Teledyne 6400A User Manual

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INSTRUCTION MANUAL

MODEL 6400A

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

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table of Contents

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

1.1 SAFETY MESSAGES....................................................................................................1-2

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

2.1 INSTALLATION ............................................................................................................2-1

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

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

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

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

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

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

4 THE 6400A SO2 ANALYZER....................................................................4-1

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

4.2 INSTRUMENT DESCRIPTION .........................................................................................4-4

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

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

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

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

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

SAMPLE MODE...........................................................................................................5-7

5.2

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

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

5.3

SET-UP MODE .........................................................................................................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

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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

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

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

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

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

6.5 PERMEATION TUBE (USED WITH IZS OPTION)................................................................6-6

6.6 4-20 MA, CURRENT LOOP OUTPUT..............................................................................6-9

6.7 STATUS OUTPUT........................................................................................................6-9

6.8 RS-232 INTERFACE..................................................................................................6-10

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

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

7.1 MANUAL ZERO/SPAN CHECK OR CALIBRATION THROUGH THE SAMPLE PORT ..................7-4

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

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

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

7.5 AUTOMATIC ZERO/SPAN CALIBRATION .........................................................................7-7

7.6 CALIBRATE ON SO

7.7 USE OF IZS OR ZERO/SPAN VALVES WITH REMOTE CONTACT CLOSURE.........................7-8

7.8 EPA PROTOCOL CALIBRATION ....................................................................................7-9

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

7.9 SPECIAL CALIBRATION REQUIREMENTS FOR DUAL RANGE OR AUTO RANGE..................7-24

7.10 CALIBRATION QUALITY............................................................................................7-25

7.11

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

PERMEATION TUBE........................................................................7-8

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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

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

8.2 REPLACING THE SAMPLE PARTICULATE FILTER.............................................................8-2

8.3 REPLACING THE PERMEATION TUBE (OPTION)...............................................................8-4

8.4 REPLACING THE IZS ZERO AIR SCRUBBER (OPTION).....................................................8-4

8.5 CLEANING ORIFICE AND ORIFICE FILTER ......................................................................8-5

8.6 CLEANING THE REACTION CELL...................................................................................8-6

8.7 PNEUMATIC LINE INSPECTION......................................................................................8-6

8.8 LEAK CHECK PROCEDURE...........................................................................................8-9

8.9 LIGHT LEAK CHECK PROCEDURE...............................................................................8-10

8.10 EPROM REPLACEMENT PROCEDURE......................................................................8-10

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

9.1 OPERATION VERIFICATION - 6400A DIAGNOSTIC TECHNIQUES.......................................9-3

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 6400A 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 PERFORMANCE 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

ELECTRONIC SUBSYSTEM TROUBLESHOOTING AND ADJUSTMENTS...............................9-30

9.3

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

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

9.4 OPTICAL SENSOR MODULE TROUBLESHOOTING..........................................................9-58

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

9.5 PNEUMATIC SYSTEM TROUBLESHOOTING...................................................................9-60

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

10 TAI 6400A SPARE PARTS LIST..........................................................10-1

APPENDIX A MAINTENANCE SCHEDULE FOR 6400A .......................... A-1

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

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

List of Figures

FIGURE 2-1: REMOVAL OF SHIPPING SCREWS....................................................................2-3

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

FIGURE 2-3: REAR PANEL PNEUMATIC RECOMMENDATIONS................................................2-5

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

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

FIGURE 4-1: 6400A SULFUR DIOXIDE ANALYZER ...............................................................4-3

FIGURE 4-2: FRONT PANEL DISPLAY .................................................................................4-7

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

FIGURE 5-2: SETUP MENU TREE.......................................................................................5-2

FIGURE 6-1: PERMEATION TUBE INSTALLATION ..................................................................6-8

FIGURE 7-1: MODEL 6400A CALIBRATION SETUP...............................................................7-3

FIGURE 7-2: DIAGRAM OF CALIBRATION SYSTEM .............................................................7-15

FIGURE 7-3: DIAGRAM F PERMEATION CALIBRATION SYSTEM............................................7-17

FIGURE 8-1: REPLACING THE PARTICULATE FILTER ............................................................8-3

FIGURE 8-2: REACTION CELL............................................................................................8-7

FIGURE 8-3: PNEUMATIC DIAGRAM....................................................................................8-8

FIGURE 9-1: CPU BOARD JUMPER SETTINGS ..................................................................9-32

FIGURE 9-2: RS-232 PIN ASSIGNMENTS .........................................................................9-34

FIGURE 9-3: V/F BOARD DIP SWITCH SETTINGS ..............................................................9-41

FIGURE 9-4: POWER SUPPLY MODULE LAYOUT................................................................9-46

FIGURE 9-5: ELECTRICAL BLOCK DIAGRAM......................................................................9-47

FIGURE 9-6: FLOW/PRESSURE SENSOR ..........................................................................9-50

FIGURE 9-7: SO FIGURE 9-8: SO

FIGURE 9-9: PMT COOLER SUBSYSTEM.......................................................................... 9-55

FIGURE 9-10: HIGH VOLTAGE POWER SUPPLY.................................................................9-57

FIGURE 9-11: KICKER LEAK CHECK.................................................................................9-61

SENSOR MODULE................................................................................9-51

SENSOR MODULE................................................................................9-52

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

List of Tables

TABLE 2-1: FINAL TEST AND CALIBRATION VALUES...........................................................2-12

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

TABLE 4-1: SYSTEM MODES DISPLAY................................................................................4-6

TABLE 4-2: FRONT PANEL STATUS LED'S .........................................................................4-7

TABLE 5-1: 6400A SAMPLE MENU STRUCTURE .................................................................5-3

TABLE 5-2: 6400A SETUP MENU STRUCTURE ...................................................................5-4

TABLE 5-3: 6400A MENU STRUCTURE - SETUP MENU #2...................................................5-5

TABLE 5-4: 6400A MENU STRUCTURE - SETUP MENU #3...................................................5-6

TABLE 5-5: CALIBRATE, SETUP PASSWORDS ...................................................................5-17

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

TABLE 6-2: SETUP AUTOMATIC ZERO/SPAN CALIBRATION...................................................6-4

TABLE 6-3: STATUS OUTPUT PIN ASSIGNMENTS ................................................................6-9

TABLE 6-4: RS-232 PORT SETUP - FRONT PANEL............................................................6-11

TABLE 6-5: RS-232 SWITCHING FROM TERMINAL MODE TO COMPUTER MODE ..................6-12

TABLE 6-6: RS-232 TERMINAL MODE EDITING KEYS........................................................6-13

TABLE 6-7: RS-232 COMMAND SUMMARY.......................................................................6-14

TABLE 6-8: RS-232 COMMAND SUMMARY.......................................................................6-15

TABLE 6-9: RS-232 INTERFACE COMMAND TYPES ...........................................................6-16

TABLE 6-10: RS-232 TEST MESSAGES ...........................................................................6-17

TABLE 6-11: RS-232 WARNING MESSAGES ....................................................................6-18

TABLE 6-12: RS-232 CALIBRATION MESSAGES ...............................................................6-19

TABLE 6-13: RS-232 CALIBRATION COMMANDS...............................................................6-20

TABLE 6-14: RS-232 DIAGNOSTIC COMMAND SUMMARY..................................................6-21

TABLE 6-15: RS-232 DAS COMMANDS...........................................................................6-21

TABLE 6-16: RS-232 OPERATING MODES .......................................................................6-24

TABLE 7-1: TYPES OF ZERO/SPAN CHECKS AND CALIBRATIONS ..........................................7-2

TABLE 7-2: MANUAL ZERO CALIBRATION PROCEDURE - ZERO GAS THROUGH SAMPLE

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

ABLE 7-3: ENTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE...........................7-5

T TABLE 7-4: MANUAL SPAN CALIBRATION PROCEDURE - SPAN GAS THROUGH SAMPLE

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

ABLE 7-5: MANUAL ZERO CALIBRATION PROCEDURE - Z/S VALVES ...................................7-6

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

TABLE 7-7: IZS OR Z/S VALVES MODES WITH REMOTE CONTACT CLOSURE.........................7-9

TABLE 7-8: ACTIVITY MATRIX FOR CALIBRATION EQUIPMENT & SUPPLIES ..........................7-11

TABLE 7-9: ACTIVITY MATRIX FOR CALIBRATION PROCEDURE ...........................................7-12

ABLE 7-10: EPA ZERO CALIBRATION PROCEDURE .........................................................7-14

TABLE 7-11: EPA EXPECTED SPAN GAS CONCENTRATION PROCEDURE............................7-15

ABLE 7-12: EPA SPAN CALIBRATION PROCEDURE .........................................................7-16

T T

ABLE 7-13: DEFINITION OF LEVEL 1 AND LEVEL 2 ZERO AND SPAN CHECKS ......................7-20

ABLE 7-14: ACTIVITY MATRIX........................................................................................7-21

T TABLE 7-15: NIST-SRM'S AVAILABLE FOR TRACEABILITY OF CALIBRATION AND AUDIT

AS STANDARDS ......................................................................................7-24

ABLE 7-16: CALIBRATION QUALITY CHECK.....................................................................7-25

TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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

TABLE 9-1: TEST FUNCTIONS............................................................................................9-3

TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-4

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

T T

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

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

TABLE 9-1: TEST FUNCTIONS (CONTINUED).......................................................................9-8

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

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

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

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

TABLE 9-5: MODEL 6400A VARIABLES ............................................................................9-19

ABLE 9-6: TEST CHANNEL OUTPUT ...............................................................................9-20

TABLE 9-7: POWER SUPPLY MODULE SUBASSEMBLIES.....................................................9-45

ABLE 9-8: POWER SUPPLY MODULE LED OPERATION ....................................................9-48

TABLE 10-1: TAI 6400A SPARE PARTS LIST....................................................................10-1

TABLE 10-1: TAI 6400A SPARE PARTS LIST (CONTINUED)...............................................10-2

ABLE 10-1: TAI 6400A SPARE PARTS LIST (CONTINUED)...............................................10-3

T T

ABLE 10-1: TAI 6400A SPARE PARTS LIST (CONTINUED)...............................................10-4

TABLE 10-2: TAI MODEL 6400A LEVEL 1 SPARES KIT....................................................10-4

TABLE 10-3: TAI MODEL 6400A 37 MM EXPENDABLES KIT.............................................10-5

TABLE 10-4: TAI MODEL 6400A 47 MM EXPENDABLES KIT.............................................10-5

TABLE 10-5: TAI MODEL 6400A EXPENDABLES KIT - IZS...............................................10-5

TABLE 10-6: TAI MODEL 6400A SPARES KIT FOR 1 UNIT...............................................10-6

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

1 HOW TO USE THIS MANUAL

The Model 6400A has been designed with serviceability, reliability and ease of operation in mind. The 6400A'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 6400A 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.

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TAI Model 6400A 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.

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TAI Model 6400A 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 6400A.

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 6400A.

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 6400A, 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.)

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TAI Model 6400A 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.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-1: Removal of Shipping Screws

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-2: Rear Panel

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-3: Rear Panel Pneumatic Recommendations

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TAI Model 6400A 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 (6400A) and the

CPU memory configuration. If you are unfamiliar with the 6400A, 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 6400A 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 6400A'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.

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TAI Model 6400A 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 SO2 span gas concentration

Step Number Action Comment

1. Press CAL-CONC This key sequence causes the 6400A 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.

concentration. Enter the SO2 span concentration

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.

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TAI Model 6400A 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 6400A 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 6400A 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 display ed. If it is not, check the Troubleshooting Section 9.2.8 for instructions on how to proceed. In certain circumstances at low span gas concentrations (<100ppb), both the ZERO and SPAN buttons will appear.

9. Press ENTR Pressing ENTR actually changes the calculation equations so that the concentration displayed is the same as the expected span concentration you entered above, thus spanning the instrument.

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

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TAI Model 6400A 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 6400A 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 6400A is now ready to measure sample gas.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-4: Front Panel

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 2-5: Assembly Layout

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TAI Model 6400A 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)

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TAI Model 6400A 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 650 ± 10% 9.2.2, 9.3.6,

IZS Purge Flow cc/min 50 ± 10 6.3

Factory Installed Options Option Installed

Power Voltage/Frequency Rack Mount, w/ Slides

Observed Value

Units Nominal Range Reference Section

Table 9-1

(above 50 ppb)

Measured Flows

Units Nominal Range Reference Section

Figure 9-6

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

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INTENTIONALLY BLANK

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TAI Model 6400A 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

autoranging Noise at Zero1 0.2 ppb RMS Noise at Span1 <0.5% of reading (above 50 ppb) Lower Detectable Limit2 0.4 ppb RMS Zero Drift3 <0.5 ppb/24 hours Zero Drift Span Drift Lag Time 20 sec Rise Time 95% in <100 sec Fall Time 95% in <100 sec Sample Flow Rate 650cc/min. ±10% Linearity 1% of full scale Precision 0.5% of reading1 Temperature Range 5-40oC Temp Coefficient < 0.1% per oC 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, Analyzer4 230v/50Hz, 2.5A Environmental Conditions Installation Category (Overvoltage Category) II

Recorder Output5 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/m3, mg/m3

1 ppb/7 days

<0.5% FS/7 days

Pollution Degree 2

voltage or current range

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.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

3.2 EPA Equivalency Designation

Teledyne Analytical Instruments, Model 6400A 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 40oC.

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 650 +/- 65 cc/min.

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 01469).

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

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

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

5. SO

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

6. SO2 Permeation tube - certified 0.4ppm @ 0.7 lpm (P/N 0150604)

7. SO

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

8. SO2 Permeation tube - uncertified 0.8ppm @ 0.7 lpm (P/N 0150608)

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

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

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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 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.

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.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

4 THE 6400A SO2 ANALYZER

4.1 Principle of Operation

The operation of the TAI Model 6400A Analyzer is based upon the well proven technology from the measurement of fluorescence of SO2 due to absorption of UV energy. Sulfur Dioxide absorbs in the 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"1 which removes PNA selectively through a membrane without affecting SO2 sample gas.

The UV lamp emits ultraviolet radiation which passes through a 214 nm bandpass filter, excites the SO2 molecules, producing fluorescence which is measured by a PMT with a second UV bandpass filter. The equations describing the above reactions are as follows:

⎯→⎯+ (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 SO2. The excited SO2 decays back to the ground state emitting a characteristic fluorescence:

hvSO*SO +⎯→⎯ (3)

When the SO2 concentration is relatively low, the path length of exciting light is short and the 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 6400A.

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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Ultraviolet light is focused through a narrow 214 nm bandpass filter into the reaction chamber. Here it excites the SO2 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 SO2. Once this background light is subtracted, the CPU will convert this electrical signal into the SO2 concentration which is directly proportional to the number of SO2 molecules.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 4-1: 6400A Sulfur Dioxide Analyzer

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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 6400A displays pressure in inches of mercury-absolute (in-HgA) and flow in cc/min.

4.2.3 Computer Hardware and Software

The 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

The 6400A 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 6400A is shown in Figure 2-4. 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 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 4-1: System Modes Display

Mode Meaning

SAMPLE xx(1) 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 6400A. This provides a quick check on the internal health of the instrument. The right hand field shows current concentration value of SO2.

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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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 6400A 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 6400A.

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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

5 SOFTWARE FEATURES

This section covers the software features of 6400A 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 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 5-2: Setup Menu Tree

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

5.1.1 Sample Menu

Table 5-1: 6400A 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: 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 5-3: 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 5-4: 6400A 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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

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 6400A 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 650 ± 65 cc/min.

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 6400A. 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±1oC. Temperatures outside this range will cause the 6400A output to drift.

Box Temperature

This TEST function measures the temperature inside the chassis of the 6400A. The temperature sensor is located on the Status/Temp Board. Typically it runs 2 to 10oC higher than the ambient

temperature. The 6400A has been engineered to maintain stable output over 5 to 40

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 SO2 permeation tubes. The oven temperature is nominally 50C. The actual temperature is stable to ± 0.1oC although it is normal to see the temperature on the front panel move ± 0.3oC due to the proximity of the temperature sensor to the heater. It can be 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 SO2 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 6400A'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 6400A 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 6400A 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 SO2 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 6400A 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 SO2 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 6400A 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 6400A 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 6400A 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 6400A 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 6400A 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 SO2 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 6400A 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 6400A. 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 6400A 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 6400A 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 6400A 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 6400A 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 6400A 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 6400A 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 6400A.

When initiating calibration remotely via the contact closures, the RS-232, or automatically via the timer, the 6400A will calibrate RANGE #1.

5.3.4.4 Dilution Ratio

The dilution feature allows the 6400A 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 6400A can display concentrations in ppb, ppm, ug/m3, mg/m3. Coefficients for mg/m3 and ug/m3 were based on 0oC (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.

760

SO in ppm

286

×× × =.

273

SO in

mmHg

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 6400A 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 6400A. 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

Optional equipment offered with the 6400A includes: Rack mount with slides (P/N 00280). Rack mount without slides, ears only (P/N 01470). Fluorocarbon zero/span valves (P/N 01491). Internal zero/span - IZS (P/N 01441). 4-20mA, isolated outputs (P/N 01471). External pump DB-50 Connector for data inputs

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 un-

energized 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 6400A 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 SO2 liquid, with a small window of PTFE which is permeable to SO the nanogram/min range. If the tube is kept at constant temperature, usually about 50 device will provide a stable source of SO2 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.

The permeation tube SO2 concentration is determined by the permeation tube specific output (ppb @ 1 slpm @ 50oC), the permeation tube temperature (oC) and the air flow across it (slpm). The specific output is a fixed function of the permeation tube and is noted on shipping container.

The temperature is set at 50.0oC. Check SETUP-MORE-VARS and scroll to the IZS_SET variable to verify that the temperature is properly set. It should be set to 50oC with over-and-under temperature warnings set at 49oC and 51oC. There is a 50 cc/min purge flow across the permeation tube at all times to prevent build-up of SO2 gas in the tubing.

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

C, the

If desired, the output of the permeation tube can be adjusted by adjusting the oven temperature up or down slightly. The adjust increment is 0.1oC 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.@ 50 Km=(24.46)/molecular weight, where 24.46 is the molar volume in liters @ 25

C, 760mmHg Km for SO2 =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:

SO2 Permeation tube uncertified 0.4ppm @ 0.7 lpm SO2 Permeation tube certified 0.4ppm @ 0.7 lpm SO2 Permeation tube certified 0.8ppm @ 0.7 lpm SO2 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 6400A 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 01471 and 01248 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 6400A.

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 6400A 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

6400A 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; com m ands 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 6400A (i.e., operating the port in COMPUTER MODE) we suggest that you order a supplementary manual "The RS-232 Interface", TAI part number 01350. 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 RS-

232 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 6400A. 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 SO2 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

35” Hg

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

above 4995mV or PMT above 4995mV WPMTTEMP PMT TEMP WARNING PMT temperature too high or too low 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. Exam ples of warning comm ands 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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An example of an actual sequence of calibration status messages is: C DDD:HH:MM IIII START MULTI-POINT CALIBRATION C DDD:HH:MM IIII FINISH MULTI-POINT CALIBRATION There are several methods of both checking the calibration and calibrating the 6400A, these are

discussed in Section 7. C LIST lists the calibration commands available. The C command executes a calibration command, which may be one of the following:

Table 6-13: RS-232 Calibration Commands

Command Description

C LIST List calibration commands C ZERO Start remote zero calibration C SPAN Start remote span calibration C COMPUTE ZERO Adjust remote zero calibration C COMPUTE SPAN Adjust remote span calibration C EXIT Terminate remote zero or span calibration C ABORT Abort calibration sequence C ASEQ X Initiate automatic sequence X if previously setup

6.8.6 DIAGNOSTIC Commands and Messages

When Diagnostic mode is entered from the RS-232 port, the diagnostic mode issues additional status messages to indicate which diagnostic test is currently selected. Examples of Diagnostic mode messages are:

D DDD:HH:MM IIII ZERO VALVE=ON D DDD:HH:MM IIII ENTER DIAGNOSTIC MODE D DDD:HH:MM IIII EXIT DIAGNOSTIC MODE

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The following is a summary of the Diagnostic commands.

Table 6-14: RS-232 Diagnostic Command Summary

Command Description

D LIST Prints all I/O signal values. See Table 9-4 for Sig I/O definitions. D name=value Examines or sets I/O signal. For a list of signal names see Table 9-4

in Section 9. Must issue D ENTER SIG command before using this

command. D LIST NAMES Prints names of all diagnostic tests D ENTER SIG D ENTER OT D ENTER ET D ENTER TASK

D EXIT Must use this command to exit SIG, ET or OT Diagnostic modes D RESET Resets analyzer software. (Same as power on.) D RESET RAM Resets analyzer software and erases RAM. Erases SO2 conc values.

D RESET EEPROM Resets analyzer software and erases RAM and EEPROM. Returns all

Executes SIGNAL I/O diagnostic test.

Executes Optic Test diagnostic test.

Executes Elect Test diagnostic test.

Displays a listing of the tasks and their status.

Use D EXIT to leave these diagnostic modes.

Keeps setup variables and calibration. (Same as installing new

software version.)

setup variables to factory defaults, resets calibration value.

6.8.7 DAS Commands and Reports

RS-232 Commands

In addition to accessing the data acquisition system and the stored data from the instrument front panel, you can also access the data acquisition and the stored data from the RS-232 interface.

There are two RS-232 commands, listed in the table below.

Table 6-15: RS-232 DAS Commands

RS-232 DAS Commands

Command Description

D [id] PRINT [“name”] Prints specified data channel’s properties D [id] REPORT “name” [RECORDS=number]

[COMPACT|VERBOSE]

Prints the data for the specified data channel

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In all of the commands, brackets ([ ]) denote optional parameters. The ID parameter is the instrument ID, useful when the multi-drop protocol is being used. The NAME parameter is the data channel’s name. It must be enclosed in quotes (i.e. D PRINT “CONC”).

The RECORDS parameter of the REPORT command indicates how many records from the most recent record and prior to print. If the RECORDS parameter is not specified, all of the records are printed. The COMPACT and VERBOSE parameters of the REPORT command specify the report format.

RS-232 Reports

There are two basic kinds of RS-232 reports: data channel summary report, and data reports.

Data Channel Summary Format:

When you press the PRNT button in the data channel edit menu, a report like the following is printed on the RS-232 channel:

SETUP PROPERTIES FOR CONC: NAME: CONC EVENT: ATIMER STARTING DATE: 25-JUL-96 SAMPLE PERIOD: 000:00:01 REPORT PERIOD: 000:00:05 NUMBER OF RECORDS: 800 RS-232 REPORT: ON COMPACT REPORT: OFF CHANNEL ENABLED: ON CAL. HOLD OFF: ON PARAMETERS: 1 PARAMETER=CONC1, MODE=AVG, PRECISION=1

In this example, the data channel’s NAME property is “CONC”; the EVENT property is ATIMER; the PARAMETERS property is 1 (indicating a single parameter); the NUMBER OF RECORDS property is 800, and the RS-232 REPORT property is ON. The list of parameters and their properties is also printed. Each data channel stores its data in a separate file in the RAM disk, and this property shows the file name.

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Data Report Format:

A data report format looks like the following:

D 31:10:06 0412 CONC :AVG CONCI=6.8 PPB

This report uses the traditional TAI format of a leading first character (“D” in this example), a time stamp (“31:10:06”), and the instrument ID (“0412”). The other fields in the report are the data channel name (“CONC”), the sampling mode (“AVG”), the parameter (“CONC1”), the parameter value (“6.8”), and the units (“PPB”).

If the RS-232 interface is in the quiet mode, then these reports are not printed, although they can be requested by a user or host computer at a later time.

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6.8.8 VARIABLES Commands and Messages

Table 6-16: RS-232 Operating Modes

Mode Description

ZERO CAL A Automatic zero calibration ZERO CAL R Remote zero calibration ZERO CAL M Manual zero calibration SPAN CAL A Automatic span calibration SPAN CAL R Remote span calibration SPAN CAL M Manual span calibration M-P CAL Manual multi-point calibration DIAG ELEC Electrical diagnostic test DIAG OPTIC Optical diagnostic test DIAG AOUT D/A output diagnostic test DIAG Main diagnostic menu DIAG I/O Signal I/O diagnostic DIAG RS232 RS232 output diagnostic DIAG ERASE Memory erase diagnostic SETUP x.x Setup mode (x.x is software version) SAMPLE A Sampling; automatic cal. enabled SAMPLE Sampling; automatic cal. disabled

The 6400A operational modes are listed above. To list the analyzer's current mode type:

V MODE Lists 6400A current operational mode

See Table 6-14 for list of operational modes and meanings. Model 6400A Internal Variables The 6400A has a number of internal setup variables. Essentially all of these are set at time of

manufacture and should not need to be changed in the field. A list of user accessible variables is shown in Table 9-5.

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A list of variables and their settings can be requested over the RS-232 port by:

V LIST Lists internal variables and values

The output from this command is quite long and will not be shown here. The general format of the output is:

name = value warning_lo warning_hi <data_lo> <data_hi> Where:

name = name of the variable value = current value of variable warning_lo = lower limit warning (displayed if applicable) warning_hi = upper limit warning (displayed if applicable) data_lo = lower limit of allowable values data_hi = upper limit of allowable values

Variables can be changed. Before changing the settings on any variables, please make sure

you understand the consequences of the change. We recommend you call the factory before changing the settings on any variables. The general format for changing the settings on a

variable is: V LIST name[=value [warn_lo [warn_hi]]] For example to change the warning limits on the box temperature type: V BOX_SET 30 10 50 and the CPU should respond with: V DDD:HH:MM IIII BOX_SET=30 10 50(0-60) The CONFIG command lists the software configuration. For example: V CONFIG list software configuration The format of this listing is shown in the example below. CONFIG[ 0]=Revision H.7

CONFIG[ 1]=SO2 Analyzer CONFIG[ 2]=SBC40 CPU

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INTENTIONALLY BLANK

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7 CALIBRATION AND ZERO/SPAN CHECKS

There are several ways to check and adjust the calibration of the 6400A. These different methods are summarized in the following Table 7-1. In addition, all of the methods described in this section can be initiated and controlled via the RS-232 port, see Section 6.8 for details.

NOTE

If you are using the 6400A for EPA monitoring, it is recommended to follow the

calibration method described in Section 7.8. All other calibration methods,

except in Section 7.6, are also applicable to EPA SLAMS if calibrated under

the proper conditions as explained in Section 7.8.

NOTE

If there are any problems completing any of the following

procedures refer to Section 9.2.8 and 9.2.9 – Unable to Span or Zero

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Table 7-1: Types of Zero/Span Checks and Calibrations

Section Type of Cal or Check Description

7.1 Manual Z/S Check - Cal gas through sample port

7.2 Manual Z/S Check or Calibration with Z/S valve Option

7.3 Manual Z/S Check or Calibration with IZS Option

7.4 Automatic Z/S Check with Z/S Valves or IZS Option

7.5 Dynamic Z/S Calibration with Z/S Valves or IZS Option

7.6 Calibrate using SO2 Permeation Tube

7.7 Use of Z/S Valve or IZS with Remote Contact Closure

7.8 EPA Protocol Calibration Covers methods to be used if data is for EPA

This calibration option expects the calibration gas coming in through the sample port. IZS and Zero/Span valves do not operate.

How to operate Zero/Span Valve Option. Can be used to check or adjust calibration.

How to operate IZS Option. Can be used to check or adjust calibration.

Operates Z/S valves or IZS once per day to check the calibration.

Operates Z/S valves or IZS once per day and adjusts the calibration.

Allows calibration using SO2 gas from the IZS permeation tube.

Operates Z/S valves or IZS with rear panel contact closures. Without valves or IZS, can be used to switch instrument into zero or span cal mode. Used for either checking or adjusting zero/span.

SLAMS monitoring.

7.9 Special calibration requirements for Dual Range or Auto Range

7.10 Calibration Quality Information on how to determine if the calibration

7.11 References Contains a list of references on quality control and

Covers special requirements if using Dual Range or Auto Range.

performed will result in optimum instrument performance.

calibration.

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Figure 7-1: Model 6400A Calibration Setup

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7.1 Manual Zero/Span Check or Calibration through the Sample Port

The zero and span calibration of the instrument can be checked or adjusted using gases supplied through the normal sample port. This method is often used when the calibration gas is supplied from an external calibrator system.

This mode provides a calibration mechanism if the instrument is purchased without IZS or Zero/Span Valve options.

Since the zero gas concentration is defined as 0 ppb, it is not necessary to enter the expected zero value. Table 7-2 details the zero calibrate procedure with zero gas coming in through the sample port.

Table 7-2: Manual Zero Calibration Procedure - Zero Gas Through Sample Port

Step Number Action Comment

1. Press CAL The 6400A enters the calibrate mode from sample mode. The zero gas must come in through the sample port.

2. Wait 10 min Wait for reading to stabilize at zero value

3. Press ZERO If you change your mind after pressing ZERO, you can still press EXIT here without zeroing the instrument.

4. Press ENTR Pressing ENTR actually changes the calculation equations.

5. Press EXIT The 6400A returns to sampling. Immediately after calibration, data is not added to the DAS averages.

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Enter the expected SO2 span gas concentration:

Table 7-3: Enter Expected Span Gas Concentrations Procedure

Step Number Action Comment

1. Press CAL-

CONC

This key sequence causes the 6400A to prompt for the expected SO

concentration. Enter the SO2 span concentration

value by pressing the key under each digit until the expected value is set. This menu can also be entered from CALS.

2. Press ENTR ENTR stores the expected SO2 span value.

3. Press EXIT Returns instrument to SAMPLE mode.

Table 7-4: Manual Span Calibration Procedure - Span Gas Through Sample Port

Step Number Action Comment

1. Press CAL The 6400A enters the calibrate mode. External span gas should be fed to the sample port.

2. Wait 10 min Wait for reading to stabilize at span value

3. Press SPAN If you change your mind after pressing SPAN, you can still press EXIT here without spanning the instrument.

4. Press ENTR Pressing ENTR actually changes the calibration equations and causes the instrument to read the SO

5. Press EXIT The 6400A returns to sampling. Immediately after calibration, data is not added to the DAS averages.

span concentrations.

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7.2 Manual Zero/Span Check or Calibration with Zero/Span Valves Option

The Zero/Span valve option can be operated from the front panel keyboard. In the Zero/Span valve option the zero and span gas come into the valves through ports on the rear panel of the instrument.

Table 7-5: Manual Zero Calibration Procedure - Z/S Valves

Step Number Action Comment

1. Press CALZ The analyzer enters the zero calibrate mode. This switches the sample/cal and zero/span valves to allow zero gas to come in through the zero gas inlet port or the rear panel.

2. Wait 10 min Wait for reading to stabilize at zero value

3. Press ZERO If you change your mind after pressing ZERO, you can still press EXIT here without zeroing the instrument.

4. Press ENTR Pressing ENTR actually changes the calculation equations, forcing the reading to zero.

5. Press EXIT The 6400A returns to sample mode. Immediately after calibration, readings do not go into the DAS averages.

Table 7-6: Manual Span Calibration Procedure - Z/S Valves

Step Number Action Comment

1. Press CALS The 6400A enters the calibrate mode from sample mode. This operates the sample/cal and zero/span valves to allow span gas to come in through the cal gas inlet port or the rear panel.

2. Wait 10 min Wait for reading to stabilize at span value.

3. Press SPAN If you change your mind after pressing SPAN, you can still press EXIT here without spanning the instrument.

4. Press ENTR Pressing ENTR actually changes the calculation equations.

5. Press EXIT The 6400A returns to sampling. Immediately after calibration, data is not added to the DAS averages during HOLDOFF period.

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7.3 Manual Zero/Span Check with IZS Option

The Internal Zero/Span (IZS) system can be operated from the front panel keyboard. When the 6400A is in the SAMPLE mode, and the IZS option is installed, the CALS (Calibrate-Span) or CALZ (Calibrate-Zero) buttons will be visible. When the buttons are pressed, valves are switched to allow zero air or SO2 span gas to be input into the instrument.

To do a manual zero check with the IZS Option, press CALZ, then wait about 10 minutes for the zero reading to stabilize. The zero value in the display, and analog output is the zero value. Press EXIT to return to SAMPLE mode. This procedure does not change the zero calibration of the instrument.

To do a manual SO stabilize. The concentration value in the display, and analog output is the span value. Press EXIT to return to SAMPLE mode. This procedure does not change the span calibration of the instrument.

span check, press CALS, then wait about 10 minutes for the SO2 reading to

7.4 Automatic Zero/Span Check

In a typical air monitoring application it is desirable to have the analyzer automatically check (AUTOCAL) its calibration each day. If provided with the proper options, the 6400A provides this capability by using the time of day clock to signal the computer system to check operations. When enabled, the instrument software will automatically check zero and span (AUTOCAL) on a timed basis. Optionally, the Z/S cycle can be moved backwards or forwards a fixed time each day(to avoid missing measurements at the same time each day).

Setup of the AUTOCAL is covered in Section 6.4.

7.5 Automatic Zero/Span Calibration

The AUTOCAL system described above can also optionally be used to calibrate the instrument on a timed basis. The automatic calibration is enabled by setting CALIBRATE button to ON under each SEQUENCE setup (Refer to Section 6.4).

Before proceeding with enabling Automatic Z/S you must setup the AUTOCAL feature. Enabling this feature is described in Section 6.4.

With automatic calibration turned on, the instrument will re-set the slope and offset values for the SO subtle fault conditions in the analyzer. It is recommended that if Automatic Calibration is enabled, the TEST functions, and SLOPE and OFFSET values in the 6400A are checked frequently to assure high quality and accurate data from the instrument.

concentration. This continual re-adjustment of calibration parameters can often mask

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7.6 Calibrate on SO2 Permeation Tube

If the 6400A is equipped with the IZS option, it is possible to span the instrument on the permeation tube(refer to Section 6.5). If this feature is enabled, the instrument internal valves are set so that SO this known SO

permeation tube is intended to be used as a periodic span check and is not to be used as a calibration device.

Note that this method of calibration is NOT approved by the USEPA. Permeation

tubes are known to change as temperatures are cycled, and as they age. It is

recommended that if permeation tube is used, then the instrument calibration be

gas is routed through the permeation tube. The software is programmed to use

gas concentration to span the instrument by pressing CALS button. The IZS

NOTE

checked frequently by independent means to assure accurate data.

7.7 Use of IZS or Zero/Span Valves with Remote Contact Closure

The Zero/Span valve or IZS options can be operated using Remote Contact Closures provided on the rear panel. See Figure 2-2 for connector location and pinout. When the contacts are closed, the analyzer will switch to zero or span mode. The contacts must remain closed for at least 1 second, and the Analyzer will remain in zero or span mode as long as the contacts are closed. If either DYN_ZERO or DYN_SPAN is enabled (refer Table 9-5), the calibration is adjusted at the end of the zero or span time, otherwise zero or span is just checked, not adjusted. To set DYN_ZERO or DYN_SPAN, press SETUP-MORE-VARS-ENTR and press NEXT repeatedly until DYN_ZERO is shown. Press EDIT and toggle OFF (disabled) or ON (enabled).

The CPU monitors these two contact closures and will switch the Analyzer into zero or span mode when the contacts are closed for at least 1 second.

In order to do another remote check, both contact closures should be held open for at least 1 second, then may be set again. Table 7-8 shows what type of check is performed based on the settings of the two contact closures.

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Table 7-7: IZS or Z/S Valves Modes with Remote Contact Closure

Ext Zero CC Ext Span CC Operation

Contact Open Contact Open State when in SAMPLE mode, normal monitoring. Contact Open Contact Closed Span check or calibrate* Contact Closed Contact Open Zero check or calibrate*

* Calibrate only if Dynamic Calibration is enabled (see Table 9-5).

7.8 EPA Protocol Calibration

If the 6400A is to be used for EPA SLAMS monitoring, it must be calibrated in accordance with the instructions in this section.

In order to insure that high quality, accurate measurements are obtained at all times, the 6400A must be calibrated prior to use. A quality assurance program centered on this aspect and including attention to the built-in warning features of the 6400A, periodic inspection, regular zero/span checks and routine maintenance is paramount to achieving this.

In order to have a better understanding of the factors involved in assuring continuous and reliable information from the 6400A, it is strongly recommended that Publication No. PB 273518 Quality Assurance Handbook for Air Pollution Measurement Systems (abbreviated, Q.A. Handbook) be purchased from the NTIS (phone 703-605-6000). Special attention should be paid to Section 2.9 which deals with fluorescence based SO2 analyzers and upon which most of this section is based. Specific regulations regarding the use and operation of ambient sulfur dioxide analyzers can be found in 40 CFR 50 and 40 CFR 58. Both publications are available from the U.S. Government Printing Office (phone 202-512-0327).

7.8.1 Calibration of Equipment

In general, calibration is the process of adjusting the gain and offset of the 6400A against some recognized standard. The reliability and usefulness of all data derived from any analyzer depends primarily upon its state of calibration. In this section the term dynamic calibration express a multipoint check against known standards and involves introducing gas samples of known concentration into the instrument in order to adjust the instrument to a predetermined sensitivity and to produce a calibration relationship. This relationship is derived from the instrumental response to successive samples of different known concentrations. As a minimum, three reference points and a zero point are recommended to define this relationship. The true values of the calibration gas must be traceable to NIST-SRM's.

is used to

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

All monitoring instrument systems are subject to some drift and variation in internal parameters and cannot be expected to maintain accurate calibration over long periods of time. Therefore, it is necessary to dynamically check the calibration relationship on a predetermined schedule. Zero and span checks must be used to document that the data remains within control limits. These checks are also used in data reduction and validation. Table 7-9 summarizes the initial quality assurance activities for calibrating equipment. Table 7-10 is a matrix for the actual dynamic calibration procedure.

Calibrations should be carried out at the field monitoring site. The Analyzer should be in

operation for at least several hours (preferably overnight) before calibration so that it is fully warmed up and its operation has stabilized. During the calibration, the 6400A should be

in the CAL mode, and therefore sample the test atmosphere through all components used during normal ambient sampling and through as much of the ambient air inlet system as is practicable.

If the Instrument will be used on more than one range, it should be calibrated separately on each applicable range (see Section 7.9). Calibration documentation should be maintained

with each analyzer and also in a central backup file.

7.8.2 Calibration Gas Sources

Compressed SO2 in nitrogen The NIST-SRM's provide references against which all calibration gas mixtures must be

compared (Section 2.0.7, Q.A. Handbook). The procedure requires the comparison of the concentration of a commercial, working calibration standard to an NIST-SRM. This is described in Subsection 7.1 of Section 2.0.7, Q.A. Handbook. Subsections 7.1.4 and 7.1.5 describe the verification and reanalysis of cylinder gases.

SO2 permeation tubes The steps required to compare the concentration of a commercial working calibration standard to

an NIST-SRM are described in Subsection 7.2.3 of Section 2.0.7, Q.A. Handbook. See Subsection 7.2.6 for the re-analysis of permeation tubes.

Dilution air Zero air (free of contaminants that could cause a detectable response with the Sulfur Dioxide

Analyzer) is commercially available, or can be generated by the user. A clean air system utilizing ambient air may be more desirable to use for zero and dilution purposes. If compressed air cylinder is used, the air should have O2, N2, and CO2 content similar to that of ambient air and less than 0.1ppm aromatic hydrocarbons.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 7-8: Activity Matrix for Calibration Equipment & Supplies

Equipment/supplies Acceptance limits

Recorder Compatible with

Frequency and method of measurement

Check upon receipt Return equipment to output signal of analyzer; min. chart width of 150 mm (6 in) is recommended

Sample line and manifold

Calibration equipment

Constructed of PTFE or glass

Meets guidelines of reference 1 and

Check upon receipt Return equipment to

See Section 2.3.9 (Q.A.

Handbook) Section 2.3.2 (Q.A. Handbook)

Working standard

cylinder gas or

permeation tube

Traceable to NISTSRM meets limits in traceability protocol for accuracy and

Analyzed against NIST-

SRM; see protocol in

Section 2.0.7, Q.A.

Handbook stability (Section

2.0.7, Q.A. Handbook)

Zero air Clean dry ambient

air, free of

See Section 2.9.2 (Q.A.

Handbook) contaminants that cause detectable response with the

analyzer.

Action if requirements are not met

supplier

supplier Return equipment/

supplies to supplier or take corrective action

Obtain new working standard and check for traceability

Obtain air from another source or regenerate.

Record form Develop standard

forms

Audit equipment Must not be the

same as used for calibration

N/A Revise forms as

appropriate

System must be checked

out against known

standards

Locate problem and correct or return to supplier

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 7-9: Activity Matrix for Calibration Procedure

Equipment/supplies Acceptance limits

Calibration gases NIST traceable Assayed against an

Dilution gas Zero air, free of

contaminants

Multi-point calibration

Use calibration procedure in Subsec. 2.2 (Q.A. Handbook); also Federal Register

Frequency and method

of measurement

NIST-SRM semi-

annually, Sec. 2.0.7,

(Q.A. Handbook)

See Section 2.9.2 (Q.A.

Manual)

Perform at least once

every quarter or anytime

a level span check

indicates a discrepancy,

or after maintenance

which may affect the

calibration; Subsec 2.5

(Q.A. Manual)

Action if requirements are not met

Working gas standard is unstable, and/or measurement method is out of control; take corrective action such as obtaining new calibration gas.

Return to supplier or take appropriate action with generation system

Repeat the calibration

7.8.3 Data Recording Device

Either a strip chart recorder, data acquisition system, digital data acquisition system should be used to record the data from the 6400A RS-232 port or analog outputs. If analog readings are being used, the response of that system should be checked against a NIST referenced voltage source or meter. Data recording device should be capable of bi-polar operation so that negative readings can be recorded.

7.8.4 Dynamic Multipoint Span Calibration

Dynamic calibration involves introducing gas samples of known concentrations to an instrument in order to adjust the instrument to a predetermined sensitivity and to derive a calibration relationship. A minimum of three reference points and one zero point uniformly spaced covering 0 to 80 percent of the operating range are recommended to define this relationship.

The analyzer's recorded response is compared with the known concentration to derive the calibration relationship.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

7.8.5 SO2 Calibration Procedure

There are two calibration procedures for 6400A such as dynamic dilution procedure using compressed gas cylinder or using permeation tube. The procedures for multipoint calibration of the SO general procedures to the case of the 6400A.

Calibration must be performed with a calibrator that meets all conditions specified in Subsection

2.9.2 (Q.A. Handbook). The user should be sure that all flow meters are calibrated under the conditions of use against a reliable standard. All volumetric flow rates should be corrected to 25 the concentration at a sufficient flow over the whole range of concentration that will be encountered during calibration.

All operational adjustments to the 6400A should be completed prior to the calibration. The following software features must be set into the desired state before calibration.

1. Single range selection. See Section 5.3.4, this manual. If the instrument will be used more

analyzer are specified in the Code of Federal Regulation.1 This section applies those

C (77oF) and 760mm (29.92in) Hg. Make sure the calibration system can supply the range of

than one range, it should be calibrated separately on each applicable range.

2. Automatic temperature/pressure compensation. See Table 9-5.

3. Alternate units, make sure ppb units are selected for EPA monitoring. See Section 5.3.4.2. The analyzer should be calibrated on the same range for monitoring. If autoranging option is

selected, the highest of the ranges will result in the most accurate calibration, and should be used.

7.8.5.1 Calibration Using Cylinder Gas Dilution

This calibration procedure consists of diluting a gas cylinder of SO

standard with clean dry dilution

air. Possible dilution system is shown in Figure 7-2. Flow controller

maintaining constant flow rates to within ±1%. Flowmeters

should be capable of

capable of measuring flow rates to within ± 2% are required. NIST-traceable soap bubble flowmeter or wet-test meter are suitable for flow determination. Mixing chamber mixing of SO

gas with dilution air. Output manifold should be of a sufficient diameter to ensure

must be made of glass or Teflon and provide thorough

a minimum pressure drop and must be vented to create ambient pressure at the manifold. Also must have enough flow to prevent back diffusion of ambient air into the manifold. Gas cylinder containing 50 to 100 ppm SO

in air is used as the dilution source (refer Table 7-16).

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Zero calibration procedure.

Table 7-10: EPA Zero Calibration Procedure

Step Number Action Comment

1. Press CAL The 6400A enters the calibrate mode from sample mode.

2. Wait 10 min Wait for reading to stabilize at the zero value.

3. Press ZERO To select a zero calibration.

4. Press ENTR Pressing ENTR actually changes the equations

5. Press EXIT 6400A returns to the CAL menu.

1. Adjust the SO2 concentration to approximately 80% of the URL of the range. The expected

SO2 span concentration can be determined by measuring the cylinder and diluent flows and computing the resulting concentration.

Allow the zero gas through the sample port.

Calculate the expected concentration as follows.

[] []SO

gas

total

gas22

=× ----------------------------------- Equation 7.1

where;

[SO F

gas

total

[SO

= cylinder gas concentration, ppm

2]gas

= SO2 gas flow rate, cc/min.

= total(gas + diluent) flow rate, cc/min.

] = expected SO2 concentration, ppm

Enter the expected concentration [SO

] using the procedure in Table 7-12. The expected span

concentration need not be re-entered each time a calibration is performed unless it is changed.

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Figure 7-2: Diagram Of Calibration System

Table 7-11: EPA Expected Span Gas Concentration Procedure

Step Number Action Comment

1. Press CALCONC

This key sequence causes the 6400A to prompt for the expected SO

Enter the SO

concentration.

span concentration value by pressing the key

under each digit until the expected value is set.

2. Press ENTR ENTR stores the expected SO2 span value.

3. Press EXIT Returns instrument to SAMPLE mode.

Sample the generated concentration until the SO

response is stabilized.

Span the instrument by the following procedure:

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

Table 7-12: EPA Span Calibration Procedure

Step Number Action Comment

1. Press CAL The 6400A enters the calibrate mode from sample mode.

2. Wait 10 min Wait for readings to stabilize at span values.

3. Press SPAN If you change your mind after pressing SPAN, you can still

press EXIT here without spanning the instrument.

4. Press ENTR Pressing ENTR actually changes the calculation equations.

5. Press EXIT 6400A returns to SAMPLE mode.

The analog voltage output should measure approximately 80% of the voltage range selected. (e.g. 4.00VDC if 0-5V output is selected.) The reading on the front panel display should be equal to the expected SO

concentration entered in the procedure given in Table 7-12 above. See the

Troubleshooting Section 9.2.8 if there are problems. Also see the Calibration Quality Check procedure Section 7.10.

After the zero and the 80% URL points have been set, generate five approximately evenly spaced calibration points between zero and 80% URL without further adjustment to the instrument. Allow the instrument to sample these intermediate concentrations for about 10 minutes each and record the instrument SO

Plot the analyzer SO

response versus the corresponding calculated concentrations to obtain the

response.

calibration relationships. Determine the straight line of best fit (y = mx + b) determined by the method of least squares.

After the best-fit line has been drawn for the SO

calibration, determine whether the analyzer

response is linear. To be considered linear, no calibration point should differ from the best-fit line by more than 2% of full scale.

7.8.5.2 Calibration Using Dynamic Permeation Dilution

The procedure for multipoint calibration of an SO2 analyzer by an SO2 permeation system are specified in Code of Federal Regulations

Possible dilution system is shown in Figure 7-3. Permeation chamber maintained within ±0.1

C of accuracy. Should allow a minimum of 24 hours of temperature equilibrium period after power up of the temperature controller. Flow controllers capable of maintaining constant flow rate to within ±1%. Flowmeters

temperature must be

should be

capable of measuring flow rates to within ±2% are required. NIST-traceable soap bubble flowmeter or wet-test meter are suitable for flow determination. Mixing chamber mixing of SO

gas with dilution air. Output manifold should be sufficient diameter to ensure a

is made of glass and should provide thorough

minimum pressure drop and must be vented to create ambient pressure at the manifold. Permeation tube

traceability is established by referencing the permeation device to a NIST-SRM

(refer to Table 7-16).

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

1. Zero calibration procedure is identical to Table 7-11.

Generate the SO

concentration to approximately 80% of the URL of the range.

Calculate the expected concentration as follows.

[] .SO

[SO

] = SO2 gas concentration, ppm

382 10=

××

P = permeation flow rate at the specific temperature, ug·SO

= carrier flow rate over the permeation tube, SLPM (25oC, 760 mmHg)

= diluent air flow rate, SLPM (25oC, 760 mmHg)

−

--------------------------------------- Equation 7.2

/min.

Figure 7-3: Diagram F Permeation Calibration System

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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G

By rearranging Equation 7.2 it is possible to calculate total air flow which is sum of Fc and Fd.

FFF +=

dctotal

total

[]

××

382 10

−

Equation 7.3

Total air flow rate should exceed the analyzer's sample flow rate demand by margin of 10% to 50%.

Enter the expected concentration [SO

] from Equation 7.2 using the procedure in

Table 7-12.

Sample the generated concentration until the SO

Span the instrument per Table 7-13.

response is stabilized.

If the expected concentration value is 80% of the full range, then the analog voltage output should measure 80% of the voltage range selected. (e.g. 4.00VDC if 0-5V output is selected.) The reading on the front panel display should be equal to the expected SO

concentration entered

in the procedure given in step 3 above. See the Troubleshooting Section 9.2.8 if there are problems. Also see the Calibration Quality Check procedure Section 7.10.

After the zero and the 80% URL points have been set, determine five approximately evenly spaced points between zero and 80% URL without further adjustment to the instrument. And allow the instrument to sample these intermediate concentrations for about 10 minutes each and record the instrument response.

Plot the analyzer responses versus the corresponding calculated concentrations to obtain the

calibration relationship. Determine the straight line of best fit (y = mx + b) determined by the method of least squares.

After the best-fit line has been drawn for the SO

calibration, determine whether the analyzer

response is linear. To be considered linear, no calibration point should differ from the best-fit line by more than 2% of full scale.

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Teledyne 6400A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual