Teledyne T200U-NOy User Manual

T200U-NOy ANALYZER

ADDENDUM

(for use with T200 Operators Manual, PN 06858

and with the T200U Addendum, PN 06861)

© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION

9480 CARROLL PARK DRIVE

SAN DIEGO, CA 92121-5201

USA

Toll-free Phone: [phone]

Phone: [phone]

Fax: [phone]

Email: [e-mail]

Website: http://www.teledyne-api.com/

Copyright 2011-2013 07303C DCN6646
Teledyne Advanced Pollution Instrumentation 06 February 2013

SAFETY MESSAGES

Important safety messages are provided throughout this manual for the purpose of
avoiding personal injury or instrument damage. Please read these messages carefully.
Each safety message is associated with a safety alert symbol, and placed throughout this
manual and inside the instrument. The symbols with messages are defined as follows:

WARNING: Electrical Shock Hazard

HAZARD: Strong oxidizer

GENERAL WARNING/CAUTION: Read the accompanying message for specific

information.

CAUTION: Hot Surface Warning

Do Not Touch: Touching some parts of the instrument without protection or proper tools

could result in damage to the part(s) and/or the instrument.

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

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

CAUTION

This instrument should only be used for the purpose and in the manner described in
this manual. If you use this instrument in a manner other than that for which it was

intended, unpredictable behavior could ensue with possible hazardous consequences

NEVER use any gas analyzer to sample combustible gas(es)!

Note

.

For Technical Assistance regarding the use and maintenance of this instrument or any other Teledyne
API product, contact Teledyne API’s Technical Support Department:

Telephone: [phone]

Email: [e-mail]

or access any of the service options on our website at http://www.teledyne-api.com/

07303C DCN6646 i

CONSIGNES DE SÉCURITÉ

Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans
le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire
attentivement ces consignes. Chaque consigne de sécurité est représentée par un
pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à
l’intérieur des instruments. Les symboles correspondent aux consignes suivantes :

AVERTISSEMENT : Risque de choc électrique

DANGER : Oxydant puissant

AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne

complémentaire pour des renseignements spécifiques

MISE EN GARDE : Surface chaude

Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou

sans les outils appropriés pourrait entraîner des dommages aux pièces ou à
l’instrument.

Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent
être effectuées uniquement par du personnel de maintenance qualifié.

Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central
de la mise à la terre sécuritaire de l’instrument.

Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans
ce manuel. Si vous utilisez cet instrument d’une autre manière que celle pour
laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible
et entraîner des conséquences dangereuses.

NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!

MISE EN GARDE

ii 07303C DCN6646

WARRANTY

WARRANTY POLICY (02024F)

Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne
Instruments, Inc., provides that:

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

COVERAGE

After the warranty period and throughout the equipment lifetime, TAPI 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 are to be
performed by the customer.

NON-TAPI MANUFACTURED EQUIPMENT

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

PRODUCT RETURN

Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing
instructions and Return Merchandise Authorization (RMA) procedures when returning parts
for repair or calibration may void your warranty. For anti-ESD handling and packing
instructions please refer to “Packing Components for Return to Teledyne API’s Customer
Service” in the Primer on Electro-Static Discharge section of this manual, and for RMA
procedures please refer to our Website at http://www.teledyne-api.com under Customer
Support > Return Authorization.

All units or components returned to Teledyne API 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.

The complete Terms and Conditions of Sale can be reviewed at http://www.teledyne-

api.com/terms_and_conditions.asp

CAUTION – Avoid Warranty Invalidation

07303C DCN6646 iii

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iv 07303C DCN6646

Model 200EU-NOy Option Manual Addendum

TABLE OF CONTENTS

1.0 INTRODUCTION......................................................................................................7

2.0 SPECIFICATIONS ...................................................................................................9

2.1 Specifications ........................................................................................................................9

3.0 GETTING STARTED..............................................................................................11

3.1 Unpacking and Inspection..................................................................................................11

3.2 Electrical and Pneumatic Connections.............................................................................12

3.3 Initial Operation ...................................................................................................................15

4.0 THE T200U-NOY EXTERNAL CONVERTER........................................................17

4.1 Principle of Operation.........................................................................................................17

