Teledyne 4030, HEATED THC User Manual

Series 4030

INSTRUCTION, OPERATING AND

MAINTENANCE MANUAL FOR

SERIES 4030 HEATED THC

TELEDYNE ANALYTICAL INSTRUMENTS

SAMPLESPAN

SPAN GAS

BYPASS FLOW

TEMP. GAUGE

DANGER

Toxic and/or flammable gases or liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist for

a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing. Before

conducting any maintenance or servicing, consult with authorized
supervisor/manager.

P/N M77216

ECO: #XX-XXXX

DATE 12/13/05

Teledyne Analytical Instruments

Series 4030

Copyright © 2004 Teledyne Analytical Instruments

All 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 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 authorized 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 be properly trained in the
process being measured, as well as all instrumentation 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 manufacturer or its
agents, is to be construed as a warranty of adequate safety control under the user’s process
conditions.

Teledyne Analytical Instruments

Series 4030

Safety Messages

Your safety and the safety of others are 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. These
cautions warn of specific procedures which if not
followed could cause bodily Injury and/or damage the
instrument.

No

Symbol

CAUTION: HOT SURFACE WARNING: This warning is

specific to heated components within the instrument.
Failure to heed the warning could result in serious burns
to skin and underlying tissue.

WARNING: ELECTRICAL SHOCK HAZARD: Dangerous

voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed
this warning could result in injury and/or death from
electrocution.

Technician Symbol: All operations marked with this

symbol are to be performed by qualified maintenance
personnel only.

NOTE: Additional information and comments regarding

a specific component or procedure are highlighted in the
form of a note.

STAND-BY: This symbol indicates that the instrument is

on Stand-by but circuits are active.

Teledyne Analytical Instruments i

Series 4030

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 RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.

This manual provides information designed to guide you through the
installation, calibration and operation of your new analyzer. Please read
this manual and keep it available.

Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be specific to your
instrument.

Manuals do get misplaced. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.

Teledyne Analytical Instruments ii

Series 4030

Additional Safety Information

DANGER

COMBUSTIBLE GAS USAGE

This is a general purpose instrument designed for usage in a
non-hazardous area. It is the customer's responsibility to
ensure safety especially when combustible gases are being
analyzed since the potential of gas leaks always exist.

WARNING

The customer should ensure that the principles of operating
of this equipment are well understood by the user. Misuse of
this product in any manner, tampering with its components,
or unauthorized substitution of any component may
adversely affect the safety of this instrument.

Since the use of this instrument is beyond the control of
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.

WARNING: HYDROGEN GAS IS USED IN THIS INSTRUMENT AS

A FUEL. HYDROGEN IS EXTREMELY FLAMMABLE.
EXTREME CARE MUST BE USED WHEN WORKING
AROUND GAS MIXTURES CONTAINING
FLAMMABLE GASES.

A Successful leak check was performed at TI/AI on
the sample system of this instrument prior to
calibration, testing and shipping. Ensure that there
are no leaks in the fuel supply lines before applying
power to the system.

Always purge the entire system before performing
any maintenance and always leak check the system
after removing any tubing or fittings on the sample

Teledyne Analytical Instruments iii

Series 4030

system. See the procedures for purging and leak
checking this instrument on the following pages.

If toxic gases or other hazardous materials are
introduced into the sample system, the same
precautions regarding leak checking and purging
apply to the sample lines and sample supply or
delivery lines.

WARNING: ELECTRICAL SHOCK HAZARD. WITH THE

EXCEPTION OF OPENING THE DOOR AND
ADJUSTING THE PRESSURE REGULATORS, FLOW
CONTROLLER, OR OBSERVING THE PRESSURE
GAUGES AND THE FLOWMETER, ONLY
AUTHORIZED AND SUITABLY TRAINED
PERSONNEL SHOULD PERFORM WORK INSIDE OF
THE INSTRUMENT. COMPONENTS WITHIN THE
COVER ON THE INSIDE OF THE DOOR, INSIDE THE
ISOTHERMAL CHAMBER (SAMPLE SYSTEM), AND
ON THE ELECTROMETER-AMPLIFIER PC BOARD
CONTAIN DANGEROUSLY HIGH VOLTAGE
SUFFICIENT TO CAUSE SERIOUS INJURY OR
DEATH.

