Teledyne 6400A User Manual
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
Copyright 1994
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
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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
2
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
2
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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
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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
2
SENSOR MODULE................................................................................9-52
2
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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
T
ABLE 7-5: MANUAL ZERO CALIBRATION PROCEDURE - Z/S VALVES ...................................7-6
ABLE 7-6: MANUAL SPAN CALIBRATION PROCEDURE - Z/S VALVES....................................7-6
T
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
T
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
G
AS STANDARDS ......................................................................................7-24
ABLE 7-16: CALIBRATION QUALITY CHECK.....................................................................7-25
T
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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
T
TABLE 9-7: POWER SUPPLY MODULE SUBASSEMBLIES.....................................................9-45
T
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
2
2
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
2
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
2
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.
2
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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G
Figure 2-4: Front Panel
2-10
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G
Figure 2-5: Assembly Layout
2-11
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
o
C 50 ± 1 9.3.7
o
C 8-50 9.3.4.1
o
C 7 ± 1 9.3.9
o
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
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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TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G
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
3
1 ppb/7 days
3
<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)
2
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)
2
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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