5.0 CALIBRATION AND ZERO/SPAN (OPTION) CHECKS.......................................19

5.1 Calibration or Cal Check Procedure..................................................................................20

6.0 MAINTENANCE.....................................................................................................23

6.1 Maintenance Schedule........................................................................................................23

6.2 Replacing the Sample Particulate Filters..........................................................................24

6.3 Checking Analyzer Flow Rate ............................................................................................26

6.4 Replacing the Converter.....................................................................................................26

6.6 Checking for Leaks .............................................................................................................29

7.0 TROUBLESHOOTING, ADJUSTMENTS...........................................................31

7.1 Operation Verification – Diagnostic Techniques.............................................................31

7.1.1 Pneumatic System.............................................................................................................31

7.1.2 Leak Check........................................................................................................................31

7.1.3 501Y Bypass Pump Diagnostic Procedures......................................................................32

7.1.4 Electrical Fault Isolation.....................................................................................................32

7.2 Setting the Converter Temperature.........................................................................................32

7.2.1 Temperature Controller Setup ...........................................................................................32

8.0 T200U-NOY SPARE PARTS LIST.....................................................................37

07303C DCN6646 v

Model 200EU-NOy Option Manual Addendum

List of Figures

Figure 1. Rear Panels: T200U-NOy Analyzer (top) and 501Y (center); Converter (bottom)......................13

Figure 2. Rear Panel Pneumatic Connections............................................................................................14

Figure 3. Replac
Figure 4. NOy Converter Guts
Figure 5. Pneumatics
Figure 6. Location of O

Figure 7. Pneumatics ...................................................................................Error! Bookmark not defined.

Figure 8 Electrical Diagram........................................................................................................................35

ing the Particulate Filter...................................................................................................25

Assembly Location....................................................................................27

..................................................................................................................................28

Generator Air Inlet................................................................................................29

3

List of Tables

Table 1 Specifications for the External Converter and the 501Y Bypass Pump..........................................9

Table 2 Final Test and Calibration Values.................................................................................................15

Table 3 Manual Zero Calibration Procedure..............................................................................................20

Table 4 Enter Expected Span Gas Concentrations Procedure For NO & NOy.........................................20

Table 5 Span Calibration Procedure..........................................................................................................21

Table 6 Preventative Maintenance Calendar.............................................................................................23

Table 7 Temperature Controller Programming Guide ...............................................................................33

vi 07303C DCN6646

1.0 INTRODUCTION

The T200U-NOy analyzer consists of an external Converter designed to support a
NOx analyzer by converting multiple, unstable compounds grouped under the
name NOy. The converter is mounted externally at the sample inlet to minimize
flow time between sample in and converter, thereby optimizing measurement
accuracy.

This manual addendum is to be used in conjunction with two additional
documents with operation instructions:

 T200 operation manual (part number 06858)
 T200U addendum (part number 06861).

It is recommended that you read/familiarize yourself with all sets of instructions
in order to use the analyzer and converter correctly.

07303C DCN6646 7

Model T200EU-NOy Option Manual Addendum 1.0 Introduction

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8 07303C DCN6646

2.0 SPECIFICATIONS

2.1 Specifications

Table 1 Specifications for the External Converter and the 501Y Bypass Pump

Converter Remotely mounted molybdenum external Converter with

temperature controller in a NEMA – 4 enclosure.

Converter Temperature

o

C  7oC with read-out on front panel of bypass pump chassis.

315

Tube/Electrical Cable
Assembly

Power, 501Y Bypass Pump
Assembly

Power, Converter Assembly 120V~ 50/60 Hz, 60 watts
Converter Efficiency >96% for NO2
Weight, 501Y Bypass Pump

Assembly
Weight, Remote Converter 30 lbs (11 kg)
501Y Bypass Pump Chassis

Dimensions HxWxD
Remote Converter Assy

Dimensions HxWxD
Environmental Installation Category (Over-voltage Category) II

Bypass Flow rate
Cal gas Flow rate

Up to 50 feet (15 m) maximum length

120V~ 60 Hz, 230V~ 50 Hz 360 watts

35 lbs (16 kg)

9" x17" x23.6" (23cm x 43cm x 61cm)

12"x19"x7" (31cm x 48cm x 18cm)

Pollution Degree 2
800 cc/min  10%, each channel

4000 cc/min (approx.)

07303C DCN6646 9

Model T200EU-NOy Option Manual Addendum 2.0 Specifications

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10 07303C DCN6646

3.0 GETTING STARTED

The NOy converter has been designed to operate with the T200U low level NOx
analyzer, with some additional modification.The combination is referred to as the
T200U-NOy analyzer.

3.1 Unpacking and Inspection

CAUTION!

Avoid personal injury: use two persons each to lift and carry the analyzer and the
Model 501 Pump Pack chassis.

The T200U- NOy comes in three boxes:

 The analyzer with AC power cord
 501Y Bypass Pump Chassis (typically referred to as “501Y herein) with AC

power cord

 External Converter housed in a stainless steel shelter, and an umbilical cable

assembly (herein referred to as “Converter” or “external Converter”)

 External Pump (herein referred to as “external Pump” not to be confused with

the 501Y By

pass Pump)

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

occurred please advise shipper first, then TAPI. (Keep original
container and packaging for shipper’s inspection).

2. Before operating the analyzer, remove the shipping screws as shown in

the T200 Manual.

3. Please check the voltage and frequency label on the rear panel of the

instrument for compatibility with the local power before connecting
the instruments to a power source.

07303C DCN6646 11

Model T200U-NOy Option Manual Addendum

3.2 Electrical and Pneumatic Connections

NOTE

To maintain compliance with EMC standards, it is required that the cable length (at the

rear of the analyzer) be no greater than 3 meters for all I/O connections, which include

Analog In, Analog Out, Status Out, Control In, Ethernet/LAN, USB, RS-232, and RS-485.

1. Mount the Converter (Figure 1, bottom) on a suitable mast.

2. Route the umbilical cable assembly into the shelter of the Converter.

3. Locate the analyzer and 501Y Bypass Pump Chassis in close proximity,
preferably mounting one over the other in a 19” rack.

4. Connect the T200U-NOy analyzer rear panel electrical connectors per the
T200 operation manual.

5. Connect the pneumatic cable fittings from the analyzer rear panel (Figure 1,
top) to the 501Y rear panel (Figure 1, center) and from the 501Y rear panel
to the Converter (Figure 1, bottom).

Refer to Figure 2 for an illustration of the pneumatic connections; refer to the
tags on each tube to match up the correct tube with the appropriate rear panel
fitting.

6. Connect the pneumatic cable fitting from the calibrator to the 501Y rear panel
(

Figure 2).

7. Also connect the EXHAUST port of the analyzer rear panel to the external
Pump.

8. Connect the 7-pin power and signal cable from the external Converter’s
umbilical cable assembly to the CONVERTER POWER connector on the
rear of the 501Y.

9. Connect the analyzer and 501Y AC power cords from their AC power
receptacles to the correct line voltage (refer to power specs on the
respective rear panel label).

WARNING!

 Lethal voltages are present inside the chassis.
 Do not operate with cover off during normal operation
 Before operation, check for correct input voltage and frequency.
 Do not operate without proper chassis grounding
 Do not defeat the ground wire on power plug
 Turn off power before disconnecting electrical subassemblies

12 07303C DCN6646

Model T200U-NOy Option Manual Addendum

Figure 1. Rear Panels: T200U-NOy Analyzer (top) and 501Y (center); Converter (bottom)

07303C DCN6646 13

Model T200U-NOy Option Manual Addendum

Figure 2. Rear Panel Pneumatic Connections

Note: Pneumatic tubes and rear panel labels include numbers to facilitate matching connections

between instruments.

CONNECTIONS: Analyzer to Pump to Converter and Calibrator to Pump

Calibrator Analyzer Pump Chassis Converter

NO IN (1) NO OUT (1)
NOY IN (2) NOY OUT (2)
[cal gas out port] CAL IN (3)
NOY IN (4) NO OUT (4)
NO IN (5) NOY OUT (5)
CAL OUT (6) CAL IN (6)

14 07303C DCN6646

3.3 Initial Operation

1. After confirming proper supply voltage, turn on the power to the
analyzer and the 501Y bypass pump, and plug in the external Pump. If
you are unfamiliar with the T200U-NOy analyzer, we recommend that
you read the overview in Section 3 of its operation manual before
proceeding.