There are the following three types of inaccessible

shock hazards within the Analyzer:

1. Line voltages and line related voltages such as
115 VAC which exists within the 230 VAC
versions as well. These voltages stop when the
Analyzer is turned off and the mains (line) cord is
removed from the instrument.

2. The sensor anode supply voltage (approximately
250 VDC). This voltage exists on the Flame
Guard, anode power supply, PCB, the
motherboard, and the anode/igniter terminals on
the sensor. THIS VOLTAGE WILL REMAIN
HAZARDOUS FOR MANY MINUTES AFTER THE
ANALYZER HAS BEEN TURNED OFF!

3. External hazardous voltages which may be
connected to the Analyzer alarm relay
connections.

Teledyne Analytical Instruments iv

Series 4030

Procedure for Removal of Internal Inaccessible
Shock Hazards

CAUTION: SERVICING OR MAINTENANCE OF THE ANALYZER

SHOULD ONLY BE DONE BY SUITABLE TRAINED
PERSONNEL. TO AVOID THESE INACCESSIBLE
HAZARDOUS VOLTAGES WHEN SERVICING THE

power cord from the Analyzer.

contacts.

SERIES 4060, PERFORM EACH OF THE FOLLOWING
STEPS, IN THE ORDER GIVEN, BEFORE SERVICING
BEGINS:

Switch off the power to the Analyzer and remove the main (line)

Remove all external voltages from the connections to the alarm

Wait one minute.

Discharge the anode supply voltage.

a. Connect one end of an insulated (to 1000 VDC or more)

clip lead to Analyzer chassis ground (the standoff for the
upper right corner of the mother PCB).

b. Put one end of a 500V rated 1000 ohm resistor in the

other end of the clip lead.

c. Check the voltage between chassis ground (the standoff

for the upper right corner of the mother PCB) and the top
side of R2 at PCB number B74671. It should be between

-5VDC and +5VDC. If is in that range, the inaccessible

hazardous voltage removal procedure is completed, if not
repeat steps 4.a and 4.b.

If it is absolutely necessary to work inside the instrument with power

on, use the ONE HAND RULE:

Work with one hand only.

Keep the other hand free without contacting any other object. This
reduces the possibility of a ground path through the body in case of
accidental contact with hazardous voltages.

WARNING: THIS INSTRUMENT IS DESIGNED TO BE OPERATED

IN A NONHAZARDOUS AREA. THE ANALYZER USES
HYDROGEN GAS AND/OR OTHER COMBUSTIBLE
GASES IN ITS OPERATION. THIS EQUIPMENT, IF
NOT USED AND MAINTAINED PROPERLY CAN BE
AN EXPLOSION HAZARD. THE ANALYZER,

Teledyne Analytical Instruments v

Series 4030

DEPENDING ON THE APPLICATION, MAY ALSO USE
TOXIC GASES. IT IS THEREFORE, THE
CUSTOMER'S RESPONSIBILITY TO ENSURE THAT
PROPER TRAINING AND UNDERSTANDING OF THE
PRINCIPLES OF OPERATION OF THIS EQUIPMENT
ARE UNDERSTOOD BY THE USER. SINCE THE USE
OF THIS INSTRUMENT IS BEYOND THE CONTROL
OF TELEDYNE, NO RESPONSIBILITY BY TELEDYNE,
ITS AFFILIATES AND AGENTS FOR DAMAGE OR
INJURY RESULTING FROM MISUSE OR NEGLECT
OF THIS INSTRUMENT IS IMPLIED OR ASSUMED.
MISUSE OF THIS PRODUCT IN ANY MANNER,
TAMPERING WITH ITS COMPONENTS OR
UNAUTHORIZED SUBSTITUTION OF ANY
COMPONENT MAY ADVERSELY AFFECT THE
SAFETY OF THIS INSTRUMENT.

CAUTION: WHEN OPERATING THIS INSTRUMENT, THE DOORS

MUST BE CLOSED AND ALL COVERS SECURELY
FASTENED. THE GAUGES MUST BE IN PROPER
WORKING ORDER. DO NOT OVERPRESSURIZE THE
SYSTEM.

READ THIS MANUAL BEFORE OPERATING THE

INSTRUMENT AND ADHERE TO ALL WARNINGS
INCLUDED IN THIS MANUAL.

