new password or change a previously installed password you must key in and ENTER the old password first If the default password is in effect pressing the ENTER button will enter the default TAI password for you Press System to enter the System mode DIG_FILT AUTO CAL PWD LOGOUT MORE Use the lt gt arrow keys to scroll the blinking over to PWD and press Enter to select the password function Either the default TAI password or AAA place holders for an existing password will appear on screen depend ing on
39. are going use in your linear ization First the analyzer is zeroed and spanned as usual Then each special calibration fluid for each of the intermediate calibration points is flowed in turn through the sensor As each fluid flows the differential value for that intermediate calibration point is entered from the front panel of the analyzer Note The span fluid used to span the analyzer must be gt 90 of the range being analyzed Before starting linearization perform a standard calibration See section 4 4 To enter data From the System Functions screen 1 Use lt gt to select ALGORITHM and Enter 2 Select and Enter SETUP 3 Enter AUTO from the Calibration Mode Select screen The Auto Linearize Mode data entry screen appears 19 5 ppm SO2 Input O 20 00 5 Use the DN keys to set the proper value of calibration fluid and Enter Repeat this step for each cal point number as it appears in the Input x parentheses 6 Repeat step 5 for each of the special calibration fluides from the lowest to the highest concentrations Press Escape when done To end the session send st lt enter gt st lt enter gt to the analyzer from the computer 3 32 Part Teledyne Analytical Instruments Part I Control Unit Analysis Unit Maintenance 3 Maintenance Aside from normal cleaning and checking for leaks at the gas connections routine maintenance is limited to replacing filter elements and fuses and re
40. ater on the 5020 meter or output Zero verified 85ppm water in TDI 85 ppm water as determined by Karl Fischer titration grab sample from process lab technique must be verified for precision sampling device Karl Fischer titrator and operator technique que Teledyne Analytical Instruments 4 13 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit or or 85 ppm simulated water using span flag on top of dry liquid TDI delta 80 ppm agreement on slope sensitivity 0 ppm water in N2 5 ppm water on the 5000B meter or output with zero flag offset intro 0 ppm water in N2 delta 80 ppm simulated sensitivity change of water Note the span flag checks the sensitivity change of the 5000B and not the zero drift of the analyzer The mole sieve dried TDI checks the zero of the instrument provided it can be reproduce the zero by consistently removing all the water to the same ppm level somewhere in the 2 10 ppm water range The long term efficiency of removing the water by mole sieve contact should be known for the customers process fluid otherwise the customer should have an acceptable off line lab technique to analyze prepared samples be fore intro into the 5020 field analyzer With Teledyne s approach using N2 as the dry background for both zero and span checks eliminates the concern of the mole sieve being saturated with time Indeed the N2 Nitrogen background approach can be used to verify th
41. calibration WARNING SEE WARNINGS ON THE TITLE PAGE OF THIS MANUAL 4 1 Fuse Replacement The 5000B requires two 5 x 20 mm 6 3 A F type Fast Blow fuses The fuses are located inside the main housing on the Electrical Connector Panel as shown in Figure 4 3 To replace a fuse 1 Disconnect the Unit from its power source 2 Place a small screwdriver in the notch in the fuse holder cap push in and rotate 1 4 turn The cap will pop out a few millimeters Pull out the fuse cap and fuse as shown in Figure 4 1 Teledyne Analytical Instruments Partl 4 1 3 Maintenance Model 5000B Photometric Analyzer 5 0 A MAX USE 250 V 6 3A F FUSE 2 1 Ss NO USER SERVICEABLE PARTS INSIDE SERVICE ONLY BY QUALIFIED PERSONNEL Figure 4 1 Removing Fuse Block Cap and Fuse from Housing 2 Replace fuse by reversing process in step 1 4 2 System Self Diagnostic Test NOTE Always run self diagnostic with the intended zero fluid 1 Press the System button to enter the system mode 2 Use the lt gt arrow keys to move to More and press Enter 3 Use the lt gt arrow keys to move to Self Test and press Enter The following failure codes apply Table 4 1 Self Test Failure Codes Power 0 OK 1 5 V Failure 2 15 V Failures 3 Both Failed Analog 0 OK 1 DAC 0 1 V Concentration 2 DAC 0 1 V Range ID 3 Both Failed 4 2 Part Teledyne Analytical Instr
42. ct CRC will close again Forexample 1 Test the CRC When the CRC is open Send a zero command until the CRC closes The CRC will quickly close 2 When the CRC closes remove the zero command 3 When CRC opens again send a span command until the CRC closes The CRC will quickly close 4 When the CRC closes remove the span command Teledyne Analytical Instruments Part 2 7 1 Introduction Model 5000B When CRC opens again zero and span are done and the sample is being analyzed Note The Remote Bench terminal strip section 3 6 Part III provides signals to ensure that the zero and span gas valves will be controlled synchronously Range ID Relays Four dedicated RANGE ID CONTACT relays The first four ranges are assigned to relays in ascending order Range is assigned to RANGE 1 ID Range 2 is assigned to RANGE 2 ID Range 3 is assigned to RANGE 3 ID and Range 4 is assigned to RANGE 4 ID Network I O A serial digital input output for local network protocol At this printing this port is not yet functional It is to be used in future versions of the instrument RS 232 Port The digital signal output is a standard RS 232 serial communications port used to connect the analyzer to a computer terminal or other digital device The pinouts are listed in Table 2 3 Table 2 3 RS 232 Signals RS 232 Sig RS 232 Pin Purpose DCD 1 Data Carrier Detect RD 2 Received Data TD 3 Transmitted Data DTR 4 Data Ter
43. d with continuous power supply monitoring RS 232 serial digital port for use with a computer or other digital communication device Analog outputs for concentration and range identification 0 1 V dc standard and isolated 4 20 mA dc Superioraccuracy Internal calibration Manual or Automatic optional Teledyne Analytical Instruments Part 1 5 1 Introduction Model 5000B 1 4 Operator Interface controls and displays on the standard 5000B are accessible from outside the housing The instrument has two simple operator controls The operator has constant feedback from the instrument through an alphanumeric display and a digital LED meter The displays and controls are described briefly here and in greater detail in chapter 3 See Figure 1 1 1 4 1 UP DOWN Switch The UP DOWN switch is used to select between any subfunctions displayed on the VFD screen such as in the main menue the system menue the Alarm menue etc When modifiable values are displayed on the the UP DOWN switch can be used to increment or decrement the values 1 4 2 ESCAPE ENTER Switch The ESCAPE ENTER switch is used to input the data to enter a function or to exit a function displayed in the alphanumeric display e Escape Moves VED display back to the previous screen in a series If none remains returns to Analyze mode screen e Enter Within a menue the funtion selected is entered moving on to the next screen in a series With
44. d makes all of the necessary internal printed circuit board adjustments Calibration is performed to determine the proper or close proximity zero and span settings and also to verify that the analyzer response is linear After calibration TAI makes a lengthy stability check to insure that the analyzer performs within all specifications We advise that you recalibrate your equipment as part of start up for the following reasons 1 During shipment it is possible that components have been jarred out of position or damaged 2 Your process may be of a proprietary nature Beyond checking electrical stability TAI is unable to make a meaningful calibra tion of the system requiring these adjustments to be made by you 3 Inothercases precise calibration from the original feasibility proposal may have determined field calibration of the analyzer connected to your process stream is required and accuracy will only be obtainable upon representatiive matching and use of the actual process fluid background components at the operating physical conditions of flow pressure and temperature of the sample In any case it is important that you calibrate the analyzer when it is first installed Zero checks should be made routinely once or twice a week and span calibration should be performed weekly at first and monthly after reproducibility is assured que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies 4 Opera
45. d wire extends outside of the terminal blocks Stripped wire ends must insert completely into terminal blocks No uninsulated wiring should come in contact with fingers tools or clothing during normal operation Primary Input Power The power supply in the Model 6600 will accept a 115 Vac 50 60 Hz power source See Figure 2 4 for detailed connections DANGER Power is applied to the instrument s circuitry as long as the instrument is connected to the power source The standby function switches power on or off to the displays and outputs only 2 2 Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit Ground e Neutral wo 1010 0 loosen wire Insert wire m here N G H Figure 2 4 Primary Input Power Connections 115VAC Fuse Installation The fuse holders accept 5 x 20 mm 4 0 A T type slow blow fuses Fuses are not installed at the factory Be sure to install the proper fuse as part of installation See Fuse Replacement in chapter 4 maintenance Analog Outputs There are eight DC output signal connectors on the ANALOG OUTPUTS terminal block There are two connectors per output with the polarity noted See Figure 2 5 The outputs are 0 1 V of Range Voltage rises linearly with increasing sample con centration from 0 V at 0 to 1 V at 100 Full scale 100 programmed range 0 1 V dc Range 0 25
46. dix Enclosure Purging Purge air startup 40 80 PSI 3 6 BAR 0 5 CFM 15 L min Purge optical path 15 30 PSI 1 2 BAR 10 cc min purity of Nitrogen 110 F 80 C dewpoint If ordered with purge option Other Features Three user selectable ranges Signal and Range ID output 0 1VDC and 4 20maDC isolated Programmable auto ranging Range ID contacts 3A 9 250VAC resistive Two adjustable concentration alarm set points with programmable relay function Form C contacts 3A 250VAC resistive Programmable auto calibration with mode ID Form A normally open contacts Remotely operated calibration customer supplied valves and 24 VDC signal application dependent Self diagnostics with Form C failure contacts Full duplex RS232 communication link Alphanumeric VF display for set up and diagnostics General Installation Note Protect the instrument from direct sunlight and rain Teledyne Analytical Instruments A 3 Appendix Models 5000B A 2 Recommended 2 Year Spare Parts List QtyP NDescription C 75825A Motherboard Control Unit C 67990 Amplifier Control Unit D 67990 5000B Interface PCB 1 A 9306 Differential Power Supply 1 C 40265A Measuring PCB 1 L323 UV LAMP 5000B 1 B77609 Parabolic Reflector Assy 1 B74423 Detector assy C78194 assy 1 C 14449 Temperature Controller Sample Cell 2 079 O Ring Teflon 2 022 O Ring Teflon 1 1233 Span Flag Solenoid new version 5 F
