Teledyne 200A User Manual

Advanced Pollution Instrumentation

A Teledyne Technologies Company

TELEDYNE

INSTRUMENTS

INSTRUCTION MANUAL

Chemiluminescent

NO/NO

/NOX ANALYZER

2

Model 200A

© Teledyne Advanced Pollution Instrumentation

(T-API)

9480 Carroll Park Drive

San Diego, CA 92121-5201
TOLL-FREE: 800-324-5190

FAX: [phone]

TEL: [phone]

E-MAIL: [e-mail]

WEB SITE: www.teledyne-api.com

Teledyne API, Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247

HIGHLIGHTS

The purpose of this Highlights Page is to list the changes that were incorporated into this Manual per
DCN 5247.

Chapter / Page Number Description

Title Page

Text – All Pages

TOC / x

3 / 3-3, 3-4

8 / 8-15

10 / 10-1 thru 10-7

10 / 10-7, 10-8

 Changed Revision number and date.
 Added DCN number to footer.
 Changed Revision number and date.
 Added DCN to all footers of Text, P/N 02246G.
 Added “PRINTED DOCUMENTS ARE UNCONTROLLED” to all

footers of Instruction Manual, P/N 02246G.

 Updated List of Figures in TOC.
 Updated Warranty Section.
 Added note to replace the 5 dessicant bags if black PMT cover for

the Sensor Assembly is removed.

 Updated Spare Parts List, Tables 10-1 thru 10-6.
 Added Tables 10-7 and 10-8 for new Expendables Kits.

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TELEDYNE

INSTRUMENTS

Advanced Pollution Instrumentation

A Teledyne Technolog i es Company

INSTRUCTION MANUAL

MODEL 200A

NITROGEN OXIDE ANALYZER

TELEDYNE ADVANCED POLLUTION INSTRUMENTATION

Copyright 2005 API Inc.

(TELEDYNE API)

9480 CARROLL PARK DRIVE

SAN DIEGO, CA 92121-5201

TOLL-FREE: 800-324-5190

FAX: [phone]

TEL: [phone]

E-MAIL: [e-mail]

WEB SITE: www.teledyne-api.com

02246 REV. G

DCN 5247

10 December 2008

THIS PAGE IS INTENTIONALLY LEFT BLANK

Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247

SAFETY MESSAGES

Your safety and the safety of others is very important. We have provided many important safety
messages in this manual. Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety
message is associated with a safety alert symbol. These symbols are found in the manual and
inside the instrument. The definition of these symbols is described below:

GENERAL WARNING/CAUTION: Refer to the instructions for details on the
specific danger.

CAUTION: Hot Surface Warning

CAUTION: Electrical Shock Hazard

Technician Symbol: All operations marked with this symbol are to be performed
by qualified maintenance personnel only.

Electrical Ground: This symbol inside the instrument marks the central safety
grounding point for the instrument.

CAUTION

The analyzer should only be used for the purpose

and in the manner described in this manual.

If you use the analyzer in a manner other than that for which

it was intended, unpredictable behavior could ensue with

possible hazardous consequences.

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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247

TABLE OF CONTENTS

SAFETY MESSAGES .......................................................................................................I

TABLE OF CONTENTS................................................................................................III

LIST OF FIGURES .......................................................................................................VII

LIST OF TABLES .......................................................................................................VIII

1 HOW TO USE THIS MANUAL ............................................................................... 1-1

2 GETTING STARTED ................................................................................................ 2-1

2.1 UNPACKING..................................................................................................................................... 2-1

2.2 ELECTRICAL AND PNEUMATIC CONNECTIONS.................................................................................2-1

2.3 INITIAL OPERATION ........................................................................................................................ 2-6

3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY.............................. 3-1

3.1 SPECIFICATIONS ..............................................................................................................................3-1

3.2 EPA EQUIVALENCY DESIGNATION ................................................................................................. 3-2

3.3 WARRANTY..................................................................................................................................... 3-3

4 THE M200A NOX ANALYZER ................................................................................ 4-1

4.1 PRINCIPLE OF OPERATION ...............................................................................................................4-1

4.2 OPERATION SUMMARY.................................................................................................................... 4-3

4.2.1 Sensor Module, Reaction Cell, Detector ................................................................................4-3

4.2.2 Pneumatic Sensor Board......................................................................................................... 4-3

4.2.3 Computer Hardware and Software.......................................................................................... 4-4

4.2.4 V/F Board................................................................................................................................ 4-4

4.2.5 Front Panel.............................................................................................................................. 4-4

4.2.6 Power Supply Module ............................................................................................................ 4-6

4.2.7 Pump, Valves, Pneumatic System ..........................................................................................4-6

4.2.8 Ozone Generator ..................................................................................................................... 4-9

4.2.9 Molydbenum Converter.......................................................................................................... 4-9

5 SOFTWARE FEATURES.......................................................................................... 5-1

5.1

INDEX TO FRONT PANEL MENUS .................................................................................................... 5-1

5.1.1 Sample Menu .......................................................................................................................... 5-4

5.1.2 Set-Up Menu...........................................................................................................................5-5

SAMPLE MODE ................................................................................................................................5-8

5.2

5.2.1 Test Functions.........................................................................................................................5-8

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5.2.2 CAL, CALS, CALZ, Calibration Functions ......................................................................... 5-12

5.3 SET-UP MODE...............................................................................................................................5-14

5.3.1 Configuration Information (CFG)......................................................................................... 5-14

5.3.2 Automatic Calibration (AutoCal) .........................................................................................5-14

5.3.3 Data Acquisition System (DAS)...........................................................................................5-14

5.3.4 Range Menu.......................................................................................................................... 5-16

5.3.5 Password Enable ................................................................................................................... 5-20

5.3.6 Time of Day Clock................................................................................................................ 5-20

5.3.7 Diagnostic Mode...................................................................................................................5-20

5.3.8 Communications Menu.........................................................................................................5-20

5.3.9 Variables Menu (VARS) ...................................................................................................... 5-21

5.3.10 M200A Operating Modes ...................................................................................................5-21

5.4 STATUS OUTPUT ........................................................................................................................... 5-22

5.5 RS-232 INTERFACE ....................................................................................................................... 5-23

5.5.1 Setting Up the RS-232 Interface........................................................................................... 5-24

5.5.2 Command Summary ............................................................................................................. 5-28

5.5.3 TEST Commands and Messages ..........................................................................................5-32

5.5.4 WARNING Commands and Messages................................................................................. 5-33

5.5.5 CALIBRATION Commands and Messages......................................................................... 5-34

5.5.6 DIAGNOSTIC Commands and Messages............................................................................ 5-36

5.5.7 DAS Commands and Message.............................................................................................. 5-37

5.5.8 Internal Variables.................................................................................................................. 5-39

6 OPTIONAL HARDWARE AND SOFTWARE....................................................... 6-1

6.1 RACK MOUNT OPTIONS .................................................................................................................. 6-1

6.2 ZERO/SPAN VALVES ....................................................................................................................... 6-1

6.3 INTERNAL ZERO/SPAN (IZS)........................................................................................................... 6-3

6.4 AUTOCAL - SETUP OF IZS AND ZERO/SPAN VALVES....................................................................... 6-3

6.5 PERMEATION TUBE ......................................................................................................................... 6-5

6.6 4-20 MA CURRENT LOOP OUTPUT .................................................................................................. 6-8

7 CALIBRATION AND ZERO/SPAN CHECKS....................................................... 7-1

MANUAL ZERO/SPAN CHECK OR CAL WITH ZERO/SPAN GAS IN THE SAMPLE PORT ...................... 7-4

7.1

7.2 MANUAL ZERO/SPAN CHECK OR CALIBRATION WITH ZERO/SPAN VALVES OPTION....................... 7-6

7.3 MANUAL ZERO/SPAN CHECK WITH IZS OPTION ............................................................................. 7-7

7.4

AUTOMATIC ZERO/SPAN CHECK.....................................................................................................7-7

DYNAMIC ZERO/SPAN CALIBRATION .............................................................................................. 7-7

7.5

7.6 CALIBRATE ON NO

7.7

USE OF ZERO/SPAN VALVES OR IZS WITH REMOTE CONTACT CLOSURE...................................... 7-11

7.8 EPA PROTOCOL CALIBRATION ..................................................................................................... 7-12

7.8.1 Calibration of Equipment...................................................................................................... 7-12

7.8.2 Calibration Gas and Zero Air Sources.................................................................................. 7-14

7.8.3 Data Recording Device......................................................................................................... 7-15

7.8.4 Gas Phase Titration (GPT) System....................................................................................... 7-16

7.8.5 Dynamic Multipoint Calibration Procedure .........................................................................7-20

PERMEATION TUBE ......................................................................................... 7-9

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7.8.6 Moly Converter Efficiency ...................................................................................................7-25

7.8.7 Calibration Frequency........................................................................................................... 7-27

7.8.8 Other Quality Assurance Procedures.................................................................................... 7-27

7.8.9 Summary of Quality Assurance Checks ............................................................................... 7-29

7.8.10 ZERO and SPAN Checks ...................................................................................................7-30

7.8.11 Recommended Standards for Establishing Traceability.....................................................7-31

7.8.12 Certification Procedures of Working Standards ................................................................. 7-32

7.9 CALIBRATION OF INDEPENDENT RANGES OR AUTORANGING ........................................................ 7-34

7.9.1 Zero Calibration with AutoRange or Independent Range .................................................... 7-34

7.9.2 Span Calibration with AutoRange or Independent Range....................................................7-34

7.10 CALIBRATION QUALITY .............................................................................................................. 7-35

7.11 REFERENCES ...............................................................................................................................7-37

8 MAINTENANCE........................................................................................................ 8-1

8.1 MAINTENANCE SCHEDULE .............................................................................................................. 8-1

8.2 REPLACING THE SAMPLE PARTICULATE FILTER..............................................................................8-3

8.3 REPLACING THE OZONE SCRUBBER CHARCOAL .............................................................................. 8-5

8.4 REPLACING THE PERMEATION.........................................................................................................8-5

8.5 REPLACING THE IZS ZERO AIR SCRUBBER...................................................................................... 8-6

8.6 REPLACING THE MOLYBDENUM CONVERTER.................................................................................. 8-7

8.7 CLEANING THE REACTION CELL ..................................................................................................... 8-9

8.8 PNEUMATIC LINE INSPECTION.......................................................................................................8-11

8.9 LEAK CHECK PROCEDURE............................................................................................................. 8-15

8.10 LIGHT LEAK CHECK PROCEDURE ................................................................................................ 8-16

8.11 PROM REPLACEMENT PROCEDURE .............................................................................................. 8-16

9 TROUBLESHOOTING, ADJUSTMENTS.............................................................. 9-1

9.1 OPERATION VERIFICATION-M200A DIAGNOSTIC TECHNIQUES ...................................................... 9-3

9.1.1 Fault Diagnosis with TEST Variables .................................................................................... 9-3

9.1.2 Fault Diagnosis with WARNING Messages .......................................................................... 9-8

9.1.3 Fault Diagnosis Using DIAGNOSTIC Mode....................................................................... 9-11

9.1.4 M200A Internal Variables .................................................................................................... 9-18

9.1.5 Test Channel Analog Output ................................................................................................9-20

9.1.6 Factory Calibration Procedure .............................................................................................. 9-23

PERFORMANCE PROBLEMS ............................................................................................................ 9-26

9.2

9.2.1 AC Power Check................................................................................................................... 9-27

9.2.2 Flow Check ........................................................................................................................... 9-27

9.2.3 No Response to Sample ........................................................................................................9-28

9.2.4 Negative Output.................................................................................................................... 9-29

9.2.5 Excessive Noise ....................................................................................................................9-29

9.2.6 Unstable Span ....................................................................................................................... 9-30

9.2.7 Unstable Zero........................................................................................................................ 9-31

9.2.8 Inability to Span....................................................................................................................9-31

9.2.9 Inability to Zero .................................................................................................................... 9-32

9.2.10 Non-Linear Response ......................................................................................................... 9-33

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9.2.11 Slow Response.................................................................................................................... 9-34

9.2.12 Analog Output Doesn't Agree with Display Concentration................................................ 9-34

9.3 SUBSYSTEM TROUBLESHOOTING AND ADJUSTMENTS ................................................................... 9-35

9.3.1 Computer, Display, Keyboard .............................................................................................. 9-35

9.3.2 RS-232 Communications...................................................................................................... 9-38

9.3.3 Voltage/Frequency (V/F) Board ...........................................................................................9-41

9.3.4 Status/Temp Board................................................................................................................9-47

9.3.5 Power Supply Module .......................................................................................................... 9-49

9.3.6 Ozone Generator ................................................................................................................... 9-54

9.3.7 Flow/Pressure Sensor............................................................................................................ 9-57

9.3.8 NOx Sensor Module .............................................................................................................. 9-62

9.3.9 Z/S Valves & IZS Permeation Tube Oven ...........................................................................9-66

9.3.10 Pneumatic System...............................................................................................................9-67

10 M200A SPARE PARTS LIST................................................................................10-1

APPENDIX A ELECTRICAL SCHEMATICS ....................................................A-1

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LIST OF FIGURES

FIGURE 2-1: REMOVAL OF SHIPPING SCREWS & CHECK FOR CORRECT POWER ....................................... 2-3

FIGURE 2-2: REAR PANEL ........................................................................................................................ 2-4

FIGURE 2-3: INLET AND EXHAUST VENTING ............................................................................................2-5

FIGURE 2-4: FRONT PANEL .................................................................................................................... 2-10

FIGURE 2-5: ASSEMBLY LAYOUT ........................................................................................................... 2-11

FIGURE 4-1: BLOCK DIAGRAM ................................................................................................................. 4-2

FIGURE 4-2: EXTERNAL PUMP PACK ........................................................................................................ 4-8

FIGURE 5-1: SAMPLE MENU TREE............................................................................................................5-2

IGURE 5-2: SETUP MENU TREE............................................................................................................... 5-3

F
F

IGURE 6-1: IZS OPTION - PERMEATION TUBE INSTALLATION ................................................................ 6-7

FIGURE 7-1: CALIBRATION SETUP ............................................................................................................ 7-3

FIGURE 7-2: DIAGRAM OF GPT CALIBRATION SYSTEM ......................................................................... 7-21

FIGURE 8-1: REPLACING THE PARTICULATE FILTER................................................................................. 8-4

FIGURE 8-2: MOLYBDENUM CONVERTER ASSEMBLY .............................................................................. 8-8

FIGURE 8-3: REACTION CELL ASSEMBLY............................................................................................... 8-10

FIGURE 8-4: PNEUMATIC DIAGRAM - STANDARD CONFIGURATION ....................................................... 8-12

FIGURE 8-5: PNEUMATIC DIAGRAM WITH ZERO/SPAN VALVE OPTION .................................................. 8-13

FIGURE 8-6: PNEUMATIC DIAGRAM WITH IZS OPTION .......................................................................... 8-14

FIGURE 9-1: SPAN CALIBRATION VOLTAGE ...........................................................................................9-25

FIGURE 9-2: CPU BOARD JUMPER SETTINGS .........................................................................................9-36

FIGURE 9-3: RS-232 PIN ASSIGNMENTS................................................................................................9-40

FIGURE 9-4: V/F BOARD SETTINGS ........................................................................................................ 9-46

FIGURE 9-5: POWER SUPPLY MODULE LAYOUT.....................................................................................9-51

FIGURE 9-6: ELECTRICAL BLOCK DIAGRAM .......................................................................................... 9-52

FIGURE 9-7: OZONE GENERATOR SUBSYSTEM ....................................................................................... 9-56

FIGURE 9-8: FLOW/PRESSURE SENSOR...................................................................................................9-59

IGURE 9-9: NOX SENSOR MODULE ....................................................................................................... 9-60

F
FIGURE 9-10: NO
F

IGURE 9-11: PMT COOLER SUBSYSTEM............................................................................................... 9-63

FIGURE 9-12: HIGH VOLTAGE POWER SUPPLY....................................................................................... 9-65

SENSOR MODULE ..................................................................................................... 9-61

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LIST OF TABLES

TABLE 2-2-1: REMOVAL OF SHIPPING SCREWS & CHECK FOR CORRECT POWER .....................................2-3

TABLE 2-2-2: REAR PANEL ......................................................................................................................2-4

TABLE 2-2-3: INLET AND EXHAUST VENTING .......................................................................................... 2-5

TABLE 2-2-4: FRONT PANEL .................................................................................................................. 2-10

TABLE 2-2-5: ASSEMBLY LAYOUT.........................................................................................................2-11

TABLE 2-2-6: FINAL TEST AND CALIBRATION VALUES.......................................................................... 2-12

TABLE 2-1: FINAL TEST AND CALIBRATION VALUES (CONTINUED)....................................................... 2-13

TABLE 4-4-1: BLOCK DIAGRAM...............................................................................................................4-2

ABLE 4-4-2: FRONT PANEL STATUS LED'S ............................................................................................4-5

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ABLE 4-4-3: EXTERNAL PUMP PACK ...................................................................................................... 4-8

TABLE 4-4-4: OZONE GENERATOR START-UP TIMING ............................................................................. 4-9

TABLE 5-5-1: SAMPLE MENU TREE.......................................................................................................... 5-2

TABLE 5-5-2: SETUP MENU TREE ............................................................................................................ 5-3

TABLE 5-5-3: M200A SAMPLE MENU STRUCTURE..................................................................................5-4

TABLE 5-5-4: M200A SETUP MENU STRUCTURE..................................................................................... 5-5

TABLE 5-5-5: M200A MENU STRUCTURE - SETUP MENU #2................................................................... 5-6

TABLE 5-5-6: M200A MENU STRUCTURE - SETUP MENU #3................................................................... 5-6

TABLE 5-5-7: DAS DATA CHANNEL EDITING........................................................................................5-16

TABLE 5-5-8: CALIBRATE, SETUP PASSWORDS ......................................................................................5-20

TABLE 5-5-9: M200A OPERATING MODES ............................................................................................5-22

TABLE 5-5-10: STATUS OUTPUT PIN ASSIGNMENTS .............................................................................. 5-23

TABLE 5-5-11: RS-232 PORT SETUP - FRONT PANEL ............................................................................. 5-25

TABLE 5-5-12: RS-232 SWITCHING FROM TERMINAL MODE TO COMPUTER MODE ..............................5-26

TABLE 5-5-13: RS-232 TERMINAL MODE EDITING KEYS ...................................................................... 5-26

TABLE 5-5-14: RS-232 COMMAND SUMMARY....................................................................................... 5-29

TABLE 5-5-15: RS-232 COMMAND SUMMARY....................................................................................... 5-30

TABLE 5-5-16: RS-232 INTERFACE COMMAND TYPES...........................................................................5-31

ABLE 5-5-17: RS-232 TEST MESSAGES ............................................................................................... 5-32

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TABLE 5-5-18: RS-232 WARNING MESSAGES ....................................................................................... 5-33

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ABLE 5-5-19: RS-232 CALIBRATION COMMANDS................................................................................ 5-34

TABLE 5-5-20: RS-232 CALIBRATION EXAMPLES.................................................................................. 5-35

ABLE 5-5-21: RS-232 CALIBRATION MESSAGES.................................................................................. 5-36

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TABLE 5-5-22: RS-232 DIAGNOSTIC COMMAND SUMMARY .................................................................. 5-37

TABLE 6-6-1: ZERO/SPAN VALVE OPERATION......................................................................................... 6-2

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ABLE 6-6-2: IZS SEQUENCE MODES ......................................................................................................6-3

ABLE 6-6-3: IZS SEQUENCE ATTRIBUTES .............................................................................................. 6-4

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TABLE 6-6-4: IZS SEQUENCE EXAMPLE................................................................................................... 6-4

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ABLE 6-6-5: EXAMPLE OF AUTOCAL SETUP .......................................................................................... 6-5

TABLE 6-6-6: IZS OPTION - PERMEATION TUBE INSTALLATION ..............................................................6-7

ABLE 7-7-1: TYPES OF ZERO/SPAN CHECK AND CALIBRATION..............................................................7-2

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ABLE 7-7-2: CALIBRATION SETUP.......................................................................................................... 7-3

TABLE 7-7-3: MANUAL ZERO CALIBRATION PROCEDURE - ZERO GAS THRU SAMPLE PORT ................... 7-4

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TABLE 7-7-4: ENTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE ........................................... 7-5

TABLE 7-7-5: MANUAL SPAN CALIBRATION PROCEDURE - SPAN GAS THRU SAMPLE PORT .................... 7-5

TABLE 7-7-6: MANUAL ZERO CALIBRATION PROCEDURE - Z/S VALVES ................................................. 7-6

TABLE 7-7-7: MANUAL SPAN CALIBRATION PROCEDURE - Z/S VALVES ................................................. 7-6

TABLE 7-7-8: ENABLING DYNAMIC ZERO/SPAN ......................................................................................7-8

TABLE 7-7-9: ENABLING CAL-ON-NO2 ............................................................................................... 7-10

TABLE 7-7-10: IZS OR Z/S VALVES MODES WITH REMOTE CONTACT CLOSURE...................................7-11

TABLE 7-7-11: ACTIVITY MATRIX FOR CALIBRATION EQUIPMENT AND SUPPLIES................................. 7-13

TABLE 7-7-12: ACTIVITY MATRIX FOR CALIBRATION PROCEDURE ....................................................... 7-14

TABLE 7-7-13: DIAGRAM OF GPT CALIBRATION SYSTEM .....................................................................7-21

TABLE 7-7-14: ZERO CALIBRATION PROCEDURE ...................................................................................7-22

TABLE 7-7-15: EXPECTED SPAN GAS CONCENTRATION PROCEDURE..................................................... 7-23

TABLE 7-7-16: SPAN CALIBRATION PROCEDURE ................................................................................... 7-23

TABLE 7-7-17: AUTOMATIC CALCULATION OF CONVERTER EFFICIENCY .............................................. 7-26

TABLE 7-7-18: DEFINITION OF LEVEL 1 AND LEVEL 2 ZERO AND SPAN CHECKS ................................... 7-28

TABLE 7-7-19: ACTIVITY MATRIX FOR DATA QUALITY ........................................................................ 7-29

TABLE 7-7-20: NIST-SRM'S AVAILABLE FOR TRACEABILITY OF CALIBRATION AND AUDIT GAS

STANDARDS..................................................................................................................................... 7-32

TABLE 7-7-21: CALIBRATION QUALITY CHECK .....................................................................................7-36

TABLE 8-8-1: PREVENTATIVE MAINTENANCE SCHEDULE ........................................................................ 8-1

TABLE 8-8-2: PREVENTATIVE MAINTENANCE SCHEDULE ........................................................................ 8-2

TABLE 8-8-3: REPLACING THE PARTICULATE FILTER .............................................................................. 8-4

TABLE 8-8-4: MOLYBDENUM CONVERTER ASSEMBLY ............................................................................ 8-8

TABLE 8-8-5: REACTION CELL ASSEMBLY............................................................................................. 8-10

TABLE 8-8-6: PNEUMATIC DIAGRAM - STANDARD CONFIGURATION ..................................................... 8-12

TABLE 8-8-7: PNEUMATIC DIAGRAM WITH ZERO/SPAN VALVE OPTION................................................8-13

TABLE 8-8-8: PNEUMATIC DIAGRAM WITH IZS OPTION ........................................................................ 8-14

TABLE 9-9-1: TEST FUNCTIONS................................................................................................................ 9-4

TABLE 9-1: TEST FUNCTIONS (CONTINUED) ............................................................................................9-5

TABLE 9-1: TEST FUNCTIONS (CONTINUED) ............................................................................................9-6

ABLE 9-1: TEST FUNCTIONS (CONTINUED) ............................................................................................9-7

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TABLE 9-9-2: FRONT PANEL WARNING MESSAGES ................................................................................. 9-9

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ABLE 9-2: FRONT PANEL WARNING MESSAGES (CONTINUED) ............................................................ 9-10

ABLE 9-9-3: SUMMARY OF DIAGNOSTIC MODES.................................................................................. 9-12

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TABLE 9-9-4: DIAGNOSTIC MODE - SIGNAL I/O..................................................................................... 9-13

TABLE 9-4: DIAGNOSTIC MODE - SIGNAL I/O (CONTINUED).................................................................. 9-14

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ABLE 9-4: DIAGNOSTIC MODE - SIGNAL I/O (CONTINUED).................................................................. 9-15

ABLE 9-4: DIAGNOSTIC MODE - SIGNAL I/O (CONTINUED).................................................................. 9-16

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TABLE 9-9-5: MODEL 200A INTERNAL VARIABLES...............................................................................9-20

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ABLE 9-9-6: TEST CHANNEL READINGS............................................................................................... 9-21

ABLE 9-6: TEST CHANNEL READINGS (CONTINUED)............................................................................ 9-22

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ABLE 9-9-7: SPAN CALIBRATION VOLTAGE ......................................................................................... 9-25

ABLE 9-9-8: CPU BOARD JUMPER SETTINGS ....................................................................................... 9-36

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ABLE 9-9-9: RS-232 PIN ASSIGNMENTS.............................................................................................. 9-40

TABLE 9-9-10: MOTHERBOARD JUMPER SETTINGS ................................................................................ 9-43

ABLE 9-9-11: V/F BOARD SWITCH SETTINGS ......................................................................................9-44

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TABLE 9-9-12: V/F BOARD SETTINGS....................................................................................................9-46

TABLE 9-9-13: POWER SUPPLY MODULE SUBASSEMBLIES ....................................................................9-50

TABLE 9-9-14: POWER SUPPLY MODULE LAYOUT................................................................................. 9-51

TABLE 9-9-15: ELECTRICAL BLOCK DIAGRAM ......................................................................................9-52

TABLE 9-9-16: POWER SUPPLY MODULE LED OPERATION ...................................................................9-53

TABLE 9-9-17: OZONE GENERATOR CONTROL CONDITIONS..................................................................9-55

TABLE 9-9-18: OZONE GENERATOR SUBSYSTEM...................................................................................9-56

TABLE 9-9-19: FLOW/PRESSURE SENSOR............................................................................................... 9-59

TABLE 9-9-20: NO
TABLE 9-9-21: NO

SENSOR MODULE...................................................................................................9-60

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SENSOR MODULE...................................................................................................9-61

X

TABLE 9-9-22: PMT COOLER SUBSYSTEM............................................................................................. 9-63

TABLE 9-9-23: HIGH VOLTAGE POWER SUPPLY .................................................................................... 9-65

TABLE 10-1: TELEDYNE API M200A SPARE PARTS LIST ...................................................................... 10-1

TABLE 10-2: TELEDYNE API MODEL 200A 37 MM FILTER EXPENDABLES KIT ................................... 10-5

TABLE 10-3: TELEDYNE API MODEL 200A 47 MM FIITER EXPENDABLES KIT .................................... 10-5

TABLE 10-4: TELEDYNE API MODEL 200A EXPENDABLES KIT - IZS.................................................. 10-6

TABLE 10-5: TELEDYNE API MODEL 200A LEVEL 1 SPARES KIT ........................................................10-6

TABLE 10-6: TELEDYNE API MODEL 200A SPARES KIT FOR 1 UNIT...................................................10-7

TABLE 10-7: TELEDYNE API MODEL 200A 37 MM FIITER EXPENDABLES KIT WITH CH1 .................. 10-7

TABLE 10-8: TELEDYNE API MODEL 200A 47 MM FIITER EXPENDABLES KIT WITH CH1 .................. 10-8

TABLE A-1: ELECTRICAL SCHEMATICS ....................................................................................................... 1

TABLE A-1: ELECTRICAL SCHEMATICS (CONTINUED) ................................................................................ 2

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Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247

1 HOW TO USE THIS MANUAL

The Model 200A has been designed to provide serviceability, reliability and ease of operation.
The M200A's microprocessor continually checks operating parameters such as temperatue, flow,
and critical voltages. The instruments modular design uses captive screws to facilitate repair and
ease of access. If you encounter any difficulty refer to Section 9 General Troubleshooting Hints.

We recognize that the need for information in this manual changes as time passes. When the
instrument first arrives, it is necessary to get it up and running quickly and verify its correct
operation. As time passes, more detailed information is often required on special configurations,
calibration alternatives and other operational details. Finally there is the need for periodic
maintenance and to quickly troubleshoot problems to assure maximum reliability and data
integrity.

To address these needs, we have created three indexes to the information inside. They are:

Table of Contents:

Outlines the contents of the manual in the order the information is presented. This is a good
overview of the topics covered in the manual. There is also a list of Tables and a list of Figures.

Index to M200A Front Panel Menus:

The Menu Index (Table 5-5-1 and Table 5-5-2, Table 5-5-3 and Table 5-5-4) briefly describes
the front panel menus and refers you to other sections of the manual that have a detailed
explanation of each menu selection.

Troubleshooting Section 9:

The Troubleshooting Section, outlined in the Table of Contents, allows you to diagnose and
repair the instrument based on variables in the TEST menu, the results of DIAGNOSTIC tests,
and performance faults such as excessive noise or drift. The troubleshooting section also
explains the operation, adjustment, diagnosis and testing of each instrument subsystem.

If you are unpacking the instrument for the first time, please refer to Getting Started in
Section 2.

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2 GETTING STARTED

2.1 Unpacking

1. Verify that there is no apparent shipping damage. If damage has occurred please advise

shipper first, then Teledyne API.

CAUTION

To avoid personal injury, always use two persons to

lift and carry the Model 200A.

2. Before operation, it is necessary to remove the shipping hold-down screws. Remove the

instrument cover, then refer to Table 2-2-1 for screw location.

3. Also check for internal shipping damage, and generally inspect the interior of the

instrument to m
boards are seated properly.

ake sure all circuit boards and other components are in good shape and all

4. Please check the voltage and frequency label on the rear panel of the instrument for

compatability with the local power before plugging in the M200A.

2.2 Electrical and Pneumatic Connections

1. Refer to Table 2-2-2 to locate the rear panel electrical and pneumatic connections.

2. Attach the pump to the Exhaust Out port on the rear panel as shown in Table 2-2-3.

3. If you are connecting to a calibrator, attach a vented sample inlet line to the sample inlet

port. The pressure of the sample gas at the inlet port should be at ambient pressure. The
exhaust from the pump should be vented to atmospheric pressure. See Table 2-2-3 for inlet
and exhaust line venting recommendations during calibration.

4. If desired, attach the analog output connections to a strip chart recorder and/or

datalogger. Refer to Table 9-9-12 for the jumper settings for the desired analog output
voltage range. Factory default setting is 0-5 VDC.

5. Connect the power cord to the correct voltage line, then turn to Section 2.3 Initial

Operation.

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WARNING

Analyzer Exhaust – O3 Scrubber – Pump

Pack Danger – Analyzer exhaust contains ozone.

Ozone scrubber must always be present

between analyzer exhaust and pump.

Vent pump exhaust to well ventilated area at atmosphere

pressure FIRE or EXPLOSION HAZARD.

Do not use charcoal treated with halogen compounds –

use only Teledyne API P/N 00596 charcoal.

Wait at least 5 minutes after turning off pump

before removing ozone scrubber WARNING.

WARNING

Lethal voltages present inside case.

Do not operate with cover off during normal operation.

Before operation check for correct input

voltage and frequency.

Do not operate without proper chassis grounding.

Do not defeat the ground wire on power plug.

Turn off analyzer power before disconnecting

electrical subassemblies.

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Table 2-2-1: Removal of Shipping Screws & Check for Correct Power

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Table 2-2-2: Rear Panel

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Table 2-2-3: Inlet and Exhaust Venting

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2.3 Initial Operation

1. Turn on the instrument power.

2. The display should immediately light, displaying the instrument type (M200A) and the

computer's memory configuration. If you are unfamiliar with the M200A, we recommend
that you read the overview Section 4 before proceeding. A diagram of the software menu
trees is in Table 5-5-1 and Table 5-5-2.

3. The M200A requires about 30 minutes for all internal com

temperature. During this time the ozone generator power is OFF until the membrane dryer
has time to purge itself, therefore there will be no response from the instrument, even if span
gas is coming in the sample port. During this time temperatures and other conditions are out
of specification. Because many warning conditions could be displayed warning conditions
are suppressed for 30 minutes after power up. After 30 minutes, warning messages will be
displayed until the respective warning conditions are within specifications. Use the CLR key
on the front panel to clear warning messages.

4. While waiting for instrument temperatures to come up, you can check for correct

operation by using some of the M200A's diagnostic and test features.

5. Examine the TEST functions by comparing the values listed in Table 2-2-6 to those in the

display. Rememb
final values yet. If you would like to know more about the meaning and utility of each TEST
function, refer to Table 9-9-1. Also, now is a good time to verify that the instrument was
shipped with the options you ordered. Table 2-2-6 includes a list of options. Section 6 covers
setting up the options.

6. Electric Test and Optic Test both generate simulated signals in the M200A.
A. Electric Test tests the electronics of the PMT signal path. To operate Electric Test from

the front panel press SETUP-MORE-DIAG, then scroll to ELECTRICAL TEST and press
ENTR to turn on the electric test. When ELEC test is operating, scroll the TEST function
to PMT and compare instrument response to the values indicated in Table 2-2-6 . To turn
off this test press EXIT. For more information on the circuitry being tested refer to the
Troubleshooting Section 9.1.3.2.

er that as the instrument warms up the values may not have reached their

ponents to come up to

B. Optic Test is an "end to end" test of the analyzer HVPS/PMT/ electronics/computer. It

lates a signal by turning on a LED in the Sensor Module. To operate Optic Test from

simu
the front panel press SETUP-MORE-DIAG, then scroll to OPTIC test and press ENTR to
turn on the optic test. Scroll the TEST function PMT and compare instrument response to
the values indicated in Table 2-2-6. To turn off this test press EXIT. To return to the
SAMPLE mode press EXIT until SAMPLE is displayed in the upper left display. For
more information about OT operation, see Section 9.1.3.3.

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7. When the instrument is warmed up, re-check the TEST functions against Table 2-2-6. All

of the readings should compare closely with those in the Table. If they do not, see Section

9.1.1. The next task is to calibrate the analyzer. There are several ways to do a calibration,
they are summarized in Table 7-7-1. For a preliminary checkout we recommend calibration
with zero air and span gas coming in through the sample port. The procedure is:

Step 1 - Enter the expected NOx and NO span gas concentrations:

Step Number Action Comment

1. Press
CAL-CONC-NOx

2. Press ENTR ENTR stores the expected NOx span value. This value will be

3. Press
CAL-CONC-NO

4. Press EXIT-EXIT Returns instrument to SAMPLE mode.

5. Press
SETUP-RNGE­MODE-SING-ENTR

6. Press
SETUP-RNGE-SET

7. Press EXIT Returns instrument to SAMPLE mode.

This key sequence causes the M200A to prompt for the
expected NOx concentration. Enter the NOx span
concentration value by pressing the key under each digit until
the expected value is set.

used in the internal formulas to compute subsequent NOx
concentration values.

In the same CAL-CONC sub menu press the NO button and
enter the expected NO span value, then ENTR. As before this
value will be used in the internal formulas to compute the
subsequent NO concentration values.

If necessary you may want to change ranges. Normally the
instrument is shipped in single range mode set at 500 ppb. We
recommend doing the initial checkout on the 500 ppb range.

After SETUP-RNGE-SET, enter 500 and press ENTR. The
instrument will now be in the 500 ppb range.

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Step 2 - Calibrate the instrument:

Zero/Span Calibration Procedure

Step Number Action Comment

1. Input Zero gas Allow Zero gas to enter the sample port on the rear of the

instrument.

2. Press CAL The M200A enters the calibrate mode from sample mode.

3. Wait 10 min Wait for reading to stabilize at the zero value. If you wait less

than 10 minutes the final zero value may drift.

4. Press ZERO The ZERO button will be displayed.

5. Press ENTR Pressing ENTR actually changes the calculation equations and

zeroes the instrument.

6. Input Span Gas Switch gas streams to span gas.

7. Wait 10 min Wait for reading to stabilize at the span value. If you wait less

than 10 minutes the final span value may drift.

8. Press SPAN The SPAN button should be displayed. If it is not, check the

Troubleshooting Section 9.2.8 for instructions on how to
proceed. In certain circumstances at low span gas
concentrations (<100ppb), both the ZERO and SPAN buttons
will appear.

9. Press ENTR Pressing ENTR actually changes the calculation equations so

that the concentration displayed is the same as the expected
span concentration you entered above, thus spanning the
instrument.

10. Press EXIT Pressing EXIT returns the instrument to SAMPLE mode.

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Step 3 - Review the quality of the calibration:

Calibration Quality Check Procedure

Step Number Action Comment

1. Scroll the TEST
function menu until
the NO
displayed.

2. Scroll the TEST
function menu until
the NO SLOPE is
displayed.

3. Scroll the TEST
function menu until
the NOx OFFSET is
displayed.

4. Scroll the TEST
function menu until
the NO OFFSET is
displayed.

SLOPE is

x

The SLOPE value for NOx should be 1.0 ± 0.3. If the value is
not in this range, check Section 7.10 or 9. If the SLOPE value
is in the acceptable range, the instrum
optimally.

The SLOPE value for NO should be 1.0 ± 0.3. If the value is
not in this range, check Section 7.10 or 9. If the SLOPE is in
the acceptable range, the instrum

NOTE:
The NO and NOx slopes should be equal within ± 0.1.

The M200A will display the OFFSET parameter for the NOx
equation. This number should be near zero. A value of 0.0
± 150 mV indicates calibration in the optimal range. If the
OFFSET value is outside this range, check Section 7.4 or 9 for
procedures to correct the OFFSET value to near zero.

The instrument will now display the NO OFFSET value. It
should also have a value near zero (0.0 ± 150 mV).

ent will perform

ent will perform

optimally.

Step 4 - The M200A is now ready to measure sample gas.

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Table 2-2-4: Front Panel

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Table 2-2-5: Assembly Layout

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Table 2-2-6: Final Test and Calibration Values

Test Values

Observed
Value

Units Nominal Range Reference Section

RANGE PPB 50-20,000 5.3.4

STABILITY
(Zero Gas)

PPB < 0.2 9.1.1, Table 9-9-1,

9.2.5

SAMP FLW cc/min 500 ± 50 9.3.7, Table 9-9-1

OZONE FL cc/min 60 - 90 9.3.6, 9.3.7

PMT mV 0-5000 9.3.8.1, Table 9-9-1

AZERO mV -20 - 150 Table 9-9-1

HVPS V 450 - 900 constant 9.3.8.5

DCPS mV 2500 ± 200 9.3.5, 9.3.4

RCELL TEMP

BOX TEMP

PMT TEMP

IZS TEMP

MOLY TEMP

o

C 50 ±1 9.3.8.2

o

C 8-48 9.3.4.1

o

C 7 ± 1 9.3.8.4

o

C 50 ± 0.4 9.3.9

o

C 315 ± 5 9.3.4.1

RCEL PRES IN-Hg-A 4 - 10 constant 9.3.7

SAMP PRES IN-Hg-A 25 - 30 constant 9.3.7

Electric Test & Optic Test

Electric Test

PMT Volts mV 2000 ± 500 9.1.3.2

NO Conc PPB 1000 ± 250 9.1.3.2

NOx Conc PPB 1000 ± 250 9.1.3.2

Optic Test

PMT Volts mV 2000 ± 1000 9.1.3.3

NO Conc PPB 1000 ± 500 9.1.3.3

NOx Conc PPB 1000 ± 500 9.1.3.3

(table continued)

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Table 2-1: Final Test and Calibration Values (Continued)

Parameter

NO Span Conc PPB 20 - 20,000 Table 7-7-4

NOx Span Conc PPB 20 - 20,000 Table 7-7-4

NO Slope - 1.0 ± 0.3 Table 7-7-21

NOx Slope - 1.0 ± 0.3 Table 7-7-21

NO Offset mV -10 to +150 Table 7-7-21

NOx Offset mV -10 to +150 Table 7-7-21

Moly Efficiency % 0.96 - 1.02 7.8.6, 5.2.2.6

Stability at Zero PPB < 0.2 Table 9-9-1

Stability at Span PPB < 2 ppb @ 400ppb

Sample Flow cc/min 500 ± 50 9.3.7, Table 9-9-19

Ozone Flow cc/min 60 - 90 9.3.7, Table 9-9-19

IZS Purge Flow cc/min 60 ± 15 6.3

Observed
Value

Units Nominal Range Reference Section

Table 9-9-1

span gas

Measured Flows

Factory Installed Options Option Installed

Power Voltage/Frequency

Rack Mount, w/ Slides

Rack Mount, w/ Ears Only

Rack Mount, External Pump w/ Slides

Rack Mount, External Pump w/o Slides

Stainless Zero/Span Valves

Internal Zero/Span - IZS

Permeation Tube Output Specification

Current Loop - NOx Chan 4-20 mA 0-20 mA Isolated Non-Isolated

Current Loop - NO Chan 4-20 mA 0-20 mA Isolated Non-Isolated

Current Loop - NO2 Chan 4-20 mA 0-20 mA Isolated Non-Isolated

Current Loop - TST Chan 4-20 mA 0-20 mA Isolated Non-Isolated

Internal Pump

PROM # Serial #
Date Technician

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