Teledyne 6200A User Manual

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MODEL 6200A

TRS ANALYZER

MANUAL ADDENDUM

TELEDYNE ANALYTICAL INSTRUMENTS

03655 Rev. A, August, 2000

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TABLE OF CONTENTS

TABLE OF CONTENTS TABLE OF FIGURES

1.0 WARRANTY

1.1 Claims for damaged shipments

1.2 Claims for shipping discrepancies

2.0 INTRODUCTION

2.1 Specifications

2.1.1 Analyzer Specifications

2.1.2 TRS Converter Specifications

2.2 The Sulfides Analyzer

2.3 Configurations

2.4 The TRS – Total Reduced Sulfur Converter

2.5 Installation

2.6 Operation and Calibration

2.6.1 Calibration Theory

2.6.2 Zero and Span Calibration Procedure

2.7 M501TRS Temperature Controller

2.7.1 Changing the Temperature Set Point

2.7.2 Adjusting the P-I-D Parameters

3.0 TROUBLESHOOTNG

4.0 MAINTENANCE

4.1 SO2 Analyzer Maintenance

4.2 Changing the Quartz Tube

4.3 Checking the Converter Efficiency

4.4 Sample Diluter Maintenance

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3 3 3 4 4 8 10 12 12 13 14 14 15

17 19

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TABLE OF FIGURES

FIGURE 2.1 – STANDARD CONFIGURATION 5 FIGURE 2.2 – WITH IZS OPTION 6 FIGURE 2.3 – WITH M702 CALIBRATOR OPTION 7 FIGURE 2.4 – TRS CONVERTER LAYOUT 9 FIGURE 2.5 – PNEUMATIC CONNECTIONS 11 FIGURE 3.1 – TRS WIRING DIAGRAM 18 FIGURE 4.1 – DILUTER FLOW BLOCK ASSEMBLY 21

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TABLE OF TABLES

TABLE 2.1 – TRS CONVERTER SPECIFICATIONS TABLE 2.2 – ZERO CALIBRATION PROCEDURE TABLE 2.3 – SPAN CALIBRATION PROCEDURE TABLE 2.4 – TEMPERATURE CONTROLLER - INITIAL SETTINGS TABLE 2.5 – TEMPERATURE CONTROLLER - SECONDARY MENU

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3 13 14 16 16

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TAI - Thermal Converter Operator Manual - Page 1

1.0 WARRANTY

TELEDYNE ANALYTICAL INSTRUMENTS

Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment failure occur, TAI assures its customers that prompt service and support will be available.

COVERAGE

After the warranty period and throughout the equipment lifetime, TAI stands ready to provide on-site or inplant service at reasonable rates similar to those of other manufacturers in the industry. All maintenance and the first level of field troubleshooting are to be performed by the customer.

GENERAL

TAI warrants each Product manufactured by TAI to be free from defects in material and workmanship under normal use and service for a period of one year from the date of delivery. All replacement parts and repairs are warranted for 90 days after the purchase.

If a Product fails to conform to its specifications within the warranty period, TAI shall correct such defect by, in TAI's discretion, repairing or replacing such defective Product or refunding the purchase price of such Product.

02024c

The warranties set forth in this section shall be of no force or effect with respect to any Product: (i) that has been altered or subjected to misuse, negligence or accident, or (ii) that has been used in any manner other than in accordance with the instruction provided by TAI or (iii) not properly maintained.

THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED. THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN. TAI SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TAI'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE.

TERMS AND CONDITIONS

All units or components returned to TAI should be properly packed for handling and returned freight prepaid to the nearest designated Service Center. After the repair, the equipment will be returned, freight prepaid.

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1.1 Claims for damaged shipments

All instruments should be thoroughly inspected immediately upon receipt. Material in the container should be checked against the enclosed packing list. If the contents are damaged and/or the instrument fails to operate properly, the carrier and TAI should be notified immediately.

The following documents are necessary to support claims:

Original freight bill and bill of lading

•

Original invoices or photocopy of original invoice

•

Copy of the packing list

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Photographs of damaged equipment and container

•

1.2 Claims for shipping discrepancies

All containers should be checked against packing list immediately upon receipt. If a shortage occurs, notify the carrier and TAI immediately. TAI will not be responsible for shortages against the packing list unless they are reported immediately.

The following information is necessary to make a claim:

The instrument model number

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Serial number

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Sales order number or purchase order number

•

Upon receipt of a claim, TAI will advise disposition of the equipment for repair or replacement.

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2.0 INTRODUCTION

This manual addendum should be used in conjunction with the standard Model 6200A.

2.1 Specifications

2.1.1 Analyzer Specifications

The specifications for the SO2 analyzer are contained in the standard Model 6200A manual.

2.1.2 M501TRS Converter Specifications

TABLE 2.1 – M501TRS Converter Specifications

Specification Value Unit

Flow Rate 1000 Cc/min maximum TRS Concentration 20 ppm Converter Temperature 950 – 1050 Dilution Ratio 4.3:1 Number Conversion Eff. (H2S) >98 % Power 220 VAC, 50/60 Hz, 220 watts Weight 24 lbs

11 kg

Dimensions 7 x 17 x 22 inches

178 x 432 x 559 mm

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2.2 The 6200A Sulfides Analyzer

The TAI Model 6200A Sulfides Analyzer, is designed to measure mixed sulfur impurities, collectively referred to as TRS, in carbon dioxide (CO2) gas. Since there is no SO2 scrubber in the system, the instrument reading is the sum of the reduced sulfur compounds and SO2. The 6200A consists of a modified 6200A UV Fluorescence SO2 Analyzer and a M501TRS high temperature quartz converter.

The M501TRS converts sulfur compounds to SO2 at high temperature by flowing the gas through a hot quartz tube, the resultant reaction is as follows:

TRS + O2 --> SO

Since the gas being analyzed is CO2, which generally contains no oxygen, there is an assembly that injects a small amount of air into the sample stream resulting in about 4% oxygen in the sample. The added oxygen allows the sulfur compounds to be oxidized to SO2. Any SO2 present in the sample is unaffected by the converter. The sample gas then passes to a modified 6200A analyzer where the converted compounds are analyzed as SO2.

2.3 Configurations

There are three configurations available:

1. The standard unit consisting of: A modified 6200A Fluorescent SO2 Analyzer

•

A M501TRS High Temperature Converter

•

See Figure 2.1 for the pneumatic diagram

•

2. The standard unit described above plus: An Internal Zero/Span (IZS) Option with H2S permeation tube

•

The IZS option uses sample gas, passed through a charcoal scrubber to dilute H2S from

•

the perm tube plus a converter bypass valve to assure a high quality zero/span calibration. See Figure 2.2 for the pneumatic diagram

•

3. The standard unit described above plus: An external PRC-6000 calibrator for blending tanks of H2S or SO2 span gas with CO2.

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See Figure 2.3 for the pneumatic diagram

•

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FIGURE 2.1 – BASIC CONFIGURATION

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FIGURE 2.2 – WITH IZS OPTION

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FIGURE 2.3 – WITH M702 CALIBRATOR OPTION

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2.4 The M501TRS – Total Reduced Sulfur Converter

The M501TRS oxidizes reduced sulfur compounds to SO2 in a high temperature quartz oven.

Power to the heater is controlled by a front panel mounted programmable temperature controller. Power to the heater is switched by a solid state switch. An over-temperature alarm contact closure is located on the rear panel. The alarm set point is adjustable in the temperature controller. The heater temperature is

WARNING !

INSURE PROPER LINE VOLTAGE IS SELECTED PRIOR

TO PLUGGING UNIT INTO POWER SOURCE.

WARNING !

THE QUARTZ TUBE AND HEATER ARE VERY HOT

DO NOT TOUCH

sensed by a Type K (chromel-alumel) thermocouple probe inserted in the bore alongside the quartz tube.

The quartz tube carrying the sample mixture runs through the core of the heater and is heated by radiation from electrical heating elements at the heater bore surface. See Figure 2.4 for a layout view of the converter.

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FIGURE 2.4 – TRS CONVERTER LAYOUT

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2.5 Installation

The 6200A comes in two chassis. There is a power cord for each that should be plugged into the correct voltage and frequency receptacle. See the tag on the rear panel of each chassis for the voltage and frequency settings. The power connection must be made by an approved three-wire-grounded power cord.

The pneumatic connections are shown in Figure 2.5.

Connection to the TRS analyzer must be made with Teflon or stainless steel tubing.

•

Connect the sample inlet to the labeled fitting.

•

The sample exhaust must be routed to a well ventilated area away from the air inlet for the zero

•

air scrubber on the rear panel.

CAUTION !

DO NOT BLOCK THE SIDE AND BACK

VENTILATION OF THE M501TRS

CONVERTER

The overall pneumatic diagrams of the Model 6200A are shown in Figures 2.1, 2.2, and 2.3.

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FIGURE 2.5 – PNEUMATIC CONNECTIONS

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2.6 Operation and Calibration

Refer to the 6200A manual for the overall operation of the SO2 analyzer. This unit has some unique operating characteristics and calibration procedures detailed below.

2.6.1 Calibration Theory

The basic purpose of this instrument is to analyze CO2 sample gas for sulfur containing impurities. Unlike similar analysis, there is not any zero air available. The following procedure will to allow the instrument to be zeroed and spanned using the CO2 sample gas that may contain impurities.

The CO2 gas used for zero air is routed from the sample inlet through a charcoal scrubber to remove any SO2 present.

This gas then passes through the converter and into the reaction cell for measurement. When the signal is stable, the value Z1 is stored.

Since there are numerous other sulfur containing gasses, it is not possible to determine how well the charcoal will scrub compounds other than SO2. A 3-way valve is used to bypass the M501TRS converter, so the sample gas now passes through a charcoal scrubber, then directly to the reaction cell.

The instrument is allowed to collect data with the converter bypassed and this reading is stored as Z2. This is the actual instrument zero reading.

Span calibration uses span gas generated by a H2S permeation tube, which has been diluted by scrubbed CO2 described above.

During this phase, the converter MUST be in the pneumatic pathway so the H2S can be oxidized to SO2 and thus measured. However, the converter will not only convert the H2S, but also any impurities that were not scrubbed by the charcoal, thus producing an anomalously high reading. (If there is no additional impurities in the CO2 gas, the correction factor will be zero.)

To correct for this error, the software computes a span correction by the following equation:

Z3 = Z1 - Z2

Where:

Z2 = Zero reading with the converter bypassed. Z1 = Zero reading with the converter in place Z3 = Zero gas impurity correction factor

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When the span gas reading stabilizes, Z3 is subtracted from the span reading, yielding the actual H2S span gas value as follows:

[H2S]

Actual

= [H2S]

Apparent

– Z3

Where:

Z3 = Zero gas impurity correction factor [H2S] [H2S]

The [H2S]

Actual

= Analyzer response to H2S perm tube + impurities in the zero air.

Apparent

= H2S span reading corrected for impurities in zero air.

Actual

is the reading used to compute the span concentration.

2.6.2 Zero and Span Calibration Procedure

The following is a concise summary of the steps required to zero and span calibrate the 6200A. Please refer to the standard 6200A manual for a more complete description of the calibration procedure.

Table 2.2 – Zero Calibration Procedure

Step

Number

Press CALZ With sample gas flowing into the sample inlet of the

Action Comment

instrument, press CALZ, which routes sample air into the charcoal scrubber.

2. Press ZERO ZERO starts Phase 1 of the zero calibration procedure, allowing zero to be measured with the converter in the pneumatic pathway. Allow 10 min for stable zero.

Press ENTR

After allowing the instrument to stabilize, press ENTR, to store the Z1 zero value with the converter in the pathway. The ZERO key now re-appears, which starts Phase 2

of the zero calibration. Allow 10 min for stable zero.

4. Press ENTR The converter is not in the pathway. Allow the instrument to stabilize on the new zero value, then press ENTR to store the Z2 zero value.

Press EXIT

Returns instrument to SAMPLE mode.

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Table 2.3 – Span Calibration Procedure

Step

Number

2. Press SPAN With the converter in the pathway, the instrument will

Press CALS With sample gas flowing into the sample inlet of the

Press ENTR

Press EXIT

Action Comment

instrument, press CALS, which routes sample air into the charcoal scrubber, then over the H2S permeation tube.

respond to H2S from the perm tube plus any impurities in the zero air.

After allowing the instrument to stabilize, press ENTR. The instrument will use the span reading, corrected for impurities, to compute the actual H2S span value.

Returns instrument to SAMPLE mode.

2.7 M501TRS Temperature Controller

The heater temperature is maintained by a front panel-mounted programmable controller. The “Fuji Electric PXZ Series Operation Manual” is included with the documentation for this instrument. The controller has been set up at the factory. Should further adjustments be necessary, a brief summary of the operation of the controller is included.

By pressing the PV/SV button in the lower left corner of the controller, you can see the Present Value “PV” (actual temperature) or the Set Value “SV” (Set point Value).

2.7.1 Changing the Temperature Set Point

The temperature can be adjusted to optimize conversion efficiency, follow these steps:

1. Select SV with the PV/SV button,

2. Select the Set-Point value at approximately 960oC by Press the "up-arrow" under the digit you want to change, (the digit will flash).

NOTE:

DO NOT SET THE TEMPERATURE HIGHER THAN 1050OC

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3. Press the "up-arrow" under the digit or the "down-arrow" at the left to scroll the digit to the desired value.

4. Repeat for the other two digits,

5. Press the ENTER button.

6. Select PV with the PV/SV button to observe the actual temperature. Allow temperature to equilibrate for a minimum of 30 to 45 minutes.

NOTE:

It is normal for the ceramic heating element to emit a red glow

at the operating temperature.

2.7.2 Adjusting the P-I-D Parameters

In the event that the control parameters must be changed or in the event that a new controller is installed, it must be reprogrammed to suit the thermal characteristics of the instrument. It is recommended that the Auto Tune function be used to set the control functions if reprogramming is necessary.

The following table is a guide to the approximate values for setting the parameters that will produce the initial settings for the autotune function. Below is a summary of the autotune procedure, refer to the Fuji Manual for more detailed information.

To perform Auto Tune function, set the parameter A7 to 1, then press ENTER.

The controller will begin the autotune process, which takes several minutes. The decimal point at the lower right of the display will blink, indicating the controller is autotuning. During the process, the temperature may oscillate ±100oC or more. When the process is completed, the decimal point will stop blinking.

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Table 2.4 – Temperature Controller - Initial Settings

PRESS DISPLAY INITIAL VALUE

SEL SEL SEL SEL

SEL

SEL SEL SEL SEL

Table 2.4 shows a Secondary Menu of parameters that set more basic parameters of the controller, these include the thermocouple type, the temperature units etc.

P PROP BAND i INTEGRAL d DERIVATIVE TIME AL LOW ALARM

SETPOINT AH HIHG ALARM

SETPOINT

7C CYCLE TIME HYS HYSTERESIS A7 AUTOTUNE LOC LOCK

Table 2.5 – Temperature Controller - Secondary Menu

UP/DOWN SET TO “11” SET TO “10” SET TO “7.7” SET TO “50” (C BELOW FINAL SETPOINT)

SET TO “50” (C ABOVE FINAL SETPOINT)

SET TO “2” SET TO “3” SET TO “0” (OFF) “0” (OPEN) “1” (LOCKED) “2” (SV ONLY OPEN)

PRESS DISPLAY PARAMETER VALUE

SEL HOLD TILL p-n1 SEL p-n2 SEL SEL SEL SEL SEL SEL SEL SEL SEL SEL SEL

p-dF DIGITAL FILTER P-SL LOWER LIMIT P-SU UPPER LIMIT P-AL ALARM TYPE2 P-AH ALARM TYPE 1 P-An HYTERESIS

P-dP DECIMAL LOCATION PVOF PROCESS OFFSET

SVOF SET POINT OFFSET P-F FUZZY FUZZY LOGIC

SET TO “0” SET TO “3” (TYPE K THERMOCOUPLE) SET TO “5” SET TO “32” (32C) SET TO “1050” (1050C) SET TO “900” SET TO “1050” SET TO “3” SET TO “0” LEAVE AT “0” LEAVE AT “0” SET TO “ºC” (CENTIGRADE) SET TO “ON”

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3.0 TROUBLESHOOTNG

NO POWER: Plugged in?

Switched on? Circuit breaker Tripped?

NOT HEATING: PV/SV switch to PV. Is it heating?

PV/SV switch to SV. Set point correct? Socket in place on back of controller? Check M501TRS wiring diagram Figure 3.1

TRS ANALYZER UNSTABLE: Leak-check.

(Pressurize and see if pressure falls. Use soap bubble to find leak.)

EFFICIENCY <90%: Leaking? Leak-check.

Plugged? Compare flow through and bypassing converter. Flow too high? Set-point temperature optimized? Span gas correct? Contaminated? Check inside of Teflon tubing.

CONVERTER TEMP UNSTABLE: Perform autotune procedure in Section 2.7.2.

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FIGURE 3.1 – TRS WIRING DIAGRAM

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4.0 MAINTENANCE

4.1 SO2 Analyzer Maintenance

Maintenance of the SO2 analyzer is covered in Section 8 of the 6200A manual.

4.2 Changing the Quartz Tube

1. Turn off M501TRS and allow it to cool to room temperature.

2. See Figure 2.4. – M501TRS Layout

3. Remove the screws from the top inside of the front panel and fold panel downward.

4. Loosen front and rear fittings at each end of the tube.

5. Carefully slide tube out of heater – the ceramic bushings at each end of the heater are very fragile.

6. Slide in new tube and re-connect fittings.

7. Leak check the unit.

8. Check the converter efficiency. See Section 4.3

4.3 Checking the Converter Efficiency

After maintenance it is good practice to check the converter efficiency. To check the converter efficiency, perform the following procedure:

1. Obtain a gas blender that will create H2S span gas (either permeation tube or tank) with CO2 gas as the diluent. Remember that rotameters and mass flow controllers are calibrated with air or nitrogen. Using them with CO2 will produce large calibration errors. Since CO2 gas has considerably different characteristics, use flowmeters such as soap bubble, or BIOS – DryCal flowmeters that measure volume flow.

2. Produce a calibration gas of 400 ppb H2S at a flow greater than the demand of the instrument, vent the excess gas out of the room.

3. Allow the 6200A to stabilize at span.

4. Adjust the converter efficiency by:

Lower the set-point temperature of the Converter in 5oC increments allowing 10

•

minutes minimum between increments until a drop of approximately 1% Full Scale is observed. Note the Thermal Converter temperature. Increase the set-point temperature in 5C increments allowing 10 minutes minimum

•

between increments until a drop of approximately 1% Full Scale is observed. Note the Thermal Converter temperature. Set the set-point value to fall midway between the low and high temperatures.

•

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If no drop off occurs when the temperature is raised to 1050C, select the set-point

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temperature that maximizes analyzer reading.

4.4 Sample Diluter Maintenance

The sample diluter is used to inject a small amount of ambient air into the sample stream to provide oxygen for the converter. The diluter is located on the inside rear panel of the SO2 analyzer. It consists of a stainless steel block and 2 orifices to control the amount of sample and air that is blended.

There should be no periodic maintenance required on this assembly, but a diagram is included in case rebuilding of this assembly is required. The assembly is shown in Figure 4.1.

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FIGURE 4.1 – DILUTER FLOW BLOCK ASSEMBLY

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INSTRUCTION MANUAL

MODEL 6200A

SULFUR DIOXIDE ANALYZER

SERIAL NO. _______________

TELEDYNE ANALYTICAL INSTRUMENTS

16830 CHESTNUT STREET

CITY OF INDUSTRY, CA 91749-1020

TOLL-FREE: 888.789.8168

FAX: 626.961.2538

TEL: 626.934.1500

E-MAIL: tetci_customerservice@teledyne.com

WEB SITE: www.teledyne-ai.com

02164

REV. G

12/12/98

Page 27

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TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Table of Contents

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

AFETY MESSAGES

1.1 S

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

NSTALLATION

2.1 I

LECTRICAL AND PNEUMATIC CONNECTIONS

2.2 E

NITIAL OPERATION

2.3 I

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

PECIFICATIONS

3.1 S

3.2 EPA E

3.3 W

QUIVALENCY DESIGNATION

ARRANTY

................................................................................................................ 3-3

4 THE 6200A SO2 ANALYZER .................................................................... 4-1

RINCIPLE OF OPERATION

4.1 P

NSTRUMENT DESCRIPTION

4.2 I

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

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

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

4.2.4 V/F Board ..........................................................................................................4-5

4.2.5 Front Panel ........................................................................................................ 4-5

4.2.6 Power Supply Module........................................................................................4-8

4.2.7 Pneumatic System............................................................................................. 4-8

.................................................................................................... 1-2

............................................................................................................ 2-1

................................................................ 2-1

..................................................................................................... 2-6

........................................................................................................ 3-1

............................................................................... 3-2

.......................................................................................... 4-1

......................................................................................... 4-4

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

NDEX TO FRONT PANEL MENUS

5.1 I

5.1.1 Sample Menu .................................................................................................... 5-3

5.1.2 Set-Up Menu ..................................................................................................... 5-4

AMPLE MODE

5.2 S

........................................................................................................... 5-7

5.2.1 Test Functions ................................................................................................... 5-7

5.2.2 CAL, CALS, CALZ, Calibration Functions........................................................ 5-10

SET-UP MODE

5.3

......................................................................................................... 5-12

5.3.1 Configuration Information (CFG) ..................................................................... 5-12

5.3.2 Automatic Calibration (AutoCal)....................................................................... 5-12

5.3.3 Data Acquisition System (DAS) ....................................................................... 5-12

5.3.4 Range Menu .................................................................................................... 5-13

5.3.5 Password Enable............................................................................................. 5-17

5.3.6 Time of Day Clock ...........................................................................................5-17

5.3.7 Diagnostic Mode.............................................................................................. 5-17

5.3.8 Communications Menu .................................................................................... 5-17

5.3.9 Variables Menu (VARS)................................................................................... 5-18

................................................................................. 5-1

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TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

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

ACK MOUNT OPTIONS

6.1 R

ERO/SPAN VALVES

6.2 Z

NTERNAL ZERO/SPAN

6.3 I

UTOCAL

6.4 A

ERMEATION TUBE (USED WITH

6.5 P

6.6 4-20

6.7 S

TATUS OUTPUT

6.8 RS-232 I

ETUP OF

- S

URRENT LOOP OUTPUT

A, C

........................................................................................................ 6-9

NTERFACE

6.8.1 Setting Up the RS-232 Interface...................................................................... 6-10

6.8.2 Command Summary........................................................................................ 6-13

6.8.3 TEST Commands and Messages.................................................................... 6-17

6.8.4 WARNING Commands And Messages ...........................................................6-18

6.8.5 CALIBRATION Commands and Messages ..................................................... 6-19

6.8.6 DIAGNOSTIC Commands and Messages....................................................... 6-20

6.8.7 DAS Commands and Reports ......................................................................... 6-21

6.8.8 VARIABLES Commands and Messages ......................................................... 6-24

.............................................................................................. 6-1

................................................................................................... 6-1

(IZS) .......................................................................................6-3

AND ZERO/SPAN VALVES

IZS

OPTION

) ...............................................................6-6

..................................................... 6-3

............................................................................. 6-9

................................................................................................. 6-10

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

7.1 M

7.2 M

7.3 M

7.4 A

7.5 A

7.6 C

7.7 U

7.8 EPA P

7.9 S

7.10 C

7.11 R

ANUAL ZERO/SPAN CHECK OR CALIBRATION THROUGH THE SAMPLE PORT ANUAL ZERO/SPAN CHECK OR CALIBRATION WITH ZERO/SPAN VALVES OPTION

ANUAL ZERO/SPAN CHECK WITH UTOMATIC ZERO/SPAN CHECK UTOMATIC ZERO/SPAN CALIBRATION ALIBRATE ON SE OF

OR ZERO/SPAN VALVES WITH REMOTE CONTACT CLOSURE

IZS

ROTOCOL CALIBRATION

PERMEATION TUBE

IZS O

.................................................................................. 7-7

.................................................................................... 7-9

PTION

............................................................ 7-7

......................................................................... 7-7

....................................................................... 7-8

.................. 7-4

........... 7-6

........................ 7-8

7.8.1 Calibration of Equipment ...................................................................................7-9

7.8.2 Calibration Gas Sources.................................................................................. 7-10

7.8.3 Data Recording Device.................................................................................... 7-12

7.8.4 Dynamic Multipoint Span Calibration ............................................................... 7-12

7.8.5 SO

Calibration Procedure............................................................................... 7-13

7.8.6 Calibration Frequency...................................................................................... 7-19

7.8.7 Other Quality Assurance Procedures ..............................................................7-19

7.8.8 Summary of Quality Assurance Checks ..........................................................7-21

7.8.9 ZERO and SPAN Checks ................................................................................ 7-22

7.8.10 Recommended Standards for Establishing Traceability ................................7-23

PECIAL CALIBRATION REQUIREMENTS FOR DUAL RANGE OR AUTO RANGE

ALIBRATION QUALITY EFERENCES

......................................................................................................... 7-26

............................................................................................ 7-25

.................. 7-24

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TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

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

8.1 M

8.2 R

8.3 R

8.4 R

8.5 C

8.6 C

8.7 P

8.8 L

8.9 L

8.10 EPROM R

AINTENANCE SCHEDULE EPLACING THE SAMPLE PARTICULATE FILTER EPLACING THE PERMEATION TUBE (OPTION EPLACING THE LEANING ORIFICE AND ORIFICE FILTER LEANING THE REACTION CELL NEUMATIC LINE INSPECTION

EAK CHECK PROCEDURE IGHT LEAK CHECK PROCEDURE

IZS Z

EPLACEMENT PROCEDURE

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

ERO AIR SCRUBBER (OPTION

...................................................................... 8-5

................................................................................... 8-6

...................................................................................... 8-6

.......................................................................................... 8-9

............................................................................... 8-10

..................................................................... 8-10

............................................................. 8-2

)............................................................... 8-4

)..................................................... 8-4

9 DIAGNOSTIC, TROUBLESHOOTING......................................................9-1

9.1 O

PERATION VERIFICATION

- 6200A D

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

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

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

9.1.4 6200A Internal Variables .................................................................................9-18

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

9.1.6 Factory Calibration Procedure (Quick Cal) ...................................................... 9-21

9.2 P

ERFORMANCE PROBLEMS

....................................................................................... 9-23