Teledyne Analytical Instruments vi

Introduction

Introduction

Teledyne Analytical Instruments Series 4030 Total Hydrocarbon
(THC) Analyzer is designed to measure the quantity of hydrocarbons
present in a heated sample gas, such as gaseous mixtures or ambient air
in various industrial applications. The Analyzer is a microprocessor
controlled digital instrument based on Teledyne’s highly successful
Model 402R series Total Hydrocarbon Analyzer, coupled with carrier
gas, a switching valve and a sample draw pump (optional). This allows
for the sample into the Sample Loop kept inside a heated SAMPLE
CHAMBER and maintained at a constant temperature in the range of 50
to 120 C as per application. With a 2-position, 10 port switching valve
and Carrier Gas, the sample collected inside the Sample Loop is pushed
inside the Flame Ionization Detector (FID) and analyzed for the THC.

The sample integrity, as it enters the Analyzer, is maintained by
ensuring that condensation does not take place inside the SAMPLE
CHAMER. This is ensured by maintaining a high temperature (50 -

80°C typical) inside the SAMPLE CHAMBER. Also, the sample is

diluted with the Carrier Gas to ensure that once the mixed sample
reached FID, no further condensation takes place.

A separate SAMPLE SELECTOR MODULE unit (optional) may be
provided for use in conjunction with the Model 4030. This allows the
User to bring the heated Sample gas (Max: 120 C) and the Span gas to
the Sample Selector Unit and manually select either Sample or Span for
entry into the Model 4030. The User is responsible for making all gas
connections from the Sample point to the Sample Selector Unit and also
between Sample Selector Unit and Model 4030. The User must also
ensure that gases are heated above the dew point (Max: temp. allowed
120 C) and are cleaned to better than 2 micron filter.

1.1 Main Features of the Analyzer

The Analyzer is sophisticated yet simple to use. A dual display on
the front panel prompts and informs the operator during all phases of
operation. The main features of the analyzer include:

1. Easy-to-use front panel interface that includes a red 5-digit LED

display and a vacuum fluorescent display (VFD), driven by
microprocessor electronics.

Teledyne Analytical Instruments 7

Introduction

2. High resolution, accurate readings of concentration.

3. Versatile analysis with three user-definable analysis ranges.

4. Microprocessor based electronics: 8-bit CMOS microprocessor

with 32 KB RAM and 128 KB ROM.

5. 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.

6. Two adjustable concentration alarms and a system failure alarm.

7. Extensive self-diagnostic testing at startup and on demand.

8. RS-232 serial digital port for use with a computer or other digital

communication device.

9. Analog outputs for selectable concentration, analog input

waveform and range identification (0-1 VDC standard and
isolated 4-20 mA dc).

10. Superior Accuracy

1.2 Principle of Operation

The sample is brought to a heated SAMPLE CHAMBER (50 - 120°
C per application) and into a sample loop and a 10-port, 2 position
(Position A & B) switching valve. The carrier gas, typically nitrogen,
pushes the sample alternatively from each sample loop into the FID to
detect the hydrocarbons.

1.3 Analyzer Description

The standard analyzer is housed in a sheet steel equipment case
flush-mounted in a 19" rack. The front interface panel is mounted on a
door which, when opened, allows convenient access to the Analyzer
electronics. The entire front panel can slide out of the chassis to provide
greater access to the electronics and to the sample system. Gas pressure
and flow controls are mounted on the front panel adjacent to the LED
and VFD displays and user interface.

At the rear of the instrument are ports for the introduction of air,
carrier, fuel, span, and sample gas. A single 50-pin user-interface cable
connector contains input/output and alarm signals available to the user.
An RS-232 port is also available at the rear panel for connection to a
remote computer or other digital communication device. The Analyzer is
set up for either 120 VAC 60 Hz or 230 50/60Hz operations depending

Teledyne Analytical Instruments 8

Introduction

on the customer’s requirements. The appropriate power cord for your
unit has been shipped with this instrument.

1.4 Applications

. Monitoring the ambient air for Total Hydrocarbons in chemical and

petrochemical plants.

. Fugitive emission monitoring.

. Process emission gases in the chemical industry.