 The front panel displays should immediately light as the

instruments start up.

 The 501Y requires about 30 minutes for the external Converter to

come up to operating temperature.

 The T200U-NOy requires about 30 minutes for the ozone

generator to start up. During that time the instrument will not
respond to span gas.

 After 30 min, the display on the 501Y front panel should read

315oC, indicating that the external Converter is at operating
temperature.

 Follow the instructions in the T200 Manual and the T200U

Addendum to confirm proper operation of the analyzer.

2. Proceed to Section 4 of this manual to perform a Zero/Span check.

Table 2 Final Test and Calibration Values

Test Values Observed

Value

Model T200U-NOy Option Manual Addendum

Units Nominal

Range

CONVERTER TEMP oC
BYPASS FLOW – NO

CHANNEL
BYPASS FLOW – NOy

CHANNEL

Converter Serial # __________________________

Date _______________________ Technician _____________________

CC/MIN

CC/MIN 800 ± 80

315 7
800  80

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16 07303C DCN6646

4.0 THE T200U-NOY EXTERNAL CONVERTER

4.1 Principle of Operation

The T-API Model T200U-NOy is designed to measure the concentration of NO,

, and other compounds that are too unstable to be measured when taken in

NO

2

through the normal ambient air sample inlet system. Please refer to the T200U
manual supplied with this system for a general discussion of the operation of a
NOx analyzer. The suite of compounds known collectively as NOy is composed
of roughly 30 compounds. The NOy measurement is generally done in
conjunction with a standard NOx measurement, with the difference between the
two being the concentration of the unstable compounds, sometimes referred to as
NOz.

The analyzer measures two independent gas streams. One bypasses the external
Converter and measures NO in the sample. The other pulls the sample through
the external Converter and is displayed as NOy
conditions the NOy measurement

is equivalent to the delivered NOx calibration

gases.

Under normal calibration

.

The system is composed of four modules:

 The T200U-NOy analyzer, without a Moly converter
 A 501Y Bypass Pump containing:

 bypass pump
 flow control
 sample filtration
 moly temperature control

 pneumatic provisions for calibration
 Externally mounted molybdenum converter (external Converter)
 External Pump

The T200U-NOy system allows the point of sampling to be located in close
proximity to the Converter. This configuration provides minimal time delay
between the sample inlet and the remotely mounted (~10 meters above ground)
external Converter. Minimizing the transit time between the sample inlet and
Converter enables the conversion of labile components of NOy. The equation for
the conversion is:

315oC

3 NO

+ Mo ---> 3 NO + MoO

Y

3

07303C DCN6646 17

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18 07303C DCN6646

5.0 CALIBRATION AND CAL CHECKS

Unlike most NOx analyzers, the T200U-NOy does not have a sample inlet port
on its rear panel. The sample inlet is located on the external Converter.

Follow the steps in the T200U manual to:

 Enter the expected NO and NOy span gas concentrations in the

analyzer.

 Do the zero calibration procedure
 Do the span calibration procedure

The analyzer always routes the zero/span gas through the external Converter. In
standard configuration, the calibration gas needs to be input at the CAL IN (3)
port of the 501Y bypass pump. In all cases, the calibration gas delivered must be
under a small amount of pressure (2-5 psig) to overcome the resistance of the
tubing.

NOTE
There must be no venting of the Zero or Span gas to atmosphere prior to the analyzer. The
gases actually vent at the external Converter.

Calibration gas must be provided for both the 501Y bypass system and the
analyzer. Flow requirements are 0.80 LPM for NO bypass, 0.80 LPM for NOy
bypass and 1 LPM for the analyzer. Calibration gas flow must be in sufficient
excess (~4 LPM) to prevent any ambient air from entering the sample inlet of the
external Converter.

The maximum 50 ft length of tubing between the 501Y and the remote Converter
has been proven to generate too much backpressure for some brands of
calibrators. Teledyne calibrators are designed to overcome this potential issue.

We strongly recommend that span calibration be done with NO span gas. Span
checks can be done with one of: NO only, NO
(GPT).

Zero air used for all calibration procedures, including GPT, should have <1 ppt
NO and NO
hydrocarbons and a dew point of -5

, less than 1 ppt of major interferents such as SO2, NH3,

2

o

C or less. The calibration gasses should be
from a reliable supplier, since the quality of the tank concentration values
ultimately determines the accuracy of the analyzer.

only, or a mixture of NO and NO2

2

NOTE

The T200U-NOy does NOT have equivalency approval.

07303C DCN6646 19

Model T200U-NOy Option Manual Addendum

5.1 Calibration or Cal Check Procedure

Calibration of the analyzer can be checked or adjusted using gas introduced
through the CAL IN (3) port on the 501Y rear panel. The calibration gas is
routed to a tee fitting (see CAL IN (6) in Figure 4), near the sam
external Converter assembly.

Since the zero gas concentration is defined as 0 ppb, it is not necessary to enter
the expected zero value. Table 3 details the zero calibration procedure.

Table 3 Manual Zero Calibration Procedure

ple inlet on the

Step

Number

1. Press CAL The analyzer enters the calibrate mode.

2. Wait For Stability
Type STB < 0.1 PPB

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

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

5. Press EXIT The analyzer returns to sampling. Immediately after

Action Comment

Wait for reading to stabilize at zero value.

press EXIT here without zeroing the instrument.

calibration, data is not added to the DAS averages.

Table 4 Enter Expected Span Gas Concentrations Procedure For NO & NOy

Step Action Comment

1. Press
CAL>CONC>NOy

This menu sequence causes the analyzer to prompt for the
expected NOy concentration.
Enter the NOy span concentration value by pressing the
applicable touchscreen buttons to set the expected value.

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

3. Press
CAL>CONC>NO

4. Press ENTR Pressing ENTR stores the NO span value and returns the

5.

Press EXIT Returns instrument to SAMPLE mode.

Now enter the expected NO span concentration as in step one.

prompt to the CONC menu.

If desired, compensation for converter efficiency (CE) can be included in the
NOy concentration calculation. Prior to calibration, the converter efficiency
should either be set to 1.0 or determined per the procedure in the T200 manual.

20 07303C DCN6646

Model T200U-NOy Option Manual Addendum

Table 5 Span Calibration Procedure

Step Action Comment

1. Press CAL The analyzer enters the calibrate mode.

2. Wait For Stability
Type STB < 2 PPB

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

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

5. Press EXIT The analyzer returns to sampling. Immediately after

Wait for reading to stabilize at span value.

press EXIT here without spanning the instrument.

causes the instrument to read the NO and NOy span
concentrations.

calibration, data is not added to the DAS averages.

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22 07303C DCN6646

6.0 MAINTENANCE

6.1 Maintenance Schedule

The schedule for preventative maintenance is presented in Table 6 below.

Qualified Maintenance Personnel Required

Table 6 Preventative Maintenance Calendar

Item Maintenance Interval

Zero/Span Calibration Annually or after maintenance or repairs
Zero/Span Checks Daily
Particulate Filter Weekly as needed
Ozone Flow Check every year and replace o-ring and orifice in reaction

cell
Ozone Dryer Filter-DFU Replace every year
Reaction Cell Window Clean annually or as necessary (refer to T200 Manual
Sample Flow Check every 2 months
Converter Check efficiency every 2 months
Pneumatic Lines Check every 3 months
Factory Calibration Calibrate each year or after repairs
Leak Check Check every 6 months
Replace bypass flow orifices Every year / as needed
Rebuild 501Ybypass pump Every year (check part number on pump label)

07303C DCN6646 23

Model T200U-NOy Option Manual Addendum

6.2 Replacing the Sample Particulate Filters

The particulate filter should be inspected often for signs of plugging or
contamination. It is also common for dirt particles to cause instrument drift, and
affect accuracy.

To check and change the filter:

1. Fold down the 501Y front panel.

2. Locate both filters on the left and right side of the 501Y front panel. See
Figure 3 for an exploded view of the filter assembly.

3.

Visually inspect the filter through the glass window.

4. If the filter appears dirty, unscrew the hold-down ring, remove the Teflon o­ring and then the filter.

5. Replace the filter, being careful that the element is fully seated in the bottom
of the holder. Replace the Teflon o-ring, then screw on the hold-down ring
and hand tighten.

NOTE:

Handle the wetted surfaces as little as possible and clean with cloth prior to assembly

24 07303C DCN6646

Model T200U-NOy Option Manual Addendum

Figure 3. Replacing the Particulate Filter

07303C DCN6646 25

Model T200U-NOy Option Manual Addendum

6.3 Checking Analyzer Flow Rate

The external Pump is capable of maintaining the reaction cell pressure at less than

5.0

In-Hg-A. If a higher pressure is noted, the Pump may need servicing. Check the
Pump and pneumatic system for leaks or rebuild the Pump.

CAUTION!

Never operate the analyzer without the ozone destruct component properly
seated and connected within the pneumatic path. The ozone destruct is
integrated into the converter case, at the exhaust of the reaction cell, inside
the instrument.

The sample flow as measured at ports NO IN (1) and NOy IN (2) at the rear of
the analyzer should be 1000  100 cc/min.

See Figure 1 for component locations.

6.4 Replacing the Converter

The heater, thermocouple, and converter guts assembly is designed to be replaced
as a single unit. Check Figure 4 for the assembly location.

The converter operates at 315°C. Severe burns can result if not enough time is
allowed for the assembly to cool. Do not handle assembly until it is at room
temperature.

1. Turn off the power to the 501Y at its front panel ON/OFF switch.

2. Allow the external Converter to cool.

3. Disconnect the gas fittings and power cable from the internal box containing
the heater, thermocouple and converter guts assembly (Figure 4).

4.

Remove the entire box from the Converter shelter.
a. Remove the pneumatic fittings.
b. Remove the guts assembly box from the chassis by loosening the 4

captive screws that secures the assembly to the chassis.

CAUTION!

5. Remove bottom bracket and re-attach it to the replacement guts assembly.

6. Install the box with guts assembly back into the analyzer.

7. Re-attach the electrical and pneumatic fittings. Leak check the assembly
when completed.

26 07303C DCN6646

Model T200U-NOy Option Manual Addendum

8. Turn the 501Y power back on. The insulation can emit a burnt odor for the
first 24 hours; this is normal. Allow the Converter to burn-in for 24 hours, then
re-calibrate the instrument.

Figure 4. NOy Converter Guts Assembly Location

6.5 Inspecting Pneumatic Lines

Particulate matter in the pneumatic lines will affect both flow rate and response
time. It is important that the pneumatic system be periodically inspected and
thoroughly cleaned if necessary. Clean by disassembling and passing methanol
through three times. Dry with clean zero air.

Also inspect all pneumatic lines for cracks and abrasion on a regular basis.
Replace as necessary.

07303C DCN6646 27

Model T200U-NOy Option Manual Addendum

Figure 5. Pneumatics

28 07303C DCN6646

6.6 Checking for Leaks

If a leak checker is not available, it is possible to leak check the instrument using
the sample pump plus a shut-off valve.

1. Turn off power to the analyzer and the 501Y, and unplug the external Pump.

2. Cap the sa mple inlet of the external Converter, the BYPASS OUT port of the
501Y and the ozone generator air inlet (located inside the analyzer, Figure

6).

Model T200U-NOy Option Manual Addendum

Figure 6. Location of O

Generator Air Inlet

3

3. Insert a shut-off valve between the external Pump and the EXHAUST port at

the rear of the analyzer.

4. Turn on the analyzer power and plug in the external Pump. Set the TEST
function to RCEL, which measures the reaction cell pressure. Close the
shutoff valve and monitor the cell pressure. The pressure should not
increase more than 1"Hg (.5psi) in 5 minutes. If there is a leak, you’ll need to

it by using a pressure leak checker described below.

locate

07303C DCN6646 29

Model T200U-NOy Option Manual Addendum

If you have a leak checker:

1. Turn off power to the analyzer and 501Y, and unplug the external Pump.

2. Disconnect the external Pump from the analyzer’s rear panel. Cap the
sample inlet of the external Converter, the BYPASS OUT port of the 501Y,
the ozone generator air inlet (located inside the analyzer, Figure 6), and
connect the leak checker to the instrument exhaust port.

CAUTION!

Pressure must be