47. e the operator must 1 Press Systemkey to startthe System function DIG_FILT SELF TEST PWD LOGOUT MORE De Using the Right or Left arrow keys select MORE and press Enter The Second System screen appears AUTOCAL FILSOL TRACK CAL HOLDER TIMER MORE Or AUTOCAL FILSOL HOLD CAL HOLD TIMER MORE 3 The option on the right of the first row can be set to TRACK or HOLD by using the UP or Down keys By selecting the TRACK option the analog outputs are enabled and with the display will track the concentra tion changes while the instrument is undergoing scheduled or remote calibra tion either zero or span By selecting the HOLD option the analog outputs and display are disabled and will not track the concentration changes while the instrument is undergoing scheduled or remote calibration either zero or span In the HOLD option the analog outputs and display will freeze on the last reading before entering calibration The analog outputs are both 0 to 1 volt outputs and both 4 to 20 mA outputs 3 3 10 Calibration Hold Timer Setup This Calibration Timer lets the operator adjust the time thee instrument purges the calibration fluid prior to actually start the calibration computa tions The Sample timer lets the operator adjust the time the instrument purges sample fluid after finishing a calibration before it lets the analog outputs and display track the change in concentration Teledyne Analytical Instruments Partl 3 13
48. e Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 A zero may be established with a reproducible simulated offset zero absorbance fluid in the sample cell of the analyzer When possible this fluid should be stable for H2O content and should approximate the process being measured to minimize the offset zeroing otherwise dry air or nitrogen can be used The analyzer must first be calibrated for sensitivity full scale by using known certified analyzed samples containing the component analyte s to be measured NOTES These samples low mid high about 1 liter each must be prepared and provided for introduction into the zero and or span port of the sample system with outlet collected from the cal return port of the sample system A 500 to liter glass syringe with Luor loc to 1 4 tube connections should be used for introducing the samples into the analyzer sample cell for zero and span cal adjustments These are introduced through the calibration ports usually labelled zero or span fluid inlets The exiting samples when nontoxic are usually collected in waste containers from the cal return port of the instrument cabinet These cannot be used again as water vapor from containers and atmosphere will contaminate them They would require analysis again before reintroducing for correlation purposes Also its is a good practice to flush copiously the sampling train with each calibration sa
49. e inefficiency of the mole sieve saturation Teledyne prefers this approach using easily reproducible N2 since it is much simpler to flush out the sample cell and check the instrument provided the original calibration on TDI is used to set up the zero and span instruments of the optical filters See attached piping on how the appropriate valves are operated to switch in N2 in the reverse mode to provide a stable zero and or span check que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 Sample Return Nitrogen in dry purgeout Sample of cell when manually Flowmeter Calibration Return zeroing spanning 2 2 GPH Nitrogen in By Pass ZU Flowmeter Analyzer Pressure Relief 2 30 GPH enclosure purge Valve V 621 0 200ccm 1 Maximum inlet pressure Sample Temperature 175 psig 12 Bar A 5 Compensation 60 lt um VA Cell Fast loop and By Pass Filter zero and or span optical flags 5 microns for manual or auto calibration Sample in Span in Zero in ITEM PART NO DESCRIPTION TOLERANCE UNLESS THIS DRAWING IS THE PROPERTY OF TELEDYNE ANALYTICAL INSTRUMENTS AND CONTAINS CONFIDENTIAL OTHERWISE SPECIFIED INFORMATION IT IS NOT TO BE COPIED WITHOUT WRITTEN PERMISSION FRAC DEG ANGULAR DATE abusiness unit ofTeledyne Electronic Technologies 1 18 2001 INDUSTRY CALIFORNIA 91749 CUSTOMER MODEL Measurement s LIQUID SAMPLE SYSTE
50. e such as Cell Fail check the detector signal might be displayed ifa lamp off condition occurs 52 System Visual Check and Response Procedure 1 Verify that the signal failure alarm is notin failure condition 2 Verify that the zero and span control setting have notbeen disturbed Teledyne Analytical Instruments Part Il 5 1 5 Maintenance Model 5000B Photometric Analyzer 3 Verify thatthe chartrecorder contains anormal display 4 Verify that the recorder has a sufficient supply of chart paper and ink 5 3 Routine Maintenance Keep the sample lines and components including the measuring cell within the analyzer sample module free of deposits and leaks You must determine the interval between cleaning procedures empirically because the duration of time that the system runs without attention is related directly to the sample s condition 5 4 Suggested Preventive Maintenance Schedule DAILY 1 Visually inspect the complete system for obvious defects such as leaking tubes or connectors 2 Verify that the sample pump if applicable is running 3 Verify that the signal failure alarm is not in failure condition 4 Verify that zero and span settings are correct WEEKLY 1 Examine sample cell windows foraccumulation of solids Remove and clean as necessary 2 Calibrate the system ANNUALLY 1 Check the electronics calibration 2 Check the UV source NOTE Be sure to wear UV filtering eye goggles
51. ect MANUAL and press Enter Select range to run 01 02 03 CAL lt Use the lt gt keys to select the range 01 02 03 CAL Then press Enter Fluid use SO2 Range 10 Use the lt gt keys to toggle between the Range low end field and the Range high end field Use the DN keys to change the values of the fields Press Escape to return to the previous screen to select or define another range Press Enter to return the to the Analyze function 3 6 2 Auto Screen Autoranging will automatically set to the application that has at least two ranges setup with the same fluides In the autoranging mode the microprocessor automatically responds to concentration changes by switching ranges for optimum readout sensitivity If the upper limit of the operating range is reached the instrument automati cally shifts to the next higher range If the concentration falls to below 85 of full scale of the next lower range the instrument switches to the lower range A corresponding shift in the DC concentration output and in the range ID outputs will be noticed The autoranging feature can be overridden so that analog output stays on a fixed range regardless of the contaminant concentration detected If the concentration exceeds the upper limit of the range the DC output will saturate at 1 V de 20 mA at the current output However the digital readout and the RS 232 output of the concentra tion are unaffected by the
52. ed to selector switches in order to enable que Teledyne Analytical Instruments 4 17 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit direct meter indication which greatly eases the task of balancing the system during initial system installation and periods of calibration The DC voltage levels are fedto alogarithmicratio amplifier which pro duces a voltage output that is proportional to the logarithm of the ratio of the two DC input voltages This output voltage directly proportional to the concentration of sample is within certain limits a linear function of the concentration For purposes of transmission the voltage signal is converted by an E to I converter thus the output signal from the analysis unit is acurrent signal that is proportional to the concentration of sample in the sample module There is also an option of providing an automatic zero function see draw ing B 14729 in the control unit This circuit provides electrical signals for switching a fluid which contains none of the material to be measured into the sample module electrically adjusting the zeros and switching back to sample 4 4 1 Source Module The source module is the source of infrared energy This is provided through the use of a high intensity mini IR lamp or a quartz iodine lamp operating directly from a 5 0 volt stable supply or a 6 3 V transformer To ensure a stable source of radiation in the face of line voltage va
53. ermined factory calibration and was approximately set between 10 20 of the full scale range for the zero After the field on line calibration a zero offset value around a 10 20 meter range should be set using the potentiometer adjustment located within the analyzer control unit to bring it into the 10 20 range This may require a short term area declassification on explosion proof units in order to make this adjust ment The zero offset adjustment potentiometer is panel mount located within the control unit The potentiometer identified zero offset is adjusted while the reproducible zero fluid background is in the sample cell This zero check may be automatically or manually operated depending upon the sample system and electronic instrument design RECORD the zero calibration reading for future reference and agreement checks of the zero stability Note the instrument zero reading should typically be between 10 20 of full scale calibrated range chosen at the factory This reading should always repeat on nitrogen with the zero offset and or flag introduced If not readjust the instrument fine or coarse zero potentiometer s or microprocessor computer etc to read the correct concentration value known determined after the original on line process calibration Span calibration check after performing a process on line calibration After zero calibration above To check span on the analyzer immediately back flush out the proce
54. ess the Filter or Solenoid Flags you must 1 Press the System key to start the System function DIG_FILT SELF TEST PWD LOGOUT MORE 2 Using the Right or Left arrow keys select MORE and press Enter The second System screen appears AUTOCAL FILSOL TRACK CAL HOLD TIMER MORE 3 Select FILSOL using the Right or Left arrow keys and press Enter to start the method of calibration function Set fil sol for cal Span FIL Zero SOL There are two flag options zero and or span flags are choosen at time of purchase one for Zero calibration and the other for Span located in the Detector housing To move between the Zero and the Span flags use the Right or Left arrow keys FIL means that a filter will do this particular calibration SOL means that the signal to activate a fluid solenoid is enabled To toggle between the SOL and FIL options use the Up and Down arrow keys The connections to drive the filter and the solenoid are found on a strip terminal located on the interface board The connections are described in section 5 6 of the maintenance section of the manual 3 12 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 3 3 9 Hold Track Setup The 5000BF has ability to disable the analog outputs and freeze the display while undergoing ascheduled or remote calibration The 5000BF will track changesin the concentration if calibration is started through the front panel To setup this featur
55. esting the system This chapter covers installation ofthe Control Section Installation of the Analysis Section is covered in Part II of this manual 2 1 Unpacking the Control Analysis Unit The analyzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the Control Analysis Unit and inspect it for damage Immediately report any damage to the ship ping agent Figure 2 2 Required Front Door Clearance Allow clearance for the door to open in a 90 degree arc of radius 15 5 inches See Figure 2 2 n Figure 2 2 Required Front Door Clearance 2 Sa 2 2 Electrical Connections Figure 2 3 shows the Control Analysis Unit interface panel Connec tions for power communications and both digital and analog signal outputs are described in the following paragraphs Wire size and maximum length data appear in the Drawings at the back of this manual Teledyne Analytical Instruments Part 2 1 1 Introduction Model 5000B 9 ARA REMOTE SPAN 24V NETWORK s 1 115V 2990 58 5 4 ARR D vor ev eye RANGE ID RANGE Figure 2 3 Interface Panel of the Model 6600 Control Section For safe connections ensure that no uninsulate
56. fine Range Screen 3 24 30 2 AUTO OCN rio arca 3 25 3 6 3 Precautlofls 3 26 3 7 The Analyze Functions alain 3 28 9 85 Programming 2 53 EE sit EE Es 3 28 3 8 1 The Set Range Screen 3 29 3 8 2 The Curve Algorithm Screen 3 31 3 8 2 1 Manual Mode Linearization 3 31 3 8 2 2 Auto Mode Linearization 3 31 Maintenance 4 1 Fuse Replacement 4 1 4 2 System Self Diagnostic Test 4 2 4 3 Major Internal 4 3 Teledyne Analytical Instruments Part 1 iii Model 5000B Photometric Analyzer iv Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit Introduction 1 1 Overview The Teledyne Analytical Instruments Model 5000B Control Unit together with a 5000B Analysis Unit is versatile microprocessor based instrument Part I of this manual covers the Model 5000B General Purpose NEMA 4 Bulkhead Mount Control Unit The Analysis Unit is covered in Part II of this manual The Control Unit is for indoor outdoor use in a nonhazardous environment only The Control or Analysis Unit in the folded optics design can accomodate a variety of hazardous environments with either full explo sion proof housings or Z X Y or
57. fixed range They continue to read beyond the full scale setting until amplifier saturation is reached Below amplifier saturation the overrange readings are accurate UNLESS the application uses lineariza tion over the selected range Teledyne Analytical Instruments Partl 3 25 3 Operation Control Unit Model 5000B The concentration ranges can be redefined using the Range function Manual screen and the application fluides can be redefined using the System function if they are not already defined as necessary CAUTION Redefining applications or ranges might require relineariza tionand orrecalibration To setup automatic ranging Press Range key to start the Range function Select range mode AUTO If above screen displays use the DN arrow keys to Select AUTO and press Enter Press Escape to return to the previous Analyze Function 3 6 3 Precautions The Model 5000BF allows a great deal of flexibility in choosing ranges for automatic range switching However there are some pitfalls that are to be avoided Ranges that work well together are e Ranges that have the same lower limits but upper limits that differ by approximately an order of magnitude e Ranges whose upper limits coincide with the lower limits of the next higher range Ranges where there is a gap between the upper limit of the range and the lower limit of the next higher range Range schemes that are to be avoided include e Ranges that overlap
58. ge the parameter Once the parameters for alarm 1 have been set press Alarms again and repeat this procedure for alarm 2 AL2 e To reset a latched alarm go to Dft and then press either D two times or N two times Toggle it to Y and then back to N OR Go to Ltch and then press either D two times or N two times Toggle it to N and back to Y 3 6 The Range Select Function The Range function allows you to manually select the concentration range of analysis MANUAL or to select automatic range switching AUTO In the MANUAL screen you are further allowed to define the high and low concentration limits of each Range and select a single fixed range to run CAUTION If this is a linearized application the new range must be within the limits previously programmed using the System function if linearization is to apply throughout the range Furthermore if the limits are too small a part approx 10 96 or less ofthe originally linearized range the linearization will be compromised 3 6 1 Manual Select Define Range Screen The Manual range switching mode allows you to select a single fixed analysis range It then allows you to redefine the upper and lower limits for the range Press Range key to start the Range function 3 24 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 Select range mode MANUAL If above screen displays use the DN arrow keys to Sel
59. he same as the reference peak voltage 5 Turn the NORM ZERO switch to ZERO The analysis section meter should be made to read zero by adjusting the coarse ZERO control on the analysis section power module 6 Check the control module SPAN setting to make sure it agrees with the calibration results obtained by TAI see Specific Application Data in the Appendix 7 Adjust the ZERO control on the control module to give a zero reading on the control module meter 8 Add span fluid see Span Fluid above to the sample cell Make certain that all of the zero fluid is displaced 9 Adjust the control module SPAN control to obtain the correct meter reading with reference to the concentration of span fluid For example if the sample contains 100 of whatever the que Teledyne Analytical Instruments 4 1 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit I 4 8 instrument is set up to analyze then the SPA N control must be adjusted fora full scale reading i e 200 ppm waterinEDC 10 Re checkthe ZERO setting with zero fluid 11 If desired the linearity of the analyzer can be checked with a fluid intermediate in concentration between the zero and the span fluid 12 Theanalyzerisnow calibrated Itis often desirable to check calibration fine tune on a dynamic sample from your process double checking the 5020 analyzer response with laboratory analyzed grab samples This is desirable where there is
60. heduled calibrations can vary 2 3 per day To setup an Auto Cal cycle Choose System from the Function buttons TheVFD will display five subfunctions DIG_FILT SELF TEST PWD LOGOUT MORE Select MORE and press the Enter Key AUTOCAL FILSOL HOLD CAL HOLD TIMER MORE Use lt gt arrows to blink AUTO CAL and press Enter A new screen for ZERO SPAN set appears ZERO in 04 Qh off SPAN in d Press lt gt arrows to blink ZERO or SPAN then press Enter again You won t be able to set OFF to ON if a zero interval is entered A Span Every or Zero Every screen appears Zero schedule OFF Day 04 Hour h Use D arrows to set an interval value then use lt gt arrows to move to the start time value Use DN arrows to set a start time value To turn ON the SPAN and or ZERO cycles to activate AUTO CAL Press System again choose AUTO CAL and press Enter again When the ZERO SPAN values screen appears use the lt gt arrows to blink the ZERO or SPAN and press Enter to go to the next screen Use lt gt to select OFF ON field Use DN arrows to set the OFF ON field to ON You can now turn these fields ON because there is a nonzero span interval defined If instrument is turned off the next time the instrument is powered the instrument will automatically perform a calibration cycle after 3 minutes of entering the sample mode if AUTOCAL functions were on prior to shut down Teledyne An
61. her pulse is from the measuring filter while the alternate pulse is from the reference filter so that pulses through the measuring filter alternate with pulses through the reference filter A filter position sensor which is an optical device having an integral light source and light detector differentiates between the two The two entrained pulses received by the detector each revolution are amplified through a preamplifier which is physically located inside the sealed compartment with the filter wheel and detector This signal is then sent to a clamping circuit where an exact zero reference is established This clamped video signal is then fed through a gain control network which is controlled by the automatic gain control loop through another amplifier to the electronic switch This switch is controlled by the switch driver network which derives its information from the filter position sensor in order to separate the entrained video signal into its component parts of a measuring peak and a reference peak These peaks are then fed through a balancing network and channeled into separate peak height detectors which produce DC voltage levels which are exactly equal to the peak height or absolute magnitude of the voltage from the base to the peak of each of the pulses At this point the reference signal is fed back to the automatic gain control loop to maintain the desired system gain In addition both the mea suring and reference levels are f
62. ice or devices should be energized because the mode switch has been preset to the ZERO position 4 Ifthe test procedure was normal the devices should have been seen or heard to operate as described by personnel located at the analysis section installation site and no further check need be made at this time If operation is not as described refer to Troubleshooting in Chapter 5 0 5 Check analyzer operation by completing the calibration procedure described below in Calibration after allowing the instrument to warm up The electrical circuits take from 30 to 40 minutes to stabilize NOTE It will take at least four hours for the analyzer to completely stabilize with respect to temperature L S M 25 9 E Ed IS POD ll L Wa G pe peas eo eames aura Le que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies 4 5 4 Operations Analysis Unit 43 Calibration Standardization Fluids Two standardization fluids are necessary to calibrate the analyzer 1 ZeroFluid The zero standard fluid must have a composition similar to the sample and ideally contains none of the components of interest The zero fluid should be laboratory analyzed to determine its composition The exact composition must be known as the accuracy of the analysis can be no better than the knowledge of the standardization fluid Span Fluid The span fluid must be
63. ience when suppling photometric NIR analyzers for 0 100ppm water in solvents like EDC TDI benzene and the like the following can be incorporated for the customers pertinent solvent 1 Customer is responsible for introducing a reproducible dry zero fluid typically 75deg C dewpoint Nitrogen or reproducible dry EDC or TDI etc within 1 ppm H20 for accuracy of 1 full scale 2 When customer supplies a reproducible dry TDI zero fluid A span flag option is available to verify instrument full scale sensitivity This optical flag may be manually or automatically introduced into the light path within the temperature controlled within 1 deg C sample cell compartment This optical span flag when in this temperature stable environment simulates a very stable upscale ppm H20 reading on top of the DRY reproducible TDI zero background 3 Conversely a zero flag and or offset is manually or automatically switched into the light path of the analyzer after drying out the sample cell of process fluid Consult your manual for the factor calibration values obtained Actual concentration 5000 5020 series analyzer meter Zero check 5 ppm water TDI Sppm water in the 5020 meter or output Check or 0 ppm water in N2 Sppm water on the 5020 meter or output with zero flag offset introduction delta Oppm water or stability check on zero verified Span Check mole sieve or dried sample could be from process Sppm water in TDI Sppm w
64. in the Model 5000B is accurate to 2 3 Accordingly internally scheduled calibrations can vary 2 3 per day 1 8 Partl Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit 4 Teledyne Analytical Instruments DIGIIAL INPUL RELAY OUIPUIS 1 b o HO i o Da o Da Da Z Edo 3 BEN 9 ges Da Da RANGF2 RANGE 3 ZERO 24V o e o el e OOOO TE Pasta pepe e 115V NALOG OUTPUTS 3j 50 60 Hz 90009000 ns RR 2 3 0 A MAX USE 250 V 4 0 AT FUSE CAUTION 1 RISK OF ELECTRIC SHOCK 1 DO NOT OPEN NO USER SERVICEABLE PARTS INSIDE SERVICE ONLY BY QUALIFIED PERSONNEL Figure 1 2 Model 5000B Interface Panel Teledyne Analytical Instruments Part 1 9 1 Introduction Model 5000B 1 10 Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit Installation Installation of Model 5000B Analyzers includes 1 Unpacking mounting and interconnecting the Control Analysis Section 2 Making gas connections to the system 3 Making electrical connections to the system 4 T
65. in the control module should be positioned as follows Analyzers not equipped with Auto Zero 1 ON OFF functionality hardwired at customers remote terminal block or power switch 2 SPAN control preset to the setting noted in Specific Application Data in the Appendix Analyzers equipped with Auto Zero 1 ON OFF functionality hardwired at customers remote terminal block or power switch 2 SAMPLE ZERO switch on ZERO 3 SPAN control preset to the setting noted in Specific Application Data in the Appendix que Teledyne Analytical Instruments 4 3 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit 4 2 2 Pre Start up Electrical Checkout Afterthe preliminary procedures have been accomplished referto Prelimi nary Inspection and Control Settings above the integrity of the system inter connection and the power sources must be verified before attempting the analyti cal start up procedures The observations and measurements described in the following paragraphs are vital to the operation of the analyzer If the analyzer does not respond as described the equipment has been damaged in shipment or installation or the user installed wiring is in error Ifa problem arises correct it before proceeding further The following procedures should be employed in the same sequence in which they appear 4 2 3 Power On Observations Turn both the analysis control module at the remote wiring panel of custome
66. indows need cleaning or that a filter has deteriorated Another cause of peak imbalance might be that the sample que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 chemical background has changed In some cases TAI is not able to duplicate the background your sample for purposes of optically balancing the analyzer before shipment In these cases it is necessary for you to screen for an approximate balance and to then electronically adjust R3 for precise balance To do so 1 Reset R3 to its midpoint 2 Re screen the filter wheel as necessary to obtain a measuring voltage within 10 of the reference voltage Every time a screen is added or removed from a filter the analyzer must be turned off and the filter wheel removed from the analyzer When the filter wheel is replaced in the analyzer its rotational position is not critical but the white backing must face in the direction of the position sensor The filter wheel must also be securely tightened so that no slippage or vibration can occur See Figure 5 1 NOTE Refer to Figure 5 1 when installing filter screens Screens should be installed in the filter disk cup under the filter holder Also if a bal ance ring is used it should be placed over the screen c After screening to bring the measuring voltage to within 10 of the reference voltage adjust R3 as in step a above to make the measuring peak voltage read t
67. l in the following proce dures The VFD screen text that accompanies each operation is reproduced at 3 2 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 SetDigital Filter Self Testin Self Test Progress Results 2 Enter Change Change Verify C Password Yes No Password Password Enter SecureSystem setupnotallowed Span Zerostatus Span Zerotiming Enter and lt gt setup andon off SpaniZero Solenoidor Fitter NA Settrackor holdoutput Setcal holdandy sampleholdtimer A Selectrange Displaygasuse Select Enter I CEnter andrange Verify Setup Input Output Ba TRA Game LE GE su Go E3 Figure 3 1 Hierarchy of System Functions and Subfunctions v Teledyne Analytical Instruments Partl 3 3 3 Operation Control Unit Model 5000B the appropriate point in the procedure ina Monospaced type style Push button names are printed in Oblique type 3 3 The System Function The subfuctions of the System function are described below Specific procedures for their use follow the descriptions Dig_Filt Adjust how much digital filtering should be on the signal SELF TEST Performs a self diagnostic test to check the integrity of the power supplies outputs detector signal and preamplifier PWD Login security system for accessing to the setup functions
68. l terminate when process conditions revert to non alarm conditions 4 Are either of the alarms to be defeated The defeat alarm mode is incorporated into the alarm circuit so that maintenance can be performed under conditions which would normally activate the alarms The defeat function can also be used to reset a latched alarm See procedures below If you are using password protection you will need to enter your password to access the alarm functions Follow the instructions in section 3 3 3 to enter your password Once you have clearance to proceed enter the Alarm function Press the Alarm button on the front panel to enter the Alarm function Use the DN keys to choose between or ppm units Then press Enter to move to the next screen ALI 1000 ppm HI Dft N Fs N Ltch N Five parameters can be changed on this screen e Value of the alarm setpoint ALL e Out of range direction HI or LO e Defeated Dft Y N Yes No e Failsafe Fs Y N Yes No Teledyne Analytical Instruments Partl 3 23 3 Operation Control Unit Model 5000B e Latching Ltch Y N Yes No Todefine the setpoint use the lt gt arrow keys to move the blinking over to AL1 Then use the DN arrow keys to change the number Holding down the key speeds up the incrementing or decrementing e Tosettheother parameters use the lt gt arrow keys to move the blinking over to the desired parameter Then use the DN arrow keys to chan
69. ledyne Analytical Instruments lil Model 5000B iv Teledyne Analytical Instruments OPERATING INSTRUCTIONS Model 5000B Photometric Analyzer Part 1 Control Unit NEMA 4 Bulkhead Mount Teledyne Analytical Instruments Model 5000B Photometric Analyzer Table of Contents 1 Introduction LT sine REG oe amc eruta 1 1 1 2 Typical AppIICatlolS ton er acea eoe eco etta 1 1 1 3 Main Features of the Analyzer 1 5 1 4 Operator Interiaeo oer eain eei da 1 6 1 4 1 Up Down Switch 2 e oe etes 1 6 1 4 2 Escape Enter 1 6 1 5 Control Section Interface Panel 1 8 2 Installation 2 1 Unpacking the Control Unit Analysis Unit 2 1 2 2 Electrical Connections 2 1 2 3 Testing the System ea reped tette dete gen 2 9 3 Operation 2121 it O do toca 3 1 3 2 Using the Data Entry and Function Buttons 3 1 The System Function he Ae ond 3 4 3 3 1 Setting up an 3 4 3 9 2 Password Protection iii idad 3 6 3 3 2 1 Entering the Passw
70. lope is less than 0 01 for at least 3 min instead of Slope you will see a countdown 9 Left 8 Left and so fourth These are software steps in the zeroing process that the system must complete AFTER settling before it can go back to Analyze Software zero is indicated by S Zero in the lower right corner 502 4 Left S Zero The zeroing process will automatically conclude when the output is within the acceptable range for a good zero Then the analyzer automatically returns to the Analyze mode 3 41 2 Manual Mode Zeroing Press Zero to enter the Zero function The screen that appears allows you to select between automatic or manual zero calibration Use the D keys to toggle between AUTO and MAN zero settling Stop when MANU AL appears blinking on the display Select zero mode MANUAL Press Enter to begin the zero calibration After a few seconds the first of three zeroing screens appears The number in the upper left hand corner is the first stage zero offset The microprocessor samples the output at a prede termined rate Teledyne Analytical Instruments Partl 3 17 3 Operation Control Unit Model 5000B HLH 70 SO2 Zero adj 2048 C Zero The analyzer goes through C Zero F Zero and S Zero During C Zero and F Zero use the DN keys to adjust displayed Zero adj value as close as possible to zero Then press Enter S Zero starts During S Zero the Microcontroller takes control as in
71. measured consult factory Acetic Acid Alcohols Amines Aromatics Butadiene Carbonyls Chloroprene Esters Teledyne Analytical Instruments Partl 1 3 1 Introduction Model 5000B Hydroxyl Value Hydrocarbons Hydrogen Chloride Hydrogen Fluoride Hydroxyl Value Ketones Olefins Oximes Epoxides Methylene Ketones 1 4 Partl Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit 1 3 Main Features of the Analyzer The Model 5000B Photometric Analyzer is sophisticated yet simple to use The main features of the analyzer include A 2 line alphanumeric display screen driven by microprocessor electronics that continuously prompts and informs the operator High resolution accurate readings of concentration from low ppm levels through to 100 Large bright meter readout Versatile analysis over a wide range of applications Microprocessor based electronics 8 bit CMOS microprocessor with 32 RAM and 128 kB ROM Three user definable output ranges from 0 1 ppm through 0 100 allow best match to users process and equipment Calibration range for convenient zeroing or spanning Auto Ranging allows analyzer to automatically select the proper preset range for a given measurement Manual override allows the user to lock onto a specific range of interest Two adjustable concentration alarms and a system failure alarm Extensive self diagnostic testing at startup and on deman
72. metric Analyzer WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT AT THESE TERMINALS TRAINED PERSONNEL MUST REMOVE THE SILKSCREEN COVER ONLY EXER Vr N N 4 p N Nd CISE EXTREME CAUTION 99 mmm A E 1 d LL B 111 Lil 322 223229332322 45 span span ZERO ZERO 2 2 N G H SHLD SIG MEAS 230 5 GND SOL FLTR SOL The first strip terminal has three contacts labeled N G The labels stand for Neutral Ground and Hot Thisisthe AC power strip terminal It feeds AC power to other components of the Model 6000B System such as the D2 lamp power supply heater and temperature controller PCB The second strip terminal has four contacts labeled SHLD SIG GND MEAS and REF This strip terminals are dedicated to the signals coming from the photodetector amplifier The labels stand for SHLD Shield Shield form the preamplifier cable connects to this contact SIG GND Signal Ground Ground reference for both the measure and the reference signal MEAS Measure Signal voltage REF Reference Signal voltage The third terminal strip has eight contacts labeled 230 VDC 15 VDC 15 VDC COM SPAN FLTR SPAN SOL ZERO FLTR ZERO SOL This strip feeds the high voltage needed on the cathode of the photodetector DC power for the photodetector preamplifier and control signals for the s
73. minal Ready COM 5 Common DSR 6 Data Set Ready RTS 7 Request to Send CTS 8 Clear to Send RI 9 Ring Indicator The data sent is status Information in digital form updated every two seconds Status is reported in the following order e The concentration in percent e The range is use lt MED lt LO e The span of the range 0 100 etc Which alarm if any are disabled AL x DISABLED 2 8 Part Teledyne Analytical Instruments Photometric Analyzer Part I Control Unit e Which alarms if any are tripped AL x ON Each status output is followed by a carriage return and line feed Three input functions using RS 232 have been implemented to date They are described in Table 2 4 Table 2 4 Commands via RS 232 Input Command Description as lt enter gt Immediately starts anautospan az lt enter gt Immediately starts an autozero st lt enter gt Toggling input Stops Starts any status message output from the RS 232 Until st lt enter gt is sent again The RS 232 protocol allows some flexibility in its implementation Table 2 5 lists certain RS 232 values that are required by the 5000B Table 2 5 Required RS 232 Options Parameter Setting Baud 2400 Byte 801 Parity none Stop Bits 1 Message Interval 2 seconds Remote Bench and Solenoid Valves The 5000B is a single chassis instrument However the REMOTE BENCH and SOLENOID RETURN connectors are provided on the interface PCB The Remote Bench is
74. mple prior to accepting any read value Each sample should be allowed to stabilize before reading When a N2 flush is used to dry the sampling train before each sample is read the readings will come to equilibrium faster since no water cross contamination should be evident or occur 11 IF CALIBRATION PROCESS REPRESENTATIVE SAMPLES CANNOT BE OBTAINED THEN A DIRECT ON LINE TWO POINT CALIBRATION APPROACH CAN BE USED AS FOLLOWS Assuming customer has designed in a sampling valve this valve may contain a chromatographic septum port for a needle 1 e for toxic or flammable samples at low pressure hookup for a sampling bomb high pressure grab sample port or sealed container to draw off representative process grab samples Note All samples are brought to the analytical lab for speedy analyses preferably analyzed within 15 minutes to correlate to process conditions The sample analyzed should be by an analytical method with an acceptable precision and accuracy as used to normally monitor the process and confirm the on line analysis The on line analyzer is only as accurate que Teledyne Analytical Instruments 4 9 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit as the off line method used to verify the process variables Below is an example of an on line calibration when measuring 0 200ppm water in liquid TDI assumes TDI is a toxic liquid at standard temperature and pressure conditions The firs
75. n calibration can be performed in either the automatic or manual mode Make sure the span fluid is flowing to the instrument 3 4 21 Auto Mode Spanning Observe all precautions in sections 3 4 and 3 4 2 above Press Span to enter the span function The screen that appears allows you to select whether the span calibration is to be performed automatically or manually Use the DN arrow keys to toggle between AUTO and MAN span settling Stop when AUTO appears blinking on the display Select span mode AUTO Press Enter to move to the next screen Span Val 20 00 lt ENT gt To begin span Use the lt gt arrow keys to toggle between the span concentration value and the units field ppm Use the DN arrow keys change the value and or the units as necessary When you have set the concentration of the span fluid you are using press Enter to begin the Span calibration 06 SO2 Slope Span The beginning span value is shown in the upper left corner of the display As the span reading settles the screen displays and updates informa tion on Slope Spanning automatically ends when the span output corre sponds within tolerance to the value of the span fluid concentration Then the instrument automatically returns to the analyze mode 34 22 Manual Mode Spanning Press Span to start the Span function The screen that appears allows you to select whether the span calibration is to be performed automatically or
76. n latching and either failsafe or non failsafe or they can be defeated altogether The setpoints for the alarms are also established using this function Decide how your alarms should be configured The choice will depend upon your process Consider the following four points 1 Whichif any of the alarms are to be high alarms and which if any are to be low alarms Setting an alarm as HIGH triggers the alarm when the contaminant concentration rises above the setpoint Setting an alarm as LOW triggers the alarm when the contaminant concentration falls below the setpoint Decide whether you want the alarms to be set as 3 22 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 e Bothhigh highandhigh high alarms or e One high and one low alarm or e Both low low and low low alarms 2 Are either or both of the alarms to be configured as failsafe In failsafe mode the alarm relay de energizes in an alarm condition For non failsafe operation the relay is energized in an alarm condition You can set either or both of the concentration alarms to operate in failsafe or non failsafe mode 3 Are either of the alarms to be latching In latching mode once the alarm or alarms trigger they will remain in the alarm mode even if process conditions revert back to non alarm conditions This mode requires an alarm to be recognized before it can be reset In the non latching mode the alarm status wil
77. nd lower limits of a range AND the application of the range The Range button function only allows the user to select or define the limits or to select the application but not to define the application Normally the Model 5000BF is factory set to default to manual range selection unless it is ordered as a single application multiple range unit in which case it defaults to autoranging In either case autoranging or manual range selection can be programmed by the user In the autoranging mode the microprocessor automatically responds to concentration changes by switching ranges for optimum readout sensitivity If the upper limit of the operating range is reached the instrument automati cally shifts to the next higher range If the concentration falls to below 85 of full scale of the next lower range the instrument switches to the lower range A corresponding shift in the DC concentration output and in the range ID outputs will be noticed The autoranging feature can be overridden so that analog output stays on a fixed range regardless of the contaminant concentration detected If the concentration exceeds the upper limit of the range the DC output will saturate at 1 V de 20 mA at the current output However the digital readout and the RS 232 output of the concentra tion are unaffected by the fixed range They continue to read beyond the full Teledyne Analytical Instruments Partl 3 29 3 Operation Control Unit Model 5000B
78. ole noids and filters The labels stand for 230 VDC This is the negative high voltage fed to the photodetector cathode about 230 VDC 5 8 Part Il Teledyne Analytical Instruments Part Il Maintenance Analysis Unit Maintenance 5 15 VDC Power Supply voltage fed to the photodetector preamplifier 15 VDC 15 VDC Power Supply voltage fed to the photodetector preamplifier 15 VDC COM Common reference to the 15 VDC and the 230 VDC power supplies SPANFLTR Span filter signal AC voltage SPANSOL Span solenoid signal AC voltage ZEROFLTR Zerofilter signal AC voltage ZEROSOL Zero solenoid signal AC voltage Teledyne Analytical Instruments Part Il 5 9 5 Maintenance Model 5000B Photometric Analyzer 5 10 Part Il Teledyne Analytical Instruments Photometric Analyzer 5000B Appendix Appendix A 1 Specifications 5000B Digital Control Module Ranges FourProgrammable Ranges field selectable within limits application dependent and Auto Ranging Display 2 line by 20 alphanumeric VFD accompanied by 5 digit LED display Signal Output Two 0 1V DC concentration and range ID Two 4 20mADC isolated concentration and range ID RS232 Alarm Two fully programmable concentration alarm set points and corresponding Form C 3 amp contacts One system failure alarm contact to detect power calibration zero span and sensor failure Mounting Bulkhead Mount NEMA 4 rated Opera
79. omes the shortest retracts excessively is the measuring filter pulse Incase you cannot set the gain properly because the peaks are too short too tall or too much out of balance adjust R2 trimpot on the converter PC board until you obtain the desired peak height as observed on the scope usually 8 to 9 volt for the tallest of the two peaks Never leave the system operating with peaks exceeding 10 volts or you may saturate the logarithmic amplifier You should not permit oscillations or distortions in the peaks 5 5 5 Balancing the Optics for Equal Light Transmission with Zero Fluid in the SAMPLE CELL The objective of this procedure is to obtain measuring and reference peak heights as displayed on the oscilloscope that are approximately equal with the tallest peaks set at 8 to 9 volts This must be done with air or zero fluid in the cell 5 4 Part Il Teledyne Analytical Instruments Part Il Maintenance Analysis Unit Maintenance 5 The procedure is purely mechanical and consists of adjusting the amount of light passing through either the measuring or reference filter never both Screens wire mesh of varying density are used for this operation and are part of the small took kitaccompanying the instrument 1 Observe the oscilloscope and judge if optical balancing is needed When the difference is less than 1 volt balancing is not required The tallest of the two peaks should be adjusted to 8 or 9 volts with the gain control R
80. on related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able to provide early warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufac turer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions Teledyne Analytical Instruments Photometric Analyzer Table of Contents Part l Control Unit Part 1 1 1 Part Il Analysis Unit Part Il 4 1 A A A 1 Te
81. ontrol unit the following information is provided Figure 2 3 Power Module Block Diagram The temperature in the detector compartmentis controlled by inputs froma RTD device which feeds to a PID controller capable of set points of temperature versus temperature readout 4 4 4 Detector compartment After energy has passed through the sample it arrives at the filter wheel where itis fed alternately through two filters measuring and reference before reaching the detector These filters are specially selected for each application according to the absorption characteristics of the compounds under analysis The reference and measuring filter waveforms occur along a baseline at approximately 16 milliseconds intervals each reference or measuring waveform reoccurs at a time interval of 33 mS or one per revolution of the filter wheel At the detector infrared energy is transformed into electrical pulses and fed through an impedance matched preamplifier see dwg A 14619 De pending upon the application length of the cell spacer etc the gain of the preamplifier may vary from 1 to 10 depending upon the energy intensity at the detector to achieve an AC signal output of approximately 0 1 to 1 0 volt peak to peak Additionally the detector filters and preamplifierare housed in an electri cally and thermally isolated compartment to provide maximum stability and minimum noise This box orcompartment is normally temperature controlled at
82. ord 3 6 3 3 2 2 Installing or Changing the Password 3 7 3 3 3 Logging Out adoos 3 8 3 3 4 System Self Diagnostic Test 3 9 3 3 5 The Model Screen 3 10 3 3 6 Checking Linearity with Algorithm 3 10 3 3 7 Digital Flter Setup i 3 11 3 3 8 Filter or Solenoid Setup 3 12 3 3 9 Hold Track Setup ccooooooocccccncccccccconncccccnnnnnnanannnnnnos 3 13 3 3 10 Calibration Hold Timer Setup 3 13 3 3 11 Analog 4 to 20 mA Output Calibration 3 14 ii Part I W Teledyne Analytical Instruments Part I Control Unit 33 Mo laine 3 15 3 3 13 Show Negative xu iti deese 3 15 3 4 The Zero and Span Functions 3 16 Sut Zero Cal ue n Heo vie 3 16 3 4 1 1 Auto Mode Zeroing 3 16 3 4 1 2 Manual Mode Zeroing 3 17 9 41 39 Gall Palla 3 18 94 2 Span Gals EHE die a dames 3 19 3 4 2 1 Auto Mode Spanning 3 19 3 4 2 2 Manual Mode 3 19 94 3 Offset 522580 id E a tt 3 20 3 5 The Alarms Function pisito el 3 22 3 6 The Range Select Function 3 24 3 6 1 Manual Select De
83. oximately 0 1 to 0 4 SCFH Note Always keep the calibration fluid flow as close to the flowrate of the sample fluid as possible 3 4 1 Zero Cal The Zero function on the menu is used to enter the zero calibration function Zero calibration can be performed in either the automatic or manual mode Make sure the zero fluid is flowing to the instrument If you get a CELL CANNOT BE BALANCED message while zeroing skip to section 4 4 1 3 3 4 1 1 Auto Mode Zeroing Observe the precautions in sections 4 4 and 4 4 1 above Press Zero to enter the zero function mode The screen allows you to select whether the 3 16 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 zero calibration is to be performed automatically or manually Use the DN arrow keys to toggle between AUTO and MAN zero settling Stop when AUTO appears blinking on the display Select zero mode AUTO Press Enter to begin zeroing Do SO2 Slope 4 C Zero The beginning zero level is shown in the upper left corner of the dis play As the zero reading settles the screen displays and updates information on Slope in percent second unless the Slope starts within the acceptable zero range and does not need to settle further The system first does a coarse zero shown in the lower right corner of the screen as C Zero for 3 min and then does a fine zero and displays F Zero for 3 min Then and whenever S
84. possible when the zero offset between the process fluid and dry air or nitrogen remains close to the zero point of the actual process fluid i e after calibration the zero off set can be adjusted over the entire range of the meter plus or minus 100 from zero In the case of the calibration zero check value the requirement for installing a zero optical flag with dry nitrogen as the background fluid depends upon how unbalanced the reference and measure channel peak heights are with respect to each other as measured using an oscilloscope at Test Point 1 TP1 Violet of the AGC board designated B 1 4521 4 A good ratio ref meas estimate to keep within is 1 volt minimum 2 volt maximum to 2 volt maximum 1 volt minimum between the zero process fluid signal levels and the nitrogen calibration fluid background signal levels With the process fluid in the cell at the zero point of the calibration range the reference and measure pulses are optically balanced using density screens placed over the reference and or measure filters These signals are balanced to 9 volts each as measured at TP4 ref orange and TP3 meas yellow on the PEAK LEVEL DETECTOR BOARD designated B 14074 A The spectral background absorbance at the reference versus measure wavelengths of the process fluid determines the magnitude of the unbal anced ref meas ratio This ratio is kept within the 1 2 to 2 1 values for proper operation of the AGC circuitry and therefore prope
85. procedures Setting system parameters e Establish a security password if desired requiring Operator to log in secure in safe file for referrence e Establish and start an automatic calibration cycle if desired Routine Operation e Calibrate the instrument e Choose autoranging or select a fixed range of analysis e Setalarmsetpoints and modes of alarm operation latching fail safe etc e Program Reprogram the analyzer e Define new applications e Linearize your ranges If you choose not to use password protection the default password is automatically displayed on the password screen when you start up and you simply press Enter for access to all functions of the analyzer 3 2 Using the Data Entry and Function Buttons Data Entry Buttons The lt gt buttons select options from the menu currently being displayed on the VFD screen The selected option blinks When the selected option includes a modifiable item the DN arrow buttons can be used to increment or decrement that modifiable item Teledyne Analytical Instruments Part 3 1 3 Operation Control Unit Model 5000B The Enter button is used to accept any new entries on the VFD screen The Escape button is used to abort any new entries on the screen that are not yet accepted by use of the Enter button Figure 3 1 shows the hierarchy of functions available to the operator via the function buttons The six functions of the buttons on the analyzer a
86. r stability and signal noise levels of the instrument output After balancing on a zero sample of the process fluid if the ratio is not found to be within the 1 2 to 2 1 range a zero flag is necessary and installed in the sample cell compartment along with a span flag if ordered This zero flag when chosen is also solenoid actuated to bring the ratio within the 1 2 to 2 1 range between process zero fluid and zero nitrogen or dry air background The span flag is actuated while the zero offset level usually when nitrogen is used as a zero calibration fluid is switched in Zero calibration check after process on line calibration To check zero on the analyzer immediately back flush out the process fluid and dry the cell out with a reproducible zero fluid that should never contain any of the analyte This is usually done with N2 assuming the process fluid has low vapor pressure and can be purged dry in an acceptable short time que Teledyne Analytical Instruments 4 11 A Business Unit of Teledyne Electronic Technologies 4 Operations Analysis Unit period In this case nitrogen or dry air typically 1000F dewpoint or 2ppm water can be used Manually switch in the zero offset check from the control unit to operate the zero solenoid flag depending upon the application this may or may not simultaneously insert a zero flag into the light path indeed 90 of the time it is not needed The factory zero offset value was set from its best det
87. r to ON and make the following observations 1 Open the control analysis section detector module and verify that the chopper motor is operating Open the cover of the compartment and verify motion The motor should start turning the instant power is established If it does not check the integrity of the main fuse on the control module door If the fuse is blown re check the power service connections on TS2 in the control module and the control module to analysis section interconnection wiring refer to Electrical Installation in Chapter 3 0 Installation and dwg 2 The lamp source should light the instant power is established Open the enclosure door and view the source module to verify illumination WARNING 1 The light intensity from the Mini IR lamp or quartz iodine lamp If used is intense and should not be looked at directly without special protective eyewear Protective goggles with shaded lenses Fed Spec 5 should be worn if it is necessary to look directly at the source 2 Before opening any of the enclosure covers with the power on make certain that the area has been classified as safe to do so 4 4 Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 3 Iftheanalyzersection has been equipped with the automatic zero SOL option the zero solenoid device in the accessory sampling system should have energized the instant power was established The dev
88. re e Analyze Thisis the normal operating mode The analyzer monitors the concentration of the sample displays the percent or parts per million of target fluid or contamination and warns of any alarm conditions e System The system function consists of nine subfunctions Four of these are for ordinary setup and operation e Setup an Auto Cal e Assign Passwords e Log outto secure system e Initiate a Self Test Three of the subfunctions do auxiliary tasks Checking model and software version e Adjustelectronic filter ofthe signal Display moresubfunctions e Display negativereadings Two of these are for programming reprogramming the analyzer e Define fluid applications andranges Refer to programming section or contact factory e Use the Curve Algorithm to linearize output Refer to programming section or contact factory Zero Used to set up a zero calibration Span Used to set up a span calibration e Alarms Used to set the alarm setpoints and determine whether each alarm will be active or defeated HI or LO acting latching and or fail safe e Range Used to set up three analysis ranges that can be switched automatically with autoranging or used as individual fixed ranges Any function can be selected at any time by pressing the appropriate button unless password restrictions apply The order as presented in this manual is appropriate for an initial setup Each of these functions is described in greater detai
89. riations the lamp transformer derives its input directly from a line voltage regulating transformer selected for its ability to maintain a constant output voltage level regardless of fluctuations in the input line voltage within the control range of 105 to 130 VAC In some applications where we have an abundance of energy due to low sample absorption the focusing lens is removed to avoid excess energy reaching the detector However other systems have high energy losses in the sample module due to strong sample absorbance or exceptionally long sample path lengths These systems require a focusing lens to gather and collimate the radiation for maximum utilization of source energy The collimating lens is usually quartz but may be CaF2 for longer wavelengths Also the source lamp may be a differenct type to emit more radiation at the longer measuring wavelengths Consult manual addendum descriptions 4 18 que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 Sample Out Light Beam Tube Light Beam Tube di Detector Sample a Cell 2 F y Source NIR Lens Synchronous Filter Mo 5 Wheel Sample In Chopper Filter Position Sensor Figure 4 1 OpticalSystem 4 4 2 Sample cell The sample cell generally constructed of 316SS is located in the path
90. s to select the successive points The INPUT value is the input to the linearizer It is the simulated output of the analyzer You do not need to actually flow fluid The OUTPUT value is the output of the linearizer It should be the ACTUAL concentration of the span fluid being simulated If the OUTPUT value shown is not correct the linearization must be corrected Press ESCAPE to return to the previous screen Select and Enter SET UP to Calibration Mode screen set up will not work without a PC being connected to the analyzer Select algorithm mode AUTO There are two ways to linearize AUTO and MANUAL The auto mode requires as many calibration fluides as there will be correction points along the curve The user decides on the number of points based on the preci sionrequired 3 10 Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 The manual mode only requires entering the values for each correction point into the microprocessor via the front panel buttons Again the number of points required is determined by the user 3 3 7 Digital Filter Setup The 5000BF has the option of decreasing or increasing the amount filtering on the signal This feature enhances the basic filtering done by the analog circuits by setting the amount of digital filtering effected by the microprocessing To access the digital filter setup you must 1 Press the System key to start the System function DIG
91. sample can be flushed backflushed usually out of the sample cell using dry nitrogen or air to a reproducible back ground zero The zero offset and or span flag is introduced and set up to simulate the on line calibration only after the customer has calibrated the analyzer on the representative process fluid Thereafter no calibration fluids are needed to check analyzer 4 16 que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 4 4 Operational Theory Cont d The energy source for the analyzer is most commonly provided by as a high intensity quartz iodine lamp located in the source module Quartz iodine was chosen because it produces sufficient NIR to operate the system and maintains a nearly constant brightness over its lifetime See Figures 2 1 and 2 2 This energy is then fed through the sample which is temperature controlled and into the detector module where it passes through a rotating filter wheel before reaching the lead sulfide PbS detector PbSe also used for longer wavelengths cooled and non cooled The filter wheel driven at 30 RPS or 1800 RPM by a synchronous AC motor contains two optical filters with bandpasses selected for each applica tion thus providing reference and measuring pulses from which the required information may be obtained The detector receives pulses at the rate of 60 PPS or two pulses per revolution of the filter wheel Every ot
92. saturates because the amplifier is incapable of taking the logarithm of the slightly negative baseline 5 5 7 Inverting Amplifier The amplifier is inverting and has a gain of 1 Itinverts the output signal of the logarithmic amplifier and acts as a buffer between the logarithmic amplifier and the reed switch and integrators To observe the output of the inverter connect the scope probe to TP5 The wave must be a duplicateof that observed on TP4 except that itis inverted 5 6 Part Il Teledyne Analytical Instruments Part Il Maintenance Analysis Unit 5 5 8 Integrated Reference and Measuring Signals You can observe the reference and measuring signal at the first stage of integration by connecting the scope probe to TP6 reference signal and TP7 measuring signal at the detector unit A dual trace scope is advantageous but not required for this observation The test points significance is thatthey reveal proper switch action The display shows a sawtooth pattern thatis a charge discharge of the first capacitor inthe integrating network Thisrippleisthe AC componentofthe reference and measuring signal after the pulses are converted to DC The sawtooth patterns must be displayed 180 with respect to each other as viewed with a dual trace scope They must both be present If one is missing the switch is not switching If the sawtooth shows a broken pattern the switching action is feeble orirregular Usually you can fix the faul
93. se functions should only be reprogrammed by trained qualified personnel To program you must 1 Enter the password if you are using the analyzer s password protection capability 2 Connecta computer or computer terminal capable of sending an RS 232 signal to the analyzer RS 232 connector See chapter 2 Installation for details Send the rp command to the analyzer 3 Press the System button to start the System function DIG FILT SELF TEST PWD LOGOUT MORE Use the lt gt arrow keys to blink MORE then press Enter 3 28 Partl Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 AUTOCAL FILSOLL HOLD CAL HOLD TIMER MORE Select MORE and press ENTER one more time ALGORITHM APPLICATION MORE OUTPUT 4MA Now you will be able to select APPLICATION and ALGO RITHM set up functions 3 8 1 The Set Range Screen The Set Range screen allows reprogramming of the three analysis ranges and the calibration range background fluid low end of range high end of range and or ppm units Original programming is usually done at the factory according to the customer s application It must be done through the RS 232 port using a computer running a terminal emulation program Note It is important to distinguish between this System programming subfunction and the Range button function which is an operator control The Set Range Screen of the System function allows the user to DEFINE the upper a
94. sis on a fixed range if the concentration rises above the upper limit as established by the operator for that particular range the output saturates at 1 V dc or 20 mA How ever the digital readout and the RS 232 output continue to read regardless of the analog output range To end the session send st lt enter gt st lt enter gt 3 30 Partl Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 to the analyzer from the computer 3 8 2 The Curve Algorithm Screen The Curve Algorithm is a linearization method It provides from 1 to 9 intermediate points between the ZERO and SPAN values which can be normalized during calibration to ensure a straight line input output transfer function through the analyzer Each range is linearized individually as necessary since each range will usually have a totally different linearization requirement To linearize the ranges you must first perform the four steps indicated at the beginning of section 3 8 Programming You will then be in the second System menu screen 3 8 2 1 Manual Mode Linearization To linearize manually you must have previous knowledge of the nonlinear characteristics of your fluides You enter the value of the differen tial between the actual concentration and the apparent concentration analyz er output TAI has tabular data of this type for a large number of fluides which it makes available to customers on request See Appendix
95. ss fluid and dry the cell with a reproducible zero fluid that does not contain any of the analyte In this case nitrogen or dry air typically 75 C dew point or less than 1 PPM water should be used Manually introduce the span flag from the readout control unit to operate the solenoid containing the appropriate span filter into the light path of the analyzer this may be automatically or manually operated depending upon the sample system and electronic instru ment design RECORD the span calibration reading for future calibration reference of the span sensitivity agreement The filter span flag is chosen at the factory to represent an upscale reading of typically between 60 90 of the full scale range NOTE The zero or span flag readings should always repeat if the analyzer remains in calibration Any drift in the zero or span can 4 12 Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 always be corrected using the calibration zero and or span features SUMMARY The zero and or span calibration of 5000 series photometric Teledyne analyzers can be quickly verified manually by using Zero and or calibration zero offsets and or span flags Refer to typical Teledyne Analytical 1475 sample system below 3 way valves 1 2 3 below are used to check internal calibration using zero and or span filters with N2 CALIBRATION OF H20 IN SOLVENTS EXAMPLE Based upon our exper
96. sult factory or assure the manual has the correct version of the front panel control switches and functions 4 2 Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 The control unit digital display musthandle functions for both the analysis section and the control module 42 Start p Information contained in this paragraph is based on the premise that the analyzer has been properly installed and that itis in operable condition If difficulties arise during start up itis probable that some form of damage has incurred during shipment or some installation error has inadvertently been made Accessory test equipment is not necessary for start up of the 5000B However if the analyzer malfunctions at start up an oscilloscope and a multimeter will be required for troubleshooting TAIrecommends that a dual trace oscilloscope be used A dual trace oscilloscope will permit the operator to see two different waveforms simultaneously 4 2 1 Preliminary Inspection Before power is supplied to the analyzer all modules should be opened and inspected for damage or loose components Plug in circuit cards should be firmly seated in their sockets All barrier strip wiring connections must be inspected and user installed wiring between units verified as being in agree ment with the system interconnection diagram Control Settings Prior to turning on the power the controls on and with
97. t Function This software when installed in the 5000BF instruments provides a way to enter an offset on the zero operation of the analyser This is useful when the instrument is zeroed in some inert fluid such as Nitrogen or Argon but the background fluid of the process is different Ifthe background fluid of the process is different than the zero calibration fluid being used the reading will have an offset that will be constant throughout its working range Thus the need to provide an offset when the instrument is being zeroed How to access the offset function To access this function the instrument zero mode must be entered by pushing the Zero key on the front panel of the control unit The VFD display will show the following menu selection 3 20 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 Select zero mode AUTO or Select zero mode MAN Select whether you want the instrument to do an automatic or manual zero If you do an automatic zero the instrument does the zero by itself If you do a manual zero you must manually enter inputs to the instrument to accomplish the zero see in the corresponding section of the manual on how these two functions differ When the Enter key is pressed the following menu will appear Zero off 0 0 ppm lt ENT gt to begin Zero The offset value can be modified by using the Up Down keys Next section shows how to select this value Suffice to sa
98. t sample should be taken when the analyte H20 concentration is known to be low approximately O 002 water The sample is quickly withdrawn and analyzed in the lab to determine the water content via an acceptable lab method This may be Karl Fischer titration gas chromatogra phy IR spectroscopy or volume extraction distillation etc At this time the instrument zero is made to read exactly zero on the output of the analyzer 1 e on the or PPM of the panel digital meter 4 20 ma current or 0 1 VDC etc using the zero potentiometer of the analyzer or the digital or microprocessors zeroing calibration adjustment Record the lab value ana lyzed corresponding to the zero set point adjustment A second sample from the process must be grabbed after a steady state upscale reading has been reached Hopefully at this time the customer can make a minor changes in the process to cause a slight upscale reading 1 0 30 of the full scale or more if possible in order to obtain a steady state reading at another concentration level It this is not possible then an appropriate time interval must occur when the process naturally changes to an upscale steady state level concentra tion At this time the second calibration sample is grabbed and immediately analyzed Record this value This higher concen tration value is subtracted from the first sample analyzed Its difference value defines the slope of the calibration curve value This val
99. ting Temperature 0 50 Teledyne Analytical Instruments A 1 Appendix Models 5000B Typical Analytical Performance Specifications will vary per application Accuracy Noise Diurnal Sample Cell Cell Length Flow Rate Light Source Sensitivity Reproducibility Filter Wavelength Sample Pressure Response time 2 of full scale or better application dependent Less than 1 Less than 1 per 20 F 10 source detector dependent Stainless steel with Sapphire window standard Other materials available 01 to 10 inches 50 to 1500 cc min TungstenMini Lamp optional Quartz Halogen 015 to 3 absorbance units 1 of scale or better 750nm to 5 microns application dependant Sapphire window 250 psi Programmable Other Specifications Ambient temp range 32 122 F 0 50 C Internal calibration Optical span flag zero and span calibration NOTE 5000B 5020B sample temperature sensing and output correction Power Rating 115 230 VAC 50 60 Hz Approx 200 watts Readout Device Digital 2 line alphanumeric vacuum fluorescent display VED Analog Output Signal 0 1 V standard 4 20mA isolated Area Classification Non hazardous Model 5000B Hazardous Explosion proof Model 5020 5000B 5020B Purge options X Y Z purge Cenelec IIB AND H2 PENDING FOR ZONEIOR CLASSI DIV I B C D AREAS A 2 Teledyne Analytical Instruments Photometric Analyzer 5000B Appen
100. tions Analysis Unit 4 1 Control Functions 4 1 1 Analysis Section fully explosion proof Z or X purged Nema enclosure or Cenelec Purged pending The control functions for the analysis section are located on the Front of the Enclosure module 1 POWER ON OFF This function is hard wired into the enclosure for power to the control analysis section 2 a X C A 1000 B A For example if the range of analysis is 20 80 and a desirable alarm setpoint is 30 then A 20 B 80 and C 30 _ 80 20 1000 _ X 8000 167 2 b RANGE Control unit allows changing the range by some predetermined amount such as 4X or 5X i e triple range low range of 0 100 ppm mid of 250ppm and a high range of 0 500 3 Mode Programmable functions forincorporating an automatic zero span or autoranging Autocal also possible with fluids by valving or by filter solenoid Consult control unit sections of the manual 4 Digitaldisplayt indicates the concentration of the component of interest Consult control unit section for setting up units as ppm mg l etc 4 1 2 Explosion Proof Version Control Module When the control module is integral with the analysis section single explo sion proof enclosure ithas all of the same control functions as the General Purpose control module however the buttons are replaced by two switches These switches have different movements to achieve the same functionality as the 4 button model Con
101. ty condition of the switch by slightly changing the switch position The action of a bar magnet and a rotating chopper disc activate themagnetic mercury reed switch An aluminum motor mounting block houses a bar magnet This bar magnet is parallel with the mercury chopper switch The chopper disc is a green and black disc mounted on the filter wheel shaft next to the motor The disc is composed of both magnetic and non magnetic materials As the shaft rotates the magnetic portion of the disc shorts the magnetic flux as itpasses between the magnetand the switch The non magnetic portion of the disc enables flux lines from the bar magnet to activate the mercury switch 5 5 9 Battery Powered Oscilloscope Synchronization Point Because the line frequency cannot synchronize battery powered oscillo scopes use TP8 at the detector module to provide external synchronization 5 6 Interface Board Terminals Strip Atthe bottom of the interface PCB on the Control Unit are three terminal strip where wiring is distributed to other sections of the Model 6000B System Such as AC power for the D2 lamp power supply DC Power to the preampli fier High DC voltage for the photodetector and signals to control calibration solenoids and filters To gain access to this terminals the silkscreen cover must be removed These terminals are wired in the factory Teledyne Analytical Instruments Part Il Maintenance 5 5 7 5 Maintenance Model 5000B Photo
102. ue will be used to determine the calibration slope of the instrument range Using the span adjustment of the analyzer set the output reading to agree with this difference in concentration Once the slope is set adjust the zero of the instrument to agree with the true concentration to that of the analyzed steady state sample presently flowing through the instrument cell Now the analyzer is calibrated to the process fluid Zero calibration using secondary standard zero and span flag s AFTER the analyzer has been calibrated on the process fluid a simulation of this process on line calibration can be made using internal synthetic 4 10 que Teledyne Analytical Instruments A Business Unit of Teledyne Electronic Technologies Operations Analysis Unit 4 optical filters These optical filters are stable and are chosen to indicate the measured component at the required instrument wavelengths Therefore future faster yet much simpler calibration zero and span checks can be made without the unnecessary tedious on line calibration described above nor the consumption of expensive calibration fluids which may be difficult to handle or obtain are unstable or toxic in nature A Fitter s at the factory is chosen and installed in the instrument approxi mating in absorbance value to the anticipated stream composition back ground to give reproducible zero span value when nitrogen or air back ground is in the measuring cell This capability is
103. uments Part I Control Unit Analysis Unit Maintenance 3 Preamp 0 OK gt 0 means that some of the ten gains of the amplifier have a large offset The number is a code that tells which of the ten gtains have the large offset Cell detector 0 OK gt 0 means that the analyzer failed to balance the measuring and the reference signals the larger the number the farther off they were 4 3 Major Internal Components The major components in the Control Unit are shown in Figure 4 3 Outer Door Inner Door 2 Teledyne Analytical Instruments Main a va va val et mS va 03 LUTE felina TA 11 111111 11114114 o uav sod Ag D OE dp og og 3 04 MAX Display PCB aa Doors shown removed for clarity Electrical Connector Panel Box Subassembly Gas Connector Panel not shown Figure 4 3 Control Unit Major Internal Components Teledyne Analytical Instruments Partl 4 3 3 Maintenance Model 5000B Photometric Analyzer WARNING HAZARDOUS VOLTAGES EXIST ON CERTAIN COMPONENTS INTERNALLY WHICH MAY PERSIST FOR A TIME EVEN AFTER THE POWER IS TURNED OFF AND DISCONNECTED The 5000B Control Units contain the following major components e Power Supply e Motherboard with Microprocessor RS 232 chip and Preamplifier PCB e Front Panel Display Board and Displays 5 digit LED meter 2 line 20 character alphanumeric VFD display See the drawings in the Drawings section or addendum
104. wired at the factory as well as any optional solenoid valves included in the system 2 3 Testing the System After The Control Analysis Unitis both installed and interconnected and the system gas or liquid stream andelectrical connections are complete the system is ready to test Before plugging the unitinto its power sources e Check the integrity and accuracy of the fluid connections Make sure there are no leaks e Check the integrity and accuracy of all electrical connections Make sure there are no exposed conductors Teledyne Analytical Instruments Part 2 9 1 Introduction Model 5000B e Check that sample pressure typically between 0 and 30 psig according to the requirements of your process Power up the system and test it by performing the following operation 1 Repeat the Self Diagnostic Test 2 Zero the instrument 3 Span the instrument Consult calibration recommendation in the addendum for your particular application whether liquid or gas phase monitoring For steps 2 and 3 refer to part II for calibration 2 10 Part Teledyne Analytical Instruments Photometric Analyzer Operation Control Unit 3 Operation 3 1 Introduction Although the Model 5000B 15 usually programmed to your application at the factory it can be further configured at the operator level or even cautiously reprogrammed Depending on the specifics of the application this might include all or a subset of the following
105. word letters and the DN arrow keys to change the letters to the new password The full set of 94 characters available for pass word use are shown in the table below Characters Available for Password Definition A B G H I J K L M N O P Q R S T U V W X Y Z Y A z 5 f g h 1 k 1 m n o p q r 8 t u X y 7 y amp i 0 1 2 3 4 5 6 7 amp 9 gt Teledyne Analytical Instruments Partl 3 7 3 Operation Control Unit Model 5000B When you have finished typing the new password press Enter A verifica tion screen appears The screen will prompt you to retype your password for verification Enter PWD To Verify AAA Use the arrow keys to retype your password and press Enter when finished Your password will be stored in the microprocessor and the system will immediately switch to the Analyze screen and you now have access to all instrument functions If all alarms are defeated the Analyze screen appears as 1 95 ppm SO nRl 0 10 If an alarm is tripped the second line will change to show which alarm itis 1 95 ppm SO AL 1 NOTE If you log off the system using the LOGOUT function in the system menu you will now be required to re enter the password to gain access to Alarm and Range functions 3 3 3 Logging Out The LOGOUT function provides a convenient means of leaving the analyzer in a password protected mode without having to
106. y that whatever value you enter will be automatically added to the reading Thus if you entered 0 1 ppm at the end of the zero the display will show 0 1 ppm Once the Enter key is pressed the instrument enters the zero mode If you chose AUTO zero mode the instrument will do the work of bringing the reading back to zero plus the offset value that was entered If you chose MANual zero mode then you must enter input to the instrument as explained in the corresponding section of the manual but with one difference instead of bringing the display to read zero you must make the display read zero plus the value entered as offset How the offset value is selected To find out what the offset value should be the intended zero calibration fluid and the a mix of the process background fluid must be procured This of course assumes that the zero fluid and the process background fluid are very different and that an offset will occur 1 Let the intended zero calibration fluid flow through the SOOOBF sample cell this assumes that you have started up you system as recommended by the manual or technical personnel and do a zero on the instrument Leave the offset set to zero value 2 At the end of the zero function make sure the analyser reads zero 3 Flow a zero level of the process background fluid mix through the 5000BF sample cell on the Analyse mode Wait for the reading to become stable Write the reading down Change the sign of the reading

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