9.2.1 AC Power Check ............................................................................................. 9-23

9.2.2 Flow Check...................................................................................................... 9-24

9.2.3 No Response to Sample Gas .......................................................................... 9-24

9.2.4 Negative Concentration Display....................................................................... 9-25

9.2.5 Excessive Noise ..............................................................................................9-25

9.2.6 Unstable Span ................................................................................................. 9-26

9.2.7 Unstable Zero .................................................................................................. 9-27

9.2.8 Inability to Span ............................................................................................... 9-27

9.2.9 Inability to Zero ................................................................................................ 9-28

9.2.10 Non-Linear Response.................................................................................... 9-28

9.2.11 Slow Response.............................................................................................. 9-29

9.2.12 Analog Output Doesn't Agree With Display Concentration ............................ 9-29

9.3 E

LECTRONIC SUBSYSTEM TROUBLESHOOTING AND ADJUSTMENTS

9.3.1 Computer, Display, Keyboard.......................................................................... 9-30

9.3.2 RS-232 Communications................................................................................. 9-33

9.3.3 Voltage/Frequency (V/F) Board ....................................................................... 9-36

9.3.4 Status/Temp Board.......................................................................................... 9-42

9.3.5 Power Supply Module...................................................................................... 9-45

9.3.6 Flow/Pressure Sensor .....................................................................................9-49

9.3.7 Reaction Cell Temp .........................................................................................9-53

9.3.8 Preamp Board ................................................................................................. 9-53

9.3.9 PMT Cooler ..................................................................................................... 9-53

9.3.10 HVPS (High Voltage Power Supply) .............................................................. 9-56

IAGNOSTIC TECHNIQUES

...................................... 9-3

............................... 9-30

iii

Page 31

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

9.4 O

9.5 P

PTICAL SENSOR MODULE TROUBLESHOOTING

9.4.1 PMT ................................................................................................................. 9-58

9.4.2 UV Lamp Adjust or Replacement .................................................................... 9-58

9.4.3 UV Filter Replacement..................................................................................... 9-59

9.4.4 Shutter System ................................................................................................ 9-59

NEUMATIC SYSTEM TROUBLESHOOTING

9.5.1 Leak Check...................................................................................................... 9-60

9.5.2 Pump ...............................................................................................................9-60

9.5.3 Kicker............................................................................................................... 9-60

9.5.4 Z/S Valves & IZS Permeation Tube Oven .......................................................9-62

................................................................... 9-60

.......................................................... 9-58

10 TAI 6200A SPARE PARTS LIST ..........................................................10-1

APPENDIX A MAINTENANCE SCHEDULE FOR 6200A .......................... A-1

APPENDIX B ELECTRICAL SCHEMATICS .............................................. B-1

Page 32

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

List of Figures

IGURE

2-1: R 2-2: R 2-3: R 2-4: F 2-5: A

EMOVAL OF SHIPPING SCREWS EAR PANEL

EAR PANEL PNEUMATIC RECOMMENDATIONS RONT PANEL SSEMBLY LAYOUT

4-1: 6200A S 4-2: F 5-1: S 5-2: S 6-1: P 7-1: M 7-2: D 7-3: D 8-1: R 8-2: R 8-3: P 9-1: CPU B

RONT PANEL DISPLAY AMPLE MENU ETUP MENU TREE ERMEATION TUBE INSTALLATION

ODEL

6200A C

IAGRAM OF CALIBRATION SYSTEM

IAGRAM

EPLACING THE PARTICULATE FILTER

EACTION CELL NEUMATIC DIAGRAM

OARD JUMPER SETTINGS

9-2: RS-232 P 9-3: V/F B 9-4: P 9-5: E 9-6: F 9-7: SO 9-8: SO 9-9: PMT C 9-10: H 9-11: K

OARD DIP SWITCH SETTINGS OWER SUPPLY MODULE LAYOUT LECTRICAL BLOCK DIAGRAM LOW/PRESSURE SENSOR

SENSOR MODULE

OOLER SUBSYSTEM

IGH VOLTAGE POWER SUPPLY

ICKER LEAK CHECK

...................................................................2-3

................................................................................................2-4

...............................................2-5

............................................................................................2-10

.....................................................................................2-11

ULFUR DIOXIDE ANALYZER

...............................................................4-3

.................................................................................4-7

.............................................................................................5-1

......................................................................................5-2

..................................................................6-8

ALIBRATION SETUP

..............................................................7-3

.............................................................7-15

ERMEATION CALIBRATION SYSTEM

F P

...........................................7-17

............................................................8-3

...........................................................................................8-7

...................................................................................8-8

..................................................................9-32

IN ASSIGNMENTS

.........................................................................9-34

..............................................................9-41

...............................................................9-46

.....................................................................9-47

..........................................................................9-50

................................................................................9-51

................................................................................9-52

.........................................................................9-55

................................................................9-57

................................................................................9-61

Page 33

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

List of Tables

ABLE

2-1: F 2-1: F 4-1: S 4-2: F 5-1: 6200A S 5-2: 6200A S 5-3: 6200A M 5-4: 6200A M 5-5: C 6-1: Z 6-2: S 6-3: S 6-4: RS-232 P 6-5: RS-232 S 6-6: RS-232 T 6-7: RS-232 C 6-8: RS-232 C 6-9: RS-232 I 6-10: RS-232 T 6-11: RS-232 W 6-12: RS-232 C 6-13: RS-232 C 6-14: RS-232 D

INAL TEST AND CALIBRATION VALUES INAL TEST AND CALIBRATION VALUES (CONTINUED

YSTEM MODES DISPLAY

RONT PANEL STATUS

AMPLE MENU STRUCTURE ETUP MENU STRUCTURE

ENU STRUCTURE ENU STRUCTURE

ALIBRATE

ERO/SPAN VALVE OPERATION

ETUP AUTOMATIC ZERO/SPAN CALIBRATION TATUS OUTPUT PIN ASSIGNMENTS

ETUP PASSWORDS

, S

ORT SETUP

WITCHING FROM TERMINAL MODE TO COMPUTER MODE ERMINAL MODE EDITING KEYS OMMAND SUMMARY

OMMAND SUMMARY

NTERFACE COMMAND TYPES

EST MESSAGES

ARNING MESSAGES ALIBRATION MESSAGES ALIBRATION COMMANDS

IAGNOSTIC COMMAND SUMMARY

6-15: RS-232 DAS C 6-16: RS-232 O 7-1: T 7-2: M

7-3: E 7-4: M

7-5: M 7-6: M 7-7: IZS 7-8: A 7-9: A

YPES OF ZERO/SPAN CHECKS AND CALIBRATIONS

ANUAL ZERO CALIBRATION PROCEDURE

ORT

NTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE

ANUAL SPAN CALIBRATION PROCEDURE

ORT

ANUAL ZERO CALIBRATION PROCEDURE ANUAL SPAN CALIBRATION PROCEDURE

OR CTIVITY MATRIX FOR CALIBRATION EQUIPMENT CTIVITY MATRIX FOR CALIBRATION PROCEDURE

7-10: EPA Z 7-11: EPA E 7-12: EPA S

7-13: D

7-14: A

EFINITION OF LEVEL 1 AND LEVEL

CTIVITY MATRIX

PERATING MODES

............................................................................................................7-4

............................................................................................................7-5

Z/S V

ALVES MODES WITH REMOTE CONTACT CLOSURE

ERO CALIBRATION PROCEDURE

XPECTED SPAN GAS CONCENTRATION PROCEDURE

PAN CALIBRATION PROCEDURE

7-15: NIST-SRM'S A

AS STANDARDS

7-16: C

ALIBRATION QUALITY CHECK

..........................................................2-12

)......................................2-13

...............................................................................4-6

LED'S.........................................................................4-7

.................................................................5-3

...................................................................5-4

ETUP MENU

- S

ETUP MENU

- S

#2 ..................................................5-5

#3 ..................................................5-6

...................................................................5-17

.......................................................................6-2

..................................................6-4

................................................................6-9

RONT PANEL

- F

...........................................................6-11

..................6-12

.......................................................6-13

.......................................................................6-14

......................................................................6-15

..........................................................6-16

..........................................................................6-17

....................................................................6-18

...............................................................6-19

..............................................................6-20

..................................................6-21

OMMANDS

..........................................................................6-21

......................................................................6-24

..........................................7-2

ERO GAS THROUGH SAMPLE

- Z

...........................7-5

PAN GAS THROUGH SAMPLE

- S

- Z/S V

ALVES ALVES

...................................7-6

........................7-9

UPPLIES

& S

..........................7-11

...........................................7-12

.........................................................7-14

...........................7-15

.........................................................7-16

ERO AND SPAN CHECKS

2 Z

.....................7-20

.......................................................................................7-21

VAILABLE FOR TRACEABILITY OF CALIBRATION AND AUDIT

......................................................................................7-24

....................................................................7-25

Page 34

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

ABLE

8-1: P 9-1: T 9-1: T 9-1: T 9-1: T 9-1: T 9-1: T 9-2: F 9-2: F 9-3: S 9-4: D 9-5: M 9-6: T 9-7: P 9-8: P 10-1: TAI 6200A S 10-1: TAI 6200A S 10-1: TAI 6200A S 10-1: TAI 6200A S 10-2: TAI MODEL 6200A L

REVENTATIVE MAINTENANCE SCHEDULE

EST FUNCTIONS EST FUNCTIONS (CONTINUED EST FUNCTIONS (CONTINUED EST FUNCTIONS (CONTINUED EST FUNCTIONS (CONTINUED EST FUNCTIONS (CONTINUED RONT PANEL WARNING MESSAGES RONT PANEL WARNING MESSAGES (CONTINUED

UMMARY OF DIAGNOSTIC MODES IAGNOSTIC MODE

ODEL

6200A V

EST CHANNEL OUTPUT

OWER SUPPLY MODULE SUBASSEMBLIES OWER SUPPLY MODULE

...........................................................................................9-3

IGNAL

- S

ARIABLES

...............................................................................9-20

PARE PARTS LIST

PARE PARTS LIST (CONTINUED

EVEL

10-3: TAI MODEL 6200A 37 10-4: TAI MODEL 6200A 47 10-5: TAI MODEL 6200A E 10-6: TAI MODEL 6200A S

XPENDABLES KIT

PARES KIT FOR

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

).......................................................................9-4

).......................................................................9-5

).......................................................................9-6

).......................................................................9-7

).......................................................................9-8

...............................................................9-9

).........................................9-10

................................................................9-12

I/O ...................................................................9-13

............................................................................9-19

.....................................................9-45

LED O

PERATION

....................................................9-48

...................................................................10-1

)..E )..E )..E

PARES KIT

1 S

MM EXPENDABLES KIT

......E

- IZS..E

NIT

1 U

E E

RROR

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

! B

OOKMARK NOT DEFINED

. . . . . . . .

vii

Page 35

Page 36

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

1 HOW TO USE THIS MANUAL

The Model 6200A has been designed with serviceability, reliability and ease of operation in mind. The 6200A's microprocessor continually checks operating parameters such as temperature, 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 uptime 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 6200A Front Panel Menus:

The Menu Index (Figure 5-1 and Figure 5-2, and Table 5-2) 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.

1-1

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TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

1.1 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.

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

possibly hazardous consequences.

1-2

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TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

2 GETTING STARTED

2.1 Installation

CAUTION

To avoid personal injury, always use two persons to

lift and carry the Model 6200A.

Verify that there is no apparent shipping damage. If damage has occurred please advise shipper first, then TAI.

1. Before operation it is necessary to remove the shipping hold-down screws. Remove the instrument cover, then refer to Figure 2-1 for screw location.

Note: Save the shipping screws and re-install them whenever the unit is shipped to another location.

2. While the instrument cover is removed, please check the voltage and frequency label on the cover of the power supply module and compare that to your local power before plugging in the 6200A.

Check for internal shipping damage, and generally inspect the interior of the instrument to make sure all circuit boards and other components are in good shape.

3. Replace the instrument cover.

4. When installing the 6200A, allow at least 4” (10 cm) clearance at the back and at least 1” (2.5 cm) clearance at each side for proper venting.

2.2 Electrical and Pneumatic Connections

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

The pressure of the sample gas at the inlet port should be at atmospheric pressure (Refer to Figure 2-3 and Figure 7-1 for pneumatic system connection).

1. Connect the analyzer exhaust to a suitable vent at atmospheric pressure. (See Figure 2-3 for exhaust line venting recommendations.)

2-1

Page 39

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

2. If desired, attach the analog output connections to a strip chart recorder and/or datalogger. Refer to Figure 9-3 for jumper settings for the desired analog output voltage range. Factory default setting is 0-5VDC.

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

CAUTION

High voltages present inside case.

DO NOT LOOK AT THE UV LAMP, UV LIGHT

COULD CASE EYE DAMAGE.

ALWAYS USE SAFETY GLASSES

(PLASTIC GLASSES WILL NOT DO).

Connect the exhaust fitting on the rear panel to a

suitable vent outside of the room.

CAUTION

DO NOT OPERATE WITH COVER OFF.

Before operation check for correct line voltage and

frequency on Serial Number Sticker.

Do not plug in the power cord if the voltage or

frequency is incorrect.

Do not operate without proper chassis grounding.

Do not defeat the ground wire on power plug.

Turn off analyzer power before disconnecting or

connecting eletrical subassemblies.

Always replace shipping screws when transporting the Analyzer.

2-2

Page 40

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-1: Removal of Shipping Screws

2-3

Page 41

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-2: Rear Panel

2-4

Page 42

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-3: Rear Panel Pneumatic Recommendations

2-5

Page 43

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

2.3 Initial Operation

Turn on the instrument power.

1. The display should immediately light, displaying the instrument type (6200A) and the CPU memory configuration. If you are unfamiliar with the 6200A, we recommend that you read the overview Section 4 before proceeding. A diagram of the software menu trees is in Figure 5-1 and Figure 5-2.

The 6200A requires about 60 minutes for all internal components to come up to temperature.

2. While waiting for instrument temperatures to come up, you can check for correct operation by using some of the 6200A's diagnostic and test features.

3. Examine the TEST functions by comparing the values listed in Table 2-1 to those in the display. Remember that as the instrument warms up the values may change until they reach their final values. If you would like to know more about the meaning and utility of each TEST function refer to Table 9-1. Table 2-1 also contains the list of options. Section 6 covers setting up the options.

4. When the instrument is warmed up, re-check the TEST functions against Table 2-1. All of the readings should compare closely with those in the Table. If they do not, see Section

9.1.1.

NOTE

Do not calibrate the analyzer within 60 minutes after the power reset.

2-6

Page 44

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

The next task is to calibrate the analyzer. There are several ways to do a calibration; they are summarized in Table 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 SO

span gas concentration

Step Number Action Comment

1. Press CAL-CONC This key sequence causes the 6200A to prompt for the expected SO value by pressing the key under each digit until the expected value is set.

2. Press ENTR ENTR stores the expected SO2 span value. This value will be used in the internal formulas to compute subsequent SO concentration values.

3. Press EXIT Returns instrument to SAMPLE mode.

4. Press SETUP-

RNGE-SET

If necessary you may want to change ranges. Normally the instrument is shipped with range set at 500 ppb.

5. Press EXIT Returns the instrument to SAMPLE mode.

concentration. Enter the SO2 span concentration

2-7

Page 45

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

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 6200A 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. Press EXIT 6200A returns to the CAL menu. Now 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.

2-8

Page 46

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Step 3 - Review the quality of the calibration:

Calibration Quality Check Procedure

Step Number Action Comment

1. Scroll the TEST function menu until the SO

SLOPE is

Typical SLOPE value is 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 instrument will perform optimally.

displayed.

2. Scroll the TEST function menu until the SO

OFFSET is

displayed.

The 6200A will display the OFFSET parameter for the SO equation. A value between 50mV to 250mV indicates calibration in the optimal range. If the OFFSET value is outside this range, check Section 7.10 and 9.

Step 4 - The 6200A is now ready to measure sample gas.

2-9

Page 47

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-4: Front Panel

2-10

Page 48

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-5: Assembly Layout

2-11

Page 49

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 2-1: Final Test and Calibration Values

TEST Values

Observed Value

Units Nominal Range Reference Section

RANGE PPB 50 - 20,000 5.3.4

STABIL PPB 0.1 - 2 5.2.1, 9.1.1,

Table 9-1, 9.2.5

PRESS in-Hg 25 - 35 9.1.1, 9.3.6,

Table 9-1

SAMP FL CC / MIN 650 ± 10% 9.2.2, 9.3.6,

Table 9-1

PMT mV 0 - 5000 9.4.1

UV LAMP mV 2000 - 4000 typical 9.4.2

STR. LGT PPB <100 Table 9-1

DRK PMT mV -50 - +200 9.4.3, Table 9-1

DRK LMP mV -50 - +200 Table 9-1

SLOPE 1.0 ± 0.3 7.10

OFFSET mV <250 7.10

HVPS V 550 - 900 constant 9.3.10

DCPS mV 2500 ± 200 9.3.5

RCELL TEMP

BOX TEMP

PMT TEMP

IZS TEMP

C 50 ± 1 9.3.7

C 8-50 9.3.4.1

C 7 ± 1 9.3.9

C 50 ± 0.3 9.5.4

Electric Test & Optic Test

Electric Test

PMT Volts mV 2000 ± 1000 9.1.3.2

SO2 Conc PPB 1000 ± 500 9.1.3.2

Optic Test

PMT Volts mV 2000 ± 1000 9.1.3.3

SO2 Conc PPB 1000 ± 500 9.1.3.3

(table continued)

2-12

Page 50

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

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

Span and Cal Values

Parameter

SO2 Span Conc PPB 20 - 20,000 Table 7-3

SO2 Slope 1.0 ± 0.3 7.10

SO2 Offset mV <250 7.10

Noise at Zero (rms) PPB 0.1 - 0.2 Table 9-1

Noise at Span (rms) PPB 0.5% of reading

Parameter

Sample Flow cc/min 700 ± 10% 9.2.2, 9.3.6,

IZS Purge Flow cc/min 50 ± 10 6.3

Factory Installed Options Option Installed

Observed Value

Units Nominal Range Reference Section

(above 50 ppb)

Measured Flows

Units Nominal Range Reference Section

Table 9-1

Figure 9-6

Power Voltage/Frequency

Rack Mount, w/ Slides

Rack Mount, w/ Ears Only

Fluorocarbon Zero/Span Valves

Internal Zero/Span - IZS

Permeation Tube (Output Specification)

External Pump

4-20 mA Current Loop Output

REC DAS

SO2 (RANGE 1)

SO2 (RANGE 2)

SPARE

TEST OUTPUT

PROM # Serial # Date Technician

2-13

Page 51

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

INTENTIONALLY BLANK

2-14

Page 52

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

3 SPECIFICATIONS, AGENCY APPROVALS,

WARRANTY

3.1 Specifications

Ranges In 1ppb increments from 50ppb to 20,000ppb, dual ranges or

Noise at Zero Noise at Span Lower Detectable Limit Zero Drift Zero Drift Span Drift

0.2 ppb RMS

<0.5% of reading (above 50 ppb)

<0.5 ppb/24 hours

1 ppb/7 days

<0.5% FS/24hrs

0.4 ppb RMS

Lag Time 20 sec Rise Time 95% in <120 sec Fall Time 95% in <100 sec Sample Flow Rate 700cc/min. ±10% Linearity 1% of full scale Precision 0.5% of reading Temperature Range 5-40 Temp Coefficient < 0.1% per Humidity 0 - 95% RH, non-condensing Voltage Coefficient < 0.05% per V Dimensions HxWxD 7"x17" x 23.6" (18cm x 43cm x 61cm) Weight, Analyzer 45 lbs (20.5 kg) w/internal pump Power, Analyzer 110v/60Hz, 220v/50Hz, 240v/50Hz, 250 watts Power, Analyzer

230v/50Hz, 2.5A

Environmental Conditions Installation Category (Overvoltage Category) II

Recorder Output

0-100 mV, 0-1, 5, 10v ; resolution of 1 part in 1024 of selected

Status Option 12 Status Outputs from opto-isolator Measurement Units ppb, ppm, ug/m

autoranging

Pollution Degree 2

voltage or current range

, mg/m3

1. As defined by USEPA.

2. Defined as twice the zero noise level.

3. At constant temperature and voltage.

4. Electrical ratings for CE Mark compliance

5. Bi-polar.

3-1

Page 53

TAI Model 6200A SO2 Analyzer Operator Manual, 02164, Rev. G

3.2 EPA Equivalency Designation

Teledyne Analytical Instruments, Model 6200A Sulfur Dioxide Analyzer is designated as Reference Method Number EQSA-0495-100 as defined in 40 CFR, Part 53, when operated under the following conditions:

Range: Any range from 50 ppb to 1000 ppb.

1. Ambient temperature range of 5 to 40

2. Line voltage range of 105-125 VAC, 60Hz.

3. With 5-micron TFE filter element installed in the internal filter assembly.

4. Sample flow of 700 +/- 100%.

5. Vacuum pump (internal or external) capable of 14"Hg Absolute pressure @ 1 slpm or better.

6. Software settings:

A. Dynamic span OFF

B. Dynamic zero ON or OFF

C. AutoCal ON or OFF

D. Dual range ON or OFF

E. Autorange ON or OFF

F. Temp/Pressure compensation ON

Under the designation, the Analyzer may be operated with or without the following options:

1. Rack mount with chassis slides (P/N 01469A).

2. Rack mount without slides, ears only (P/N 01470A).

3. Fluorocarbon zero/span valves (P/N 01491A).

4. Internal zero/span (P/N 01441A).

5. SO

6. SO

7. SO

8. SO

Permeation tube - uncertified 0.4ppm @ 0.7 lpm (P/N 0150603A)

Permeation tube - certified 0.4ppm @ 0.7 lpm (P/N 0150604A)

Permeation tube - certified 0.8ppm @ 0.7 lpm (P/N 0150607A)

Permeation tube - uncertified 0.8ppm @ 0.7 lpm (P/N 0150608A)

9. Zero air scrubber (P/N 01440A).

4-20mA, isolated outputs (P/N 01471-1A).

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3.3 Warranty

WARRANTY POLICY

Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment failure occur, TAI assures its customers that prompt service and support will be available.

COVERAGE

After the warranty period and throughout the equipment lifetime, TAI stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry. All maintenance and the first level of field troubleshooting is to be performed by the customer.

NON-TAI MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by TAI is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty.

GENERAL

TAI warrants each Product provided by TAI to be free from defects in material and workmanship under normal use and service for a period of one year from the date of shipment. All replacement parts and repairs are warranted for 90 days after the purchase.

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TERMS AND CONDITIONS

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4 THE 6200A SO2 ANALYZER

4.1 Principle of Operation

The operation of the TAI Model 6200A Analyzer is based upon the well proven technology from the measurement of fluorescence of SO 190 nm - 230 nm region free of quenching by air and relatively free of other interferences. Interferences caused by PNA (poly-nuclear aromatics) are reduced by a "kicker" PNA selectively through a membrane without affecting SO

The UV lamp emits ultraviolet radiation which passes through a 214 nm bandpass filter, excites the SO

molecules, producing fluorescence which is measured by a PMT with a second UV bandpass

filter. The equations describing the above reactions are as follows:

due to absorption of UV energy. Sulfur Dioxide absorbs in the

sample gas.

which removes

→+ (1)

*2SOhvSO

The excitation ultraviolet light at any point in the system is given by:

()()

[]

SOaxexp1IIa −−= (2)

Where I0 is the UV light intensity, a is the absorption coefficient of SO2, x the path length, and (SO2) the concentration of SO

. The excited SO2 decays back to the ground state emitting a characteristic

fluorescence:

When the SO

concentration is relatively low, the path length of exciting light is short and the

hvSO*SO +→ (3)

background is air, the above expression reduces to:

(

)

SOKF =

(4)

Hence, the fluorescent radiation impinging upon the PMT is directly proportional to the concentration of SO

The block diagram in Figure 4-1 illustrates the general operation principle of the Model 6200A.

Developed by Dr. Henk, J. Vande Wiel, Laboratory for Inorganic Chemistry, RIVM, National

Institute of Public Health and Environmental Protection, Biethoven, The Netherlands.

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Ultraviolet light is focused through a narrow 214 nm bandpass filter into the reaction chamber. Here it excites the SO

molecules, which give off their characteristic decay radiation. A second filter

allows only the decay radiation to fall on the PMT. The PMT transfers the light energy into the electrical signal which is directly proportional to the light energy in the sample stream being analyzed. The preamp board converts this signal into a voltage which is further conditioned by the signal processing electronics.

The UV light source is measured by a UV detector. Software calculates the ratio of the PMT output and the UV detector in order to compensate for variations in the UV light energy. Stray light is the background light produced with zero ppb SO will convert this electrical signal into the SO number of SO

molecules.

. Once this background light is subtracted, the CPU

concentration which is directly proportional to the

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Figure 4-1: 6200A Sulfur Dioxide Analyzer

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4.2 Instrument Description

4.2.1 Sensor Module, Reaction Cell, Detector

The sensor module (Figure 9-7) is where the fluorescence light is generated and detected. It is the most complicated and critical sub-assembly in the entire analyzer. It consists of the following assemblies and functions:

1. The reaction cell

2. Reaction cell heater/thermistor

3. PMT and HVPS (high voltage power supply)

4. PMT cooler/cold block/heatsink/fan

5. Preamp assembly:

A. Preamp range control hardware

B. HVPS control

PMT cooler temp control

C. Electric and optic test electronics

Light trap and UV detector

6. UV lamp and light shutter

4.2.2 Pneumatic Sensor Board

The sensor board consists of a pressure sensor and a flow sensor. The pressure sensor measures the sample pressure at the reaction cell which is near ambient pressure. This sample pressure is displayed in the test menu. A solid state flow sensor measures the sample flow. Likewise, it is displayed as a TEST function. The 6200A displays pressure in inches of mercury-absolute (in-HgA) and flow in cc/min.

4.2.3 Computer Hardware and Software

The 6200A Analyzer is operated by an 8088 type micro-computer. The computer's multitasking operating system allows it to do instrument control, monitor test points, provide analog output and provide a user interface via the display, keyboard and the RS-232 port. These operations appear to be happening simultaneously but are actually done sequentially based on a priority queuing system maintained by the operating system. The jobs are queued for execution only when needed, therefore the system is very efficient with computer resources.