2.1 Introduction

Using a built-in pump, the heated Sample from the Sample Selector
Unit is brought to the heated SAMPLE CHAMBER of Model 4030,
housing filter cartridge, switching valve and sample loops. Using
nitrogen carrier gas and the microprocessor actuated switching valve, a
fixed volume of sample, which is collected in Sample Loop, is pushed
into the FID detector.

Series 4030 uses a Flame Ionization Detector to sense hydrocarbons.
The FID was selected based on the positive performance and extensive
experience in the use of this detector in other Teledyne analyzers namely
Model 402R and Model 4020. The FID has proven itself to be a rugged,
stable, long life sensor giving years of trouble free operation in various
applications.

Typically, Model 4030 is calibrated using a known mixture of
methane in air, and thus the THC is shown as equivalent ppm methane
concentration.

A separate SAMPLE SELECTOR MODULE Unit (optional) may be
provided with a heated chamber (120 C Typical) and a manual 3- way
valve. This allows the User to connect Sample gas and the Span gas to
the back of the Sample Selector Unit and manually select the gas to
Model 4030 for analysis. The User must ensure that the Sample gas is
kept above the dew point to avoid condensation from the Sample point
to its entry into Model 4030.

Teledyne Analytical Instruments 9

Introduction

The Series 4030 Analyzer is composed of three subsystems:

1. Sample System

2. Detector Cell

3. Electronic Signal Processing, Display and Control

2.2 Sample System

The Analyzer contains two (2) separate isothermal chambers
controlled by individual PID temperature controllers, viewed just behind
the Front Panel. The three chambers, ‘SAMPLE’ and ‘FID are
described below.

The Analyzer consists of a SAMPLE CHAMBER containing the 10­port switching valve and 2 sample loops. A sample filter with
replaceable filter cartridge is also included inside the Sample Chamber.
The Analyzer also consists of an ‘FID’ chamber containing the Flame,
pressure regulators, pressure gauges and flow restrictors.

2.2.1 Input Porting

The Analyzer is equipped with ports for the introduction of air, fuel,
carrier gas and sample gas. It is imperative that these gases are
supplied at constant pressures using two stage stainless steel diaphragm
gas regulators. The recommended pressure range is 30 to 60 psig.

Teledyne Analytical Instruments 10

Introduction

2.2.2 Gas Flow Control System

The Piping diagram is in the rear of this manual. A 10 port-switching
valve is used to control and direct gas flows to the FID detector. The
fixed volume sample loop ensures the same volume of sample injection
in the Analyzer every cycle.

2.2.3 Fuel and Blanket Air Systems

Stable flow is achieved by maintaining a constant pressure across
restrictors upstream from the cell. Each system incorporates an adjustable
pressure regulator, pressure gauge, and restrictor. A flame out light is
included to indicate when the flame fails. A fuel shut-off solenoid valve,
mounted on the line that supplies fuel, stops the fuel flow in case of flame
failure. This valve is located in line with the fuel port.

2.2.4 Flame Ionization Detection Cell

The carrier gas containing sample and fuel are combined within a tee
fitting located in the isothermal chamber. The mixed gas is emitted from
a burner within the sensor assembly. Blanket air is introduced into the
sensor (or cell) by means of a separate fitting that is located in the base
section of the assembly. The upper half of the assembly houses the
anode-igniter, collector, and flame guard thermistor.

2.3 Detection Cell

The upper section of the stainless steel flame ionization cell houses
the cylindrical collector electrode, the high voltage (+260 VDC) anode­igniter coil, and the sensing thermistor of the flame guard circuit (see
cell cross-section Figure 2-1).

WARNING: DANGEROUS HIGH VOLTAGE EXISTS AT THE

ANODE IGNITER COIL (+260 VDC). DO NOT
ATTEMPT TO DISCONNECT THE IGNITER COIL
CABLE OR DISASSEMBLE ANY OF THE FLAME
IONIZATION CELL COMPONENTS WITHOUT
TURNING OFF THE POWER AND DISCONNECTING
THE POWER CORD.

The collector is interconnected with the electrometer-amplifier PC
board by a coaxial cable. Although the cable and fittings are intended for
coaxial service, the cable is actually being used as a shielded single­conductor connection.

Teledyne Analytical Instruments 11

Introduction

The anode-igniter, as its name implies, serves two functions. When
relay K2 at PCB part number B74671 is energized, the coil becomes an
electrical heating element that glows red-hot and ignites the hydrogen
fuel. When relay K2 at B74671 is de-energized, the coil is connected to
the +260 volt DC terminal of the anode-flame guard power supply PC
board. In this configuration, the necessary potential difference is
established between the coil (anode) and collector to promote ionization
of the burned hydrocarbons. The coil functions as the high voltage anode
in all three-range positions of the selector switch.

The thermistor acts as the sensor in the flame guard circuit. Its
ambient temperature resistance is in the 100 K ohms region. When the
flame is ignited, its resistance is reduced by a factor of 100. The
thermistor is coupled to a semiconductor control circuit on the anode­flame guard power supply PC board, which will be described in a
following section.

The cell electrodes of both the anode-igniter and flame guard
thermistor are connected to the electronics chassis by means of a plug-in
cable.

Teledyne Analytical Instruments 12

Introduction

Figure 2-1: Flame Ionization Cell

The electrode section of the cell may be removed for inspection by
turning off the power, disconnecting the electrode lead plug, and
removing the screws, which retain the electrode assembly in the sensor
body.

2.3.1 Electrometer-Amplifier

The collector cable is coupled directly to a coaxial fitting located on
the electrometer-amplifier PC board. The PC board is located on the side
panel next to but outside of the isothermal chamber. See Figure 2-1 and
consists of an electrometer amplifier and an operational amplifier. This
circuit is a very high-gain, current-to-voltage converter circuit, having
an input impedance measuring in the billions of ohms. It is static
sensitive and highly susceptible to contamination. Special care must be
taken in handling this PC board.

2.3.2 Anode Power Supply

The high voltage anode power supply components are mounted on
the anode power supply printed circuit board. High voltage regulation is
achieved through the use of series-connected zener diodes. The
simplicity of this circuit’s design can be attributed to the extremely low
current demand of the anode circuit. The positive output voltage is

Teledyne Analytical Instruments 13

Introduction

nominally 125 volts. Output tolerance is ±10 volts from the specified
125 volts.

2.3.3 Flame Guard Circuit

A thermistor-controlled, transistorized switching circuit is employed
to operate a relay in the event of a flameout condition. A panel indicator
light and fuel shut-off solenoid valve are operated by the relay to alarm
personnel that a flameout condition has occurred. The fuel shut-off
solenoid valve stops the hydrogen flow.

2.3.4 Flame Ignition Circuit

The flame ignition circuit includes the anode-igniter electrode (in the
detector cell), a transformer, and processor-controlled relay. The circuit
is automatically energized when the FID cools due to lack of flame.

If automatic ignition fails five times, there will be a message that
reports this, and the flame can be manually ignited by pressing
simultaneously the Up and Down key.

Teledyne Analytical Instruments 14

Installation

Installation

Installation of the Series 4030 Analyzer includes:

1. Unpacking

2. Mounting

3. Gas connections

4. Electrical connections

5. Testing the system.

3.1 Unpacking the Analyzer

Although the Analyzer is shipped with all the materials you need to
install and prepare the system for operation. Carefully unpack the
Analyzer and inspect it for damage. Immediately report any damage or
shortages to the shipping agent.

3.2 Mounting the Analyzer

The Series 4030 and the Sample Selector Unit are general-purpose
units and as such are designed with (non-sealed) enclosures. They must
be installed in an area where the ambient temperature is not permitted to
drop below 40ºF nor rise above 100ºF. In areas outside these
temperatures, auxiliary heating/cooling must be supplied. The 4030
enclosure is oil and dust resistant and although it is designed to resist
moisture, it should NOT be considered completely watertight. Mounting
to walls or racks must be made securely. Avoid locations that are subject
to extreme vibration and sway.

Sufficient space must be provided around the analyzers to
accommodate the necessary electrical conduit and plumbing connections.
The front panel must be allowed to be pulled out for possible service
access to all components of the enclosure. Refer to the system/analyzer
outline drawings for dimensions.

Note: To completely slide the Model 4030 Analyzer out of the

enclosure, pull Analyzer out until it stops, and then push down on the
release levers found almost at the end of the sliders, both sides at the
same time.

Teledyne Analytical Instruments 15