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The 6200A is a true computer based instrument. The microprocessor does most of the instrument control functions such as temperature control, valve switching. Data collection and processing are done entirely by the CPU with the final concentration values being sent to a D/A converter to produce the instrument analog output.

The computer memory is divided into 3 sections: EPROM memory contains the multi-tasking operating system code plus the instructions that run the instrument. The RAM memory is used to hold temporary variables and current concentration data. The EEPROM memory contains the instrument set-up variables such as range and instrument ID number. The EEPROM data is nonvolatile so the instrument can lose power and the current set-up information is preserved.

4.2.4 V/F Board

Computer communication is done via 2 major hardware assemblies. These are the V/F board and the front panel display/keyboard.

The V/F board is multifunctional, consisting of A/D input channels, digital I/O channels, and analog output channels. Communication with the computer is via a STD bus interface. The computer receives all of the instrument data and provides all control functions through the V/F board.

4.2.5 Front Panel

The front panel of the 6200A is shown in Figure 4-2. The front panel consists of a 2 line display and keyboard, 3 status LED's and power switch. Communication with the display, keyboard, and status LED's is done via the computer's on-board parallel port. The 6200A was designed as a computer controlled instrument, therefore all major operations can be controlled from the front panel display and keyboard.

The display consists of 2 lines of 40 characters each (see Figure 4-2). The top line is divided into 3 fields, and displays information. The first field is the mode field.

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Table 4-1: System Modes Display

Mode Meaning

SAMPLE xx(1)

ZERO CAL x(2)

SPAN CAL x(2)

MP CAL

SETUP xxx(3)

DIAG xxx(4)

(1)xx= A (auto)

Sampling normally

Flashing indicates adaptive filter is on

Doing a zero check or adjust

Doing a span check or adjust

Doing a multi-point calibration

Configuring analyzer (sampling continues)

Diagnostic test mode

(2)x= M (manual), A (auto), R (remote)

(3)xxx= software revision (e.g.H.3)

(4)xxx= I/O (Signal I/O), AOUT (analog output), D/A (DAC cal.), OPTIC (Optic test), Elec (Electrical test), RS232 (RS-232 test), LAMP (Lamp cal.), TCHN (Test channel).

The mode field indicates the current mode of the Analyzer. Usually, it shows "SAMPLE", indicating that the instrument is in sample mode.

The center field displays TEST values. The TEST functions allow you to quickly access many important internal operating parameters of the 6200A. This provides a quick check on the internal health of the instrument. The right hand field shows current concentration value of SO

4.2.5.1 Front Panel Display

The second line of the display contains eight fields. Each field defines the key immediately below it. By redefining the keys dynamically it is possible to simplify the instrument electronics and user interface.

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Figure 4-2: Front Panel Display

4.2.5.2 Status LED's

At the right of the display there are 3 status LED's. They can be in three states, OFF, ON, and Blinking. The meanings of the LED's are given in Table 4-2.

Table 4-2: Front Panel Status LED's

LED State Meaning

Green Off

On Blinking

Yellow Off

On Blinking

Red Off

Blinking

NOT monitoring, DAS Disabled or inactive Monitoring normally, taking DAS data Monitoring, DAS in HOLDOFF mode (1)

Auto cal. disabled Autocal. Enabled Calibrating

Warnings exist No warnings exist

(1) This occurs during Calibration, DAS holdoff, Power-up Holdoff, and when

in Diagnostic mode.

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4.2.5.3 Power Switch

The power switch has two functions. The rocker switch controls overall power to the instrument; in addition it includes a circuit breaker. If attempts to power up the 6200A result in a circuit breaker trip, the switch automatically returns to the off position, and the instrument will not power up. If this occurs, consult troubleshooting section or factory.

4.2.6 Power Supply Module

The Power supply module(PSM) supplies AC and DC power to the rest of the instrument. It consists of a 4 output linear DC power supply and a 15 volt switching supply. In addition, it contains the switching circuitry to drive the DC operated valves and several switched AC loads to operate the reaction cell and IZS heaters.

4.2.7 Pneumatic System

In the basic analyzer, the sample enters through a 5-micron TFE filter element. The sample then enters the KICKER and the reaction cell. The internal (external optional) pump is supplied as standard equipment with the 6200A.

When the zero/span valve option is included, the sample passes through the TFE zero valve and then enters the sample filter. (See Section 6) By having the sample gas, zero air and span gas all pass through the sample filter, the effects of the filter are common to all gases.

Sample flow is controlled by a critical flow orifice. The orifice is a precision-drilled sapphire jewel protected by a 20-micron sintered filter. The orifice never needs adjustment. The critical flow orifice maintains precise volumetric flow control as long as the pump inlet pressure is maintained at or near 14"(350mm) Hg absolute.

Note on sample flow reading:

At altitude, the front panel "sample flow" reading will be lower than at sea level. Actually, the volumetric flow is the same at all altitudes. However, the internal mass flowmeter measures weight flow. Therefore, as the altitude increases, the indicated flow decreases because of the reduced incoming air density. Flow variations have a negligible effect on the analyzer reading.

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5 SOFTWARE FEATURES

This section covers the software features of 6200A which is designed as a computer controlled instrument. All major operations are controlled from the front panel display and keyboard through friendly menu. Sample mode is explained for the basic operation of the analyzer including calibration steps. Advanced software features are covered for experienced users under the Setup mode offering advanced instrument control capabilities for optimum operation of the instrument. For installation and initial operation, please see "Section 2 Getting Started".

5.1 Index To Front Panel Menus

The next several pages contain two different styles of indexes that will allow you to navigate the 6200A software menus. The first two pages show a "tree" menu structure to let you see at a glance where each software feature is located in the menu. The second menu contains a brief description of each key mnemonic and a reference to the section of the manual that describes its purpose and function in detail.

Figure 5-1: Sample Menu

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Figure 5-2: Setup Menu Tree

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5.1.1 Sample Menu

Table 5-1: 6200A Sample Menu Structure

Menu Level

Level 1 Level 2 Level 3 Level 4 Description

TEST TST>

CAL Zero/Span calibration w/

CALZ Zero calibration w/ zero gas

CALS Span calibration w/ span

ZERO Press ZERO then ENTR

SPAN Press SPAN then ENTR

CONC Expected SO2 span

SETUP The SETUP Menu - See

Test functions

gas through sample port

from zero valve option or IZS option

gas from span valve option or IZS option tube

will zero analyzer

will span analyzer

concentration

next table below

Reference Section

5.2.1, Table 9-1

5.2.2.1,7.1

5.2.2.2,7.2,

7.3

5.2.2.3, 7.2,

7.3

5.2.2.2

5.2.2.3

Table 5-2

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5.1.2 Set-Up Menu

Table 5-2: 6200A Setup Menu Structure

Setup Menu #1

Level 1 Level 2 Level 3 Level 4 Description

CFG CFG is primarily used for

showing special configuration options and factory special software

PREV,

NEXT, LIST

AUTOCAL Automatic zero/span check

SEQx Select SEQUENCE 1 thru 3 5.3.2, 6.2

MODE Disable or enable zero

SET SETUP automatic zero/sapn

DAS Data Acquisition System

PREV, NEXT can be used to

scroll through the configuration list

LIST automatically scrolls the list

or calibration

and/or span mode

calibration sequence

(DAS)

Reference Section

5.3.1

5.3.2, 6.2

5.3.3

EDIT SETUP Data Acquisition

System (DAS)

VIEW PREV Examine the DAS data

buffer - display previous average

PV10 Move UP prevoius 10

averages in the DAS data buffer

NEXT Examine the DAS data

buffer - display next average

NX10 Display next 10 averages in

the DAS data buffer

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Table 5-3: 6200A Menu Structure - Setup Menu #2

Setup Menu #2

Level 1 Level 2 Level 3 Level 4 Description

RNGE Range control menu 5.3.4

MODE Range mode select - Single,

Autorange, Dual

AUTO Automatically select output

range

DUAL Independent output ranges

for REC and DAS

SINGLE Single range for both REC

and DAS outputs

SET Sets range if mode is Single

range

LO Sets low range value if

Autorange enabled

HI Sets high range value if

Autorange enabled

UNITS Unit selection menu 5.3.4.5

Reference Section

5.3.4

5.3.4.1

5.3.4.2

PPB,

PPM,

UGM,

MGM

PASS Password enable/disable

ON-OFF Enable/disable password

CLOCK TIME Adjusts time on the internal

DATE Adjusts date on the internal

MORE Continue menu one MORE

Select units that instrument

uses

checking

time of day clock

level down

5.3.4.5

5.3.5

5.3.6

Table 5-3

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Table 5-4: 6200A Menu Structure - Setup Menu #3

Setup Menu #3

Level 1 Level 2 Level 3 Level 4 Description

MORE Next level of the SETUP

COMM RS-232 communications

control menu

BAUD 300-

1200240048009600-

19.2k

ID Sets the instrument ID-

VARS Internal variables 5.3.9, 9.1.4

PREV,

NEXT, JUMP, EDIT

PREV, NEXT scroll up and

Set the BAUD rate to 3001200-2400-4800-9600-19.2K

(included on all RS-232 messages)

down through the VARS menu. Jump will go to variable number selected, EDIT will allow editing of the selected variable.

Reference Section

5.3.8, 6.8

5.3.9, 9.1.4

DIAG Diagnostic menu 5.3.7, 9.1.3

PREV,

NEXT.

PREV, NEXT scroll up and

down through the DIAG menu.(SIGNAL I/O, ANALOG OUTPUT, D/A CALIBRATION, OPTIC TEST, ELECTRICAL TEST, LAMP CALIBRATION, TEST CHAN OUTPUT, RS-232 OUTPUT)

5.3.7, 9.1.3

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5.2 Sample Mode

5.2.1 Test Functions

In any of the following TEST functions, if XXXX is displayed,

that indicates an off scale and therefore meaningless reading.

To use the TEST functions to diagnose instrument faults, refer to Troubleshooting Section 9.1.

Range

This is the range of the instrument. In standard configuration there is one range for both REC and DAS outputs.

Dual range allows a different range for each output. When enabled, the RANGE test measurement is replaced with two different test measurements, RANGE1 (REC) and RANGE2 (DAS).

NOTE

Auto range option allows a low range and high range. The 6200A will automatically switch to the other range dynamically as concentration values require. The TEST values will show the range the instrument is currently operating in, and will dynamically display the alternate range as the range changes occur.

Stability

The instrument stability is used to indicate the stability of measurement of analyzer. It is computed as the standard deviation of 25 samples of a moving window with interval of 10 seconds between each sample. Typical value is 0.1 to 2 ppb when sampling constant concentration of gas.

Pressure

Sample pressure is measured using solid state pressure sensor at the downstream of the reaction cell. This reading will vary according to the altitude and local weather condition. This reading is used by the CPU to compensate the SO

Sample Flow

A solid state mass flowmeter measures the sample flow which is the weight flow and the reading will be lower at altitude. (See Section 4.2.7) Its nominal value is 700 ± 10%.

concentration due to its pressure of the sample gas.

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PMT Voltage

The PMT VOLTAGE measures the PMT signal at the output of the preamp board. The waveform of the PMT voltage can be complex, and vary up to 5000 mV when a high concentration of SO

is being measured. If the PMT reading is consistently 5000 mV, that indicates an off-scale reading. Typical readings bounce around, which is normal.

UV Lamp

UV Lamp reading is the measurement voltage from the reference detector preamp board. Reference detector is solar blind and facing directly into the UV lamp. Typical value is between 2000 mV and 4000 mV. The minimum acceptable level is 1000 mV.

Stray Light

Stray Light is the background light of the reaction cell expressed in ppb while sampling zero gas. It is only the indication of condition of the optical system such as lenses, UV filter, light leak, etc.

Dark PMT

This dark current of the PMT is measured periodically to compensate any PMT dark current drift. Typical value is near –50 + 200 mV.

Dark Lamp

This is the dark current of the UV reference detector which is used to compensate any dark current drift. This measurement is synchronized to the Dark PMT measurement period. Typical value is near –50 + 200 mV.

Slope

The coefficient of straight line equation (y=mx + b) determines the calibration of the 6200A. The slope parameter (m) can be thought of as a gain term which determines the steepness of the calibration curve.

Offset

The offset parameter (b) compensates for differences in the background signal of the optical system.

High Voltage Power Supply(HVPS)

The HVPS reading is a measure of the scaled-up HVPS programming voltage. The voltage used to set the HVPS output is generated on the preamp board. Its value is between 0 and 1 volt, corresponding to a voltage of 0 to 1000 volts out of the HVPS. The HVPS front panel TEST measurement should be greater than 500 volts and will typically be around 550-900V.

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DC Power Supply (DCPS)

The DCPS voltage is a composite of the 5 and ±15VDC voltages in the Power Supply Module. This is meant to be a quick indicator to show if the PSM is working correctly. The nominal value is 2500mV ± 200mV.

Reaction Cell Temperature

This is a measurement of the temperature of the reaction cell. It is controlled by the computer to

50±1

C. Temperatures outside this range will cause the 6200A output to drift.

Box Temperature

This TEST function measures the temperature inside the chassis of the 6200A. The temperature sensor is located on the Status/Temp Board. Typically it runs 2 to 10 temperature. The 6200A has been engineered to maintain stable output over 5 to 40

C higher than the ambient

C ambient

temperature range.

PMT Temperature

The temperature of the PMT is closely controlled by a dedicated proportional temperature controller. The nominal set-point is 7 ± 1

C. Readings outside this range will cause instrument drift due to gain

changes in the PMT detector.

IZS Temperature

The IZS option has an oven for SO The actual temperature is stable to ± 0.1 front panel move ± 0.3

C due to the proximity of the temperature sensor to the heater. It can be

permeation tubes. The oven temperature is nominally 50C.

C although it is normal to see the temperature on the

adjusted from the front panel by pressing SETUP-MORE-VARS and selecting the IZS_SET item and entering the desired temperature. Using this adjustment, the permeation rate of the SO

permeation tube can be adjusted to a desired value. See Section 9.3.4 for information on adjusting the IZS temperature.

Time

This is an output of the 6200A's internal time of day clock.

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5.2.2 CAL, CALS, CALZ, Calibration Functions

The calibration and zero/span checking of the 6200A analyzer is treated in detail in Section 7. Table 7-1 summarizes types of calibration. The basic function of each of these keys is described here.

5.2.2.1 CAL, CALS, CALZ

The above keys control the calibration functions of the analyzer. In the CAL mode the analyzer can be calibrated with zero/span gas coming in through the sample input port on the rear panel. If the analyzer is equipped with the IZS option, or Zero/Span valves, there will be CALZ and CALS buttons also. These buttons operate the Zero/Span valves or IZS system. The setup of these options is covered in Section 6.3, and operation is explained in Section 7.

5.2.2.2 Zero

Pressing the ZERO key along with ENTR will cause the instrument to adjust the OFFSET value of the internal formula so that the instrument reads zero. The 6200A allows zero adjustment over a limited range of signal levels mostly due to the background signal, therefore the signal does not have to be exactly zero for the instrument to do a zero cal. The instrument will not, however, allow a zero cal on any signal level, therefore it is not possible to zero the instrument with span gas in the reaction cell. If the ZERO key does not come on as expected, check Section 9.2.9.

5.2.2.3 Span

Pressing the SPAN key along with ENTR will cause the instrument to adjust the SLOPE value of the internal formula so the instrument displays the span value. The expected SO

span

concentration must be entered before doing a SPAN calibration. See Table 7-3.

Like the Zero calibration, the Span cal cannot be done with any concentration of span gas. If the signal level is outside certain limits, the SPAN key will not be illuminated. If you encounter this condition see Section 9.2.8. It is also possible at low levels of span concentration that both the ZERO and SPAN keys might be on, thus allowing you to either zero or span the instrument. In this case, care must be taken to perform the correct operation or the analyzer can become miscalibrated.

5.2.2.4 SO

Cal Concentration

Before the 6200A can be spanned, it is necessary to enter the expected span concentrations for SO

. This is done by using CAL-CONC. Concentration values from 50 to 19000 ppb are

accepted. If a value of XXXX is displayed, that indicates an off scale, or invalid reading. The XXXX value will often be displayed at power-up when there is no data yet available to be displayed. Certain instrument fault conditions will cause X's to be displayed, this is the same as the needle being offscale on a analog meter. See the Troubleshooting Section 9.2.8 if this occurs.

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5.2.2.5 Formula Values

The slope and offset terms should be checked after each calibration. The values for these terms contain valuable information about the internal health of the analyzer. The range of acceptable values and their meanings is given in Section 7.10.

To compute the SO

bmxy −=

concentration, the formula for a straight line is used.

Where:

y = the SO

concentration

m = the slope

x = the conditioned PMT tube output

b = the offset

In comparison with analog analyzers the slope term is equivalent to the "span pot" and the b term is equivalent to the "zero pot". Again, like an analog analyzer there is only a limited range of adjustment allowed for either term, and there are consequences of having the values near the high or low limits of their respective ranges.

The x term is the conditioned PMT signal. PMT signal is adjusted for the lamp ratio background, range, temperature, and pressure.

The offset (b) term is the total background light with the zero term subtracted out. The zero term measures detector dark current and amplifier noise. The b term is composed mostly of the optical system background.

After every zero or span calibration check the QUALITY of the calibration. The calibration of the 6200A involves balancing several sections of electronics and software to achieve an optimum balance of accuracy, noise, linearity and dynamic range. See Section 7.10 for the calibration quality check procedure.

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5.3 Set-Up Mode

5.3.1 Configuration Information (CFG)

This menu item will tell if the installed software has factory special features or other non-standard features. If you call TAI service you may be asked for information from this menu.

5.3.2 Automatic Calibration (AutoCal)

The AutoCal feature allows the 6200A to automatically operate the Zero/Span Valve or IZS option on a timed basis to check or adjust its calibration. This menu item is shown only if the IZS or Zero/Span Valve option is installed. Detailed information on setting up AutoCal is found in the Section 6.4.

5.3.3 Data Acquisition System (DAS)

The Model 6200A contains a flexible and powerful built in data acquisition system (DAS) that enables the analyzer to store concentration data as well as many diagnostic parameters in its battery backed memory. This information can be viewed from the front panel or printed out through the RS-232 port. The diagnostic data can be used for performing “Predictive Diagnostics” and trending to determine when maintenance and servicing will be required.

The logged parameters are stored in what are called “Data Channels.” Each Data Channel can store multiple data parameters. The Data Channels can be programmed and customized from the front panel. A set of default Data Channels has been included in the Model 6200A software. These are described Section 5.3.3.1. For more information on programming custom Data Channels, a supplementary document containing this information can be requested from TAI.

5.3.3.1 Data Channels

The function of the Data Channels is to store, report, and view data from the analyzer. The data may consist of SO output.

The 6200A comes pre-programmed with a set of useful Data Channels for logging SO concentration and predictive diagnostic data. The default Data Channels can be used as they are, or they can be changed by the user to fit a specific application. They can also be deleted to make room for custom user-programmed Data Channels.

The data in the default Data Channels can be viewed through the SETUP-DAS-VIEW menu. Use the PREV and NEXT buttons to scroll through the Data Channels and press VIEW to view the data. The last record in the Data Channel is shown. Pressing PREV and NEXT will scroll through the records one at a time. Pressing NX10 and PV10 will move forward or backward 10 records. For Data Channels that log more than one parameter, such as PNUMTC, buttons labeled

concentration, or may be diagnostic data, such as the sample flow or PMT

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<PRM and PRM> will appear. These buttons are used to scroll through the parameters located in each record.

The function of each of the default Data Channels is described below:

CONC:

PNUMTC:

CALDAT:

Samples SO

concentration at one minute intervals and stores an average every

hour with a time and date stamp. Readings during calibration and calibration hold off are not included in the data. The last 800 hourly averages are stored.

Collects sample flow and sample pressure data at five minute intervals and stores an average once a day with a time and date stamp. This data is useful for monitoring the condition of the pump and critical flow orifice (sample flow) and the sample filter (clogging indicated by a drop in sample pressure) over time to predict when maintenance will be required. The last 360 daily averages (about 1 year) are stored.

Logs new slope and offset every time a zero or span calibration is performed. This Data Channel also records the instrument reading just prior to performing a calibration. Note: this Data Channel collects data based on an event (a calibration) rather than a timer. This Data Channel will store data from the last 200 calibrations. This does not represent any specific length of time since it is dependent on how often calibrations are performed. As with all Data Channels, a time and date stamp is recorded for every data point logged.

5.3.4 Range Menu

The instrument operates on any full scale range from 50 to 20,000 ppb. The range is the concentration value that equals the maximum voltage output on the rear panel of the instrument.

If the range you select is between 50 and 2000 ppb the front panel will read the concentration anywhere from 0 to 2000 ppb regardless of the range selected. If the range selected is from 2001 to 20,000 ppb the front panel will read from 0 to 20,000 ppb. The apparently wider range of front panel readouts is because the 6200A has 2 internal hardware gain settings, namely 0-2000ppb (gain of 10) and 0-20,000ppb (gain of 1). If the physical gain changes, then the test measurement readings such as PMT, DARK PMT, and OFFSET will be adjusted accordingly. The analog output is scaled for the range selected, however the front panel reading can display correct concentrations over the entire physical range. If the instrument will be used on more than one range such as AUTO RANGE or DUAL RANGE, it should be calibrated separately on each applicable range (see Section 7.9 for calibration procedure).

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Only one of the following range choices can be active at any one time.

There are 3 range choices:

1. Single Range

Auto Range

2. Dual Ranges

5.3.4.1 Single Range

This range option selects a single range for both output channels (REC, DAS) of the 6200A. To select Single Range press SETUP-RNGE-MODE-SING, then press ENTR. To set the value for the range press SETUP-RNGE-SET, and enter the full scale range desired from 50 ppb to 20,000 ppb, then press ENTR.

NOTE

5.3.4.2 Auto Range

Auto Range allows output range to automatically range between a low value (RANGE1) and a higher value (RANGE2). When the instrument output increases to 98% of the low range value, it will Auto Range into Hi range. In Hi range, when the output decreases to 75% of low range, it will change to the lower range. This is only one low range and one high range for all outputs. The Hi range mode is signaled by a bit on the STATUS option, see Table 6-3. If you select a Hi range that is less than Low range, the 6200A will remain locked in Low range and behave as a Single Range instrument.

To set up Auto Range press SETUP-RNGE-MODE-AUTO, then press ENTR. To set the values press SETUP-RNGE-SET. The 6200A will prompt you for Low Range, then Hi Range which is the lower and upper ranges of Auto Range. Key in the values desired, then press ENTR.

Once desired range is selected, then 6200A should be calibrated for each range entered. (Refer to Section 7.9 for Calibration Procedure.)

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5.3.4.3 Dual Ranges

Dual Ranges allows you to select different ranges for REC and DAS analog output channels. To set up Dual Ranges press SETUP-RNGE-MODE-DUAL, then press ENTR. To set the values press SETUP-RNGE-SET. The 6200A will prompt you for the range of RANGE1 (REC) and RANGE2 (DAS) outputs (refer to Figure 2-2 for corresponding analog output terminals). Key in the desired range for each output channel, then press ENTR after each value.

If Dual Range is selected and their desired ranges are entered accordingly, the 6200A should be calibrated for each of the range selected. See Section 7.9 for Calibration Procedure.

If user has selected either Auto Range or Dual Range, then pressing CAL button will cause to display #1 and #2. #1 means RANGE1 calibration and #2 means RANGE2 calibration. Select desired range number and press ENTR to continue calibration procedure of selected range. Under each range calibration procedure, the 6200A will display separate test measurement functions accordingly to show the Slope, Offset, Range, etc for corresponding range. However once exit this calibration menu and return to the main menu (see Figure 2-4), then the test measurement parameters for RANGE1 are used throughout the 6200A.

When initiating calibration remotely via the contact closures, the RS-232, or automatically via the timer, the 6200A will calibrate RANGE #1.

5.3.4.4 Dilution Ratio

The dilution feature allows the 6200A to be used with a stack dilution probe. With the Dilution feature you can select the range and display the concentration at the value and units of the un-diluted gas in the stack. The dilution probe dilutes the gas by a fixed ratio so the analyzer is actually measuring a much lower concentration than is actually present in the stack.

The software scales the diluted sample gas concentration readings so that the outputs show the actual stack concentrations. Also, when calibrating the instrument or setting the ranges the values selected are scaled to reflect the actual stack concentrations. The scaled readings are sent to the display, analog outputs, and RS-232 port.

To use the Dilution feature:

SELECT UNITS

For stack measurement, select PPM units. To set units, press SETUP-RANGE-UNIT-PPM. Press ENTR after the unit selection is made, then EXIT to return to upper level menus.

2. SET DILUTION RATIO

The dilution ratio of the probe is entered by SETUP-RANGE-DIL (if DIL menu is not shown call factory). Accepted values are 1 to 1000. Press ENTR, and EXIT to return to upper level menus. A value of 1 disables the dilution feature.

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3. SELECT RANGE

The range selection is the same with dilution as with normal monitoring. See Section 5.3.4 for information on range selection. You should note however, the value entered should be the actual concentration of the calibration gas entering the dilution probe. The units of this number is ppm.

CALIBRATION

When the above selections have been made, the instrument now must be calibrated through the dilution probe. NOTE: units are now in PPM. See Section 7 for calibration methods.

5.3.4.5 Concentration Units

The 6200A can display concentrations in ppb, ppm, ug/m3, mg/m3. Coefficients for mg/m3 and ug/m3 were based on 0

C (25oC for U.S.EPA), 760 mmHg. Different pressure and temperature can be used by adjusting values entered for calibration gas to read the correct concentration at the conditions being used. This adjustment is not needed if units are within the same type.

To change the current units press SETUP-RNGE-UNIT from the SAMPLE mode and select the desired units.

Example: If the current units are in ppb and the span value is 400 ppb, and the units are changed to ug/m3 the span value is NOT re-calculated to the equivalent value in ug/m3. Therefore the span value now becomes 400 ug/m3 instead of 400 ppb. Use following equation to convert the unit with proper temperature and pressure adjustments.

mmHg

SO in ppm

286

×× × =.

273

760

SO in

NOTE

You should now reset the expected span concentration value which should be

adjusted with proper pressure and temperature(25oC for U.S.EPA) in the new

units and re-calibrate the instrument using one of the methods in Section 7.

Changing units affects all of the RS-232 values, all of the display values, and all

of the calibration values and therefore you must recalibrate the analyzer.

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5.3.5 Password Enable

There are two levels of password protection. The most restrictive level requires a password to do instrument calibration. The second level requires a password to do SETUP functions.

If both password levels are turned off, no passwords are required, except in the VARS menu where a password is always required. To enable password press SETUP-PASS-ON. A list of passwords is in Table 5-5.

Table 5-5: Calibrate, Setup Passwords

Password Usage Password

Calibration Password Use to get into CAL menus 512

Setup Password Use to get into SETUP menus 818

5.3.6 Time of Day Clock

The instrument has an internal time of day clock. The time of day can be set by pressing SETUPCLOCK-TIME and entering the time in 24hr format. In a similar manner the date can be entered by pressing SETUP-CLOCK-DATE and entering the date in a dd-mmm-yy format. If you are having trouble with the clock running slow or fast, the speed of the clock can be adjusted by selecting the CLOCK_ADJ variable in the SETUP-MORE-VARS menu(See Section 9.1.4).

5.3.7 Diagnostic Mode

The 6200A Diagnostic Mode allows additional tests and calibrations of the instrument. These features are separate from the TEST functions because each DIAG function has the ability to alter or disable the output of the instrument. While in DIAG mode no data is placed in the DAS averages. Details on the use of Diagnostic mode are in Section 9.1.3.

5.3.8 Communications Menu

The COMM menu allows the RS-232 BAUD rate to be set. To set the BAUD rate press SETUPMORE-COMM-BAUD, select the appropriate BAUD rate, then press ENTR.

The instrument ID number can also be set. This ID number is attached to every RS-232 message sent by the 6200A. To set the ID press SETUP-MORE-COMM-ID and enter a 4 digit number from 0000-9999, then press ENTR.

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5.3.9 Variables Menu (VARS)

This menu enables you to change the settings on certain internal variables. The VARS Table 9-5 is located in the Troubleshooting Section 9.1.4.

NOTE

Before changing the settings on any variables, please make sure you

understand the consequences of the change. The variables should only

be changed by skilled maintenance people since they can potentially

interfere with the performance of the analyzer.

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6 OPTIONAL HARDWARE AND SOFTWARE

6.1 Rack Mount Options

Rack Mount including slides and ears, permits the Analyzer to be mounted in a standard 19" wide by 24" deep RETMA rack. Can also be ordered without slides for applications requiring the instrument to be rigidly mounted in a RETMA rack.

6.2 Zero/Span Valves

The Zero/Span Valve option consists of two fluorocarbon solenoid valves. See Figure 2-5 for valve location. Connections are provided on the rear panel for span gas and zero gas inputs to the valves(See Figure 2-2). These valves can be actuated by several methods shown in Table 6-1.

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Table 6-1: Zero/Span Valve Operation

Mode Description Reference Section

1. Front panel operation via CALS and CALZ buttons.

2. Automatic operation using AUTOCAL Setup and use of AUTOCAL is described in

3. Remote operation using the RS-232 interface

4. Remote operation using external contact closures

Calibration Section 7 - Manual Zero/Span Check.

and Section 7.4.

Setup described in Table 6-2 Operation of AUTOCAL described in Section 6.8.5 and Section 7 - Calibration.

Section 7.7 - Automatic operation using external contact closures. Truth Table 7-8 and Section 9.3.4.3.

Zero/Span valves have 3 operational states:

1. Sample mode. Here both valves are un-energized and sample gas passes through the sample/cal valve and into the analyzer for analysis.

2. Zero mode. The sample/cal valve is energized to the cal mode. The zero/span valve is unenergized in the zero mode, thus allowing zero gas to be admitted through the rear panel bulkhead fitting into the analyzer.

3. Span mode. The sample/cal valve is energized and in the cal mode. The zero/span valve is energized in the span mode. With both valves on, span gas is admitted through a rear panel bulkhead fitting into the analyzer.

Zero air and span gas inlets should supply their respective gases in excess of the 700 cc/min demand of the analyzer. Supply and vent lines should be of sufficient length and diameter to prevent back diffusion and pressure effects. See Figure 2-3 for fitting location and tubing recommendations.

Adequate zero air can be supplied by connecting a charcoal scrubber and 5 micron particulate filter (TAI P/N 000369) to the zero air inlet tubing. The zero air scrubber used in conjunction with the Zero/Span Valve option provides an inexpensive source of zero air.

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6.3 Internal Zero/Span (IZS)

The IZS option includes the Zero/Span Valves described above, a temperature-controlled permeation tube oven, and rear panel mounted zero air scrubber. The IZS system is activated by the same methods as described in Table 6-1 for the zero/span valves. The setup of the IZS is the same as that of the valves and is described in Table 6-2.

The IZS system operation is similar to the zero/span valve operation, except that the source of the zero air and span gas are supplied at the analyzer via a scrubber and permeation tube respectively. See Section 7.1 - calibration for operational details. A continuous purge flow of approximately 50cc/min is drawn across the permeation tube to prevent span gas accumulation when the permeation tube is not in use.

6.4 Autocal - Setup of IZS and Zero/Span Valves

The Zero/Span valves or the IZS system can be set up to operate automatically on a timed basis. The TAI model 6200A with IZS option offers capability to check any combination of zero and span points automatically on a timed basis, through remote RS-232 operation (see Section 6.8.5), or external contact closure (see Section 7.7).

There are three auto-calibration sequences called SEQ1, SEQ2, and SEQ3. Under each SEQ, there are five parameters that affect zero/span checking: the mode enable/selection, the starting date and time of the calibration, the number of delay days and time, duration of calibration, and calibration adjust enable/disable.

1) Calibration Sequence Mode

Each sequence can generate any one of 3 different combinations of ZERO, or HI span point. Press SETUP-ACAL, and scroll up or down to select of the SEQx. Press MODE and scroll up or down by pressing PREV or NEXT. Select one of the combination shown below and press ENTR .

Combinations: 1) DISABLED; will disable corresponding SEQx setup.

2) ZERO

3) ZERO-HI

4) HI

2) Setup Calibration Timer:

Press SETUP-ACAL-SET to setup or edit the automatic calibration timer.

Following table summarizes the setup procedures;

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Table 6-2: Setup Automatic Zero/Span Calibration

Default Description

Timer Enable ON Enable or disable automatic calibration timer.

Starting Date 01-JAN-95 MM:DD:YY

Starting Time 00:00 HH:MM, 0 - 23 hours and 0 - 59 minutes

Delta Days 1 Delay days between each calibration (0 - 365 days)

Delta Time 00:00 HH:MM, 0 - 23 hours and 0 - 59 minutes

Duration 15.0 minutes 1 - 60.0 minutes

Calibrate OFF on/off. If ON is selected, it will adjust the calibration.

The Timer Enable can be set to “OFF” to disable the automatic calibration timer while the remote RS-232 calibration of specific sequence can be initiated.

NOTE

Avoid setting two or more sequences at the same time of the day. Any new

sequence which is initiated whether from a timer, the RS-232, or the contact

closure inputs will override any sequence which is in progress.

The programmed start time must be a minimum of

5 minutes later than the real time clock.

Examples of possible sequences are as following under any one of three available SEQx.

Example 1: to perform zero-span calibration check once per day at 10:30 pm, 12/20/98.

1) MODE: ZERO-HI

2) TIMER ENABLE: ON

3) STARTING DATE: 12/20/98

4) STARTING TIME: 22:30

5) DELTA DAYS: 1

6) DELTA TIME: 00:00

7) DURATION: 15.0 MINUTES

8) CALIBRATE: OFF

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Example 2: to perform zero calibration adjust once per day retarding 15 minutes everyday starting at 11:30 pm, 12/20/98.

1) MODE: ZERO

2) TIMER ENABLE: ON

3) STARTING DATE: 12/20/98

4) STARTING TIME: 23:30

5) DELTA DAYS: 0

6) DELTA TIME: 23:45

7) DURATION: 15.0 MINUTES

8) CALIBRATE: ON

Example 3: to perform zero-span calibration check once per day at 10:30 pm and zero calibration adjust once per week starting at 11:30 PM, 12/20/98.

1. Select any one of SEQx and program as example 1.

2. Select any other SEQx and program as following; Always avoid setting two or more sequences at the same time of the day.

1) MODE: ZERO

2) TIMER ENABLE: ON

3) STARTING DATE: 12/20/98

4) STARTING TIME: 23:30

5) DELTA DAYS: 7

6) DELTA TIME: 00:00

7) DURATION: 15.0 MINUTES

8) CALIBRATE: ON

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6.5 Permeation Tube (used with IZS option)

SO2 is normally a gas at room temperature and pressure, but can be liquefied at moderate pressures. The permeation tube consists of a small container of SO of PTFE which is permeable to SO

. The gas slowly permeates through the window at a rate in

the nanogram/min range. If the tube is kept at constant temperature, usually about 50 device will provide a stable source of SO

gas for a year or more. The IZS permeation tube is

intended to be used as a periodic span check and is not to be used as a calibration device. See below for permeation tube ordering information.

liquid, with a small window

C, the

The permeation tube SO 1 slpm @ 50

C), the permeation tube temperature (oC) and the air flow across it (slpm). The specific

concentration is determined by the permeation tube specific output (ppb @

output is a fixed function of the permeation tube and is noted on shipping container.

The temperature is set at 50.0 to verify that the temperature is properly set. It should be set to 50 temperature warnings set at 49 tube at all times to prevent build-up of SO

C. Check SETUP-MORE-VARS and scroll to the IZS_SET variable

C and 51oC. There is a 50 cc/min purge flow across the permeation

gas in the tubing.

C with over-and-under

If desired, the output of the permeation tube can be adjusted by adjusting the oven temperature up or down slightly. The adjust increment is 0.1

C to facilitate small adjustments of the setpoint

temperature.

When the IZS system is in SPAN mode, the flow across the permeation tube is the sum of the reaction cell flow and the purge flow, which is about 700 cc/min. The gas concentration can be calculated using following equation;

PxKm

C =

where

P=permeation rate, ng/min.@ 50oC.

Km=(24.46)/molecular weight, where 24.46 is the molar volume in liters @ 25

760mmHg Km for SO

=0.382, H2S=0.719.

F=total flow rate (sum of sample flow and purge flow), cc/min.

C=concentration, ppm.

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Suggested permeation tubes:

Permeation tube uncertified 0.4ppm @ 0.7 lpm

Permeation tube certified 0.4ppm @ 0.7 lpm

Permeation tube certified 0.8ppm @ 0.7 lpm

Permeation tube uncertified 0.8ppm @ 0.7 lpm

TAI recommends that you purchase replacement permeation tubes from:

VICI METRONICS

2991 Corvin Drive

Santa Clara, CA 95051 USA

Phone 408-737-0550 Fax 408-737-0346

The 6200A uses 700 cc/min of zero air over the perm tube. Therefore you should order a permeation tube with a SPECIFIC OUTPUT of 350 to 450 ppb at 0.7 liter/minute. This will give you a IZS Span response of 80 to 90% of full scale in the 500 ppb range. Refer to the above equation for calculating other concentrations and instrument flow rates.

Once the Analyzer has stabilized, the response to the permeation tube is not expected to change more than ± 5%. If, during a periodic span check, the response varies by more than 5%, or more importantly, shows drift, then there is a problem with the Analyzer or permeation tube.

CAUTION

Avoid turning off the analyzer with perm tube inside of the

analyzer for more than an hour. This will cause to contaminate

the analyzer with saturated perm tube gas. When transporting

the analyzer, remove the perm tube from the oven and store it

inside of the shipping container in safe cool place.

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Figure 6-1: Permeation Tube Installation

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6.6 4-20 mA, Current Loop Output

The current loop option replaces the voltage output of the instrument with an isolated 4-20 mA current output. The current outputs come out on the same terminals that were used for voltage outputs, see Figure 2-2. The REC and DAS outputs have current loop capabilities. See Troubleshooting Section 9.3.4.4 for electrical specifications and refer drawings 01471I and 01248I for the jumper settings.

6.7 Status Output

The status output is an option that reports Analyzer conditions via contact closures on the rear panel. The closures are available on a 50 pin connector on the rear panel. The contacts are NPN transistors which can pass 50 ma of direct current. The pin assignments are listed in Table 6-3 below.

Table 6-3: Status Output Pin Assignments

OUTPUT # PIN # DEFINITION CONDITION

1 1(-),2(+) ZERO CAL CLOSED IN ZERO CAL

2 3(-),4(+) SPAN CAL CLOSED IN SPAN CAL

3 5(-),6(+) FLOW ALARM CLOSED IF FLOW WARNING

4 7(-),8(+) TEMP ALARM CLOSED IF ANY TEMP WARNING

5 9(-),10(+) DIAG MODE CLOSED IN DIAG MODE

6 11(-),12(+) POWER OK CLOSED IF SYSTEM POWER OK

7 21(-),22(+) SYSTEM OK CLOSED IF SYSTEM OK

8 19(-),20(+) HVPS ALARM CLOSED IF HVPS WARNING

9 13(-),14(+) SPARE

10 23(-),24(+) HIGH RANGE CLOSED IF HIGH PMT RANGE

11 25(-),26(+) SHUTTER CLOSED IF SHUTTER WARNING

12 27(-),28(+) UV LAMP ALARM CLOSED IF UV LAMP WARNING

The Status Board schematic can be found in the Appendix Drawing 01087.

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6.8 RS-232 Interface

The RS-232 communications protocol allows the instrument to be connected to a wide variety of computer based equipment. The interface provides two basic functions in the 6200A.

1. First is a comprehensive command interface for operating and diagnosing the analyzer. This interface has in fact more capabilities than the front panel keyboard.

The interface can provide an audit trail of analyzer events. In this function the port sends out messages about instrument events like calibration or warning messages. If these messages are captured on a printer or remote computer, they provide a continuous audit trail of the analyzers operation and status.

6.8.1 Setting Up the RS-232 Interface

The baud rate is set from the front panel by SETUP-MORE-COMM-BAUD. Select the baud rate appropriate for your application, 300, 1200, 2400, 4800, 9600, 19.2K. It is important to note that

the other device must have identical settings in order for the communications to work correctly.

Second is physical wiring of the analyzer to the other unit. We have incorporated into the Analyzer LED's that signal the presence of data on the communications lines, and also jumper blocks to easily re-configure the analyzer from DCE to DTE if necessary (see drawing #01115). In addition the front panel diagnostics allow test data streams to be sent out of the port on command. This flexibility and diagnostic capability should simplify attaching our equipment to other computers or printers. If problems occur, see the Troubleshooting Section 9.3.2.

Setup from the Front Panel

There are 2 additional RS-232 setups that can be done via the front panel.

1. Set the Instrument ID number by SETUP-MORE-COMM-ID, and enter a 4 digit number from 0000-9999. This ID number is part of every message transmitted from the port.

Set the RS-232 mode bit field in the VARS menu. To get to the variable press, SETUP-MORE-VARSENTR and scroll to RS232_MODE, then press EDIT. The possible values are:

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Table 6-4: RS-232 Port Setup - Front Panel

Decimal Value Description

1 Turns on quiet mode (messages suppressed)

2 Places analyzer in computer mode (no echo of chars)

4 Enables Security Features (Logon, Logoff)

8 Enables RS-232 menus display on 6200A front panel display

16 Enables alternate protocol and setup menu

32 Enables multi-drop support for RTS

NOTE

To enter the correct value, ADD the decimal values of the features you

want to enable. For example if LOGON and front panel RS-232

menus were desired the value entered would be 4 + 8 = 12.

Security Feature

The RS-232 port is often connected to a public telephone line which could compromise instrument security. If the LOGON feature is implemented the port has the following attributes:

1. A password is required before the port will operate.

2. If the port is inactive for 1 hour, it will automatically LOGOUT.

3. If not logged on, the only command that is active is the '?'. If this command is issued the 6200A will respond with MUST LOG ON.

4. The following messages will be given at logon.

5. LOG ON SUCCESSFUL - Correct password given

6. LOG ON FAILED - Password not given or incorrect

7. LOG OFF SUCCESSFUL - Logged off

The RS-232 LOGON feature must be enabled from the front panel by setting bit 4. See Table 6-4. Once the feature is enabled, to logon type:

LOGON 940331

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940331 is the default password. The password can be changed to any number from 0 to 999999 by the variable RS232_PASS. To change the password enter the command

V RS232_PASS=xxxxxx

which sets the password to the value xxxxxx.

Protocol of Port communication

The RS-232 interface has two protocols of communication, because if the port is attached to a computer it needs to have different characteristics than if used interactively. Consequently, there are two primary styles of operation: terminal mode and computer mode.

When an operator is communicating with the analyzer via a terminal, the analyzer should be placed into TERMINAL MODE, which echoes keystrokes, allows editing of the command line using the backspace and escape keys, and allows recall of the previous command. When a host computer or data logger is connected to the analyzer, it should be placed into COMPUTER MODE, which does not echo characters received or allow the special editing keys. See Table 6-5 for relevant commands.

Table 6-5: RS-232 Switching From Terminal Mode to Computer Mode

Key Function

Control-T (ASCII 20 decimal) Switch to terminal mode (echo, edit)

Control-C (ASCII 3 decimal) Switch to computer mode (no echo, no edit)

If the command line doesn't seem to respond to keystrokes or commands, one of the first things you should do is send a Control-T to switch the command line interface into terminal mode. Also, some communication programs remove CTRL-T and CTRL-C characters from the byte stream, therefore these characters will not be sent to the analyzer. Check your communications program owners manual.

Entering Commands in Terminal Mode

In terminal mode, all commands must be terminated by a carriage return; commands are not processed until a carriage return is entered. While entering a command you may use the following editing keys:

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Table 6-6: RS-232 Terminal Mode Editing Keys

Key Function

CR (carriage return) Execute command

BS (backspace) Backspace one character to the left

ESC (escape) Erase entire line

Control-R (ASCII 18 decimal) Recall previous command

Control-E (ASCII 5 decimal) Recall and execute previous command

Commands are not case-sensitive; you should separate all command elements (i.e. keywords, data values, etc.) by spaces.

Words such as T, SET, LIST, etc. are called keywords and are shown on the help screen in uppercase, but they are not case-sensitive. You must type the entire keyword; abbreviations are not accepted.

OBTAINING HELP

Typing "?" followed by Return or Enter will cause a help screen to be displayed.

6.8.2 Command Summary

The information contained in the rest of this section covers all of the normal commands that are required to operate the instrument from a remote terminal. If you are going to be writing computer programs to communicate with the 6200A (i.e., operating the port in COMPUTER MODE) we suggest that you order a supplementary manual "The RS-232 Interface". This manual shows additional features of the port designed to support a computer driven interface program.

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Table 6-7: RS-232 Command Summary

Commands Definition

? Print help screen

T SET ALL Enable display of all test variables during T LIST

T SET name Display only NAME during T LIST

T LIST [ALL] Print all test variables enabled with T SET or ALL

warnings

T name Print single test, "name" from Table 6-9

T CLEAR ALL Disable T LIST, use with T SET name

W SET ALL Enable display of all warnings during W LIST

W LIST [ALL] Print warnings enabled with W SET or ALL warnings

W name Print individual "name" warning from Table 6-10

W CLEAR ALL Disable W LIST, use with W SET

C command Execute calibration "command" from Table 6-12

D LIST Prints all I/O signal values

D name Prints single I/O signal value/state

D name=value Sets variable to new "value"

D LIST NAMES Lists diagnostic test names

D ENTER name Enters and starts 'name' diagnostic test

D EXIT Exits diagnostic mode

D RESET Resets analyzer(same as power-on)

D RESET RAM System reset, plus erases RAM. Initializes DAS, SO2 conc

readings, calibration data not affected

D RESET EEPROM System reset, plus erases EEPROM (RAM_RESET

actions + setup variables, calibration to default values)

V LIST Print all easy variable names from Table 9-5

V name Print individual "name" variable

V name=value Sets variable to new "value"

V CONFIG Print analyzer configuration

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Table 6-8: RS-232 Command Summary

Terminal Mode Editing Keys Definition

V MODE Print current analyzer mode

BS Backspace

EXC Erase line

^R Recall last command

^E Execute last command

CR Execute command

^C Switch to computer mode

Computer Mode Editing Keys Definition

LF Execute command

^T Switch to terminal mode

Security Features Definition

LOGON password Establish connection to analyzer

LOGOFF Disconnect from analyzer

General Output Message Format

Reporting of status messages for use as an audit trail is one of the two principal uses for the RS232 interface. You can effectively disable the asynchronous reporting feature by setting the interface to quiet mode. All messages output from the analyzer (including those output in response to a command line request) have the format:

X DDD:HH:MM IIII MESSAGE

X is a character indicating the message type, as shown in the table below.

DDD:HH:MM is a time-stamp indicating the day-of-year (DDD) as a number from 1 to 366, the hour of the day (HH) as a number from 00 to 23, and the minute (MM) as a number from 00 to

59.

IIII is the 4-digit machine ID number.

MESSAGE contains warning messages, test measurements, DAS reports, variable values, etc.

The uniform nature of the output messages makes it easy for a host computer to parse them.

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Table 6-9: RS-232 Interface Command Types

First Character Message Type

C Calibration status

D Diagnostic

R DAS report

T Test measurement

V Variable

W Warning

There are 6 different types of messages output by the 6200A. They are grouped below by type in Table 6-9 - Table 6-14. The meanings of the various messages are discussed elsewhere in the manual. The TEST, DIAGNOSTIC and WARNING messages are discussed in Section 9.1, 9.2, 9.3. DAS and VARIABLES are discussed in Section 5.3.3 and 5.3.9 CALIBRATE is discussed in Section 7.

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6.8.3 TEST Commands and Messages

Table 6-10: RS-232 Test Messages

Name Message Description

RANGE1 RANGE=xxxxx PPB2 Analyzer range

STABILITY STABIL=xxxx.x PPB Std. Deviation of last 25 SO2

SAMPPRESS PRES=xxx.x IN-HG-A Sample pressure

SAMPFLOW SAMPLE FL=xxx CC/M Sample flow rate

PMTDET PMT=xxxxxx MV PMT output

UVDET UV LAMP=xxxx MV Instantaneous UV lamp reading

STRAYLIGHT STR LGT=xxx.x PPB Stray light level

DARKPMT DRK PMT=xx.x MV PMT dark current in MV

DARKLAMP DRK LMP=xx.x MV UV detector dark current in MV

concentration values

SLOPE SLOPE=x.xxx Calibration slope parameter

OFFSET OFFSET=xxx.x MV Calibration offset parameter

HVPS HVPS=xxxxx V High voltage power supply

DCPS DCPS=xxxxxx MV DC power supply

RCELLTEMP RCELL TEMP=xxx C Reaction cell temperature

BOXTEMP BOX TEMP=xxx C Internal box temperature

PMTTEMP PMT TEMP=xxx C PMT temperature

IZSTEMP3 IZS TEMP=xxxx C IZS temperature

TESTCHAN4 TEST=xxxx.x MV Test channel output

CLOCKTIME TIME=HH:MM:SS Time of day

Displayed when single or autorange is enabled.

Depends on which units are currently selected.

Only if option installed.

Only if test channel selected.

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The T command lists TEST messages. Examples of the T command are:

T LIST Lists test messages currently enabled with T SET

T LIST ALL Lists all test messages

T RCELLTEMP Prints the temperature of the reaction cell

T SO2CONC Prints SO

concentration message

T LAMPRATIO Prints Lamp Ratio

6.8.4 WARNING Commands And Messages

Table 6-11: RS-232 Warning Messages

Name Message Description

WSYSRES SYSTEM RESET Analyzer was reset/powered on

WRAMINIT RAM INITIALIZED RAM was erased

WSAMPFLOW SAMPLE FLOW WARNING Sample flow out of spec.

WSAMPPRESS SAMPLE PRESSURE WARNING Sample pressure below 15” Hg or above

WUVLAMP UV LAMP WARNING UV lamp output is below 600mV or

WPMTTEMP PMT TEMP WARNING PMT temperature too high or too low

35” Hg

above 4995mV or PMT above 4995mV

WSHUTTTER SHUTTER WARNING Shutter not functioning

WRCELLTEMP RCELL TEMP WARNING Reaction cell temp. out of spec.

WBOXTEMP BOX TEMP WARNING Box temperature too high or too low

WIZSTEMP IZS TEMP WARNING IZS temp. out of spec.

WDYNZERO CANNOT DYN ZERO Dynamic zero cal. out of spec.

WDYNSPAN CANNOT DYN SPAN Dynamic span cal. out of spec.

WHVPS HVPS WARNING HVPS too high or too low

WVFDET V/F NOT INSTALLED A/D board not installed or broken

WDCPS DCPS WARNING DC power supply output below

2300mV or above 2700mV

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Whenever a warning message is reported on the analyzer display, if the RS-232 interface is in the normal mode (i.e. not in quiet mode) the warning message is also sent to the RS-232 interface. These messages are helpful when trying to track down a problem with the analyzer and for determining whether or not the DAS reports are actually valid. The warning message format is for example:

W 194:11:03 0000 SAMPLE FLOW WARNING

The format of a warning command is W command. Examples of warning commands are:

W LIST List all current warnings

W CLEAR ALL Clear all current Warnings

Individual warnings may be cleared via the front panel or the command line interface. To clear the sample flow warning shown above the command would be:

W WSAMPFLOW

6.8.5 CALIBRATION Commands and Messages

Table 6-12: RS-232 Calibration Messages

Message Description

START ZERO CALIBRATION Beginning IZS zero calibration

FINISH ZERO CALIBRATION, SO

START SPAN CALIBRATION Beginning IZS span calibration

FINISH SPAN CALIBRATION, SO

START MULTI-POINT CALIBRATION Beginning multi-point calibration

FINISH MULTI-POINT CALIBRATION Finished multi-point calibration

Depends on which units are currently selected.

Whenever the analyzer starts or finishes an IZS calibration, it issues a status report to the RS-232 interface. If the RS-232 interface is in the normal mode, these reports will be sent. Otherwise, they will be discarded. The format of these messages is:

C DDD:HH:MM IIII CALIBRATION STATUS MESSAGE

=xxxxx PPB Finished IZS zero calibration

=xxxxx PPB Finished IZS span calibration

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Teledyne 6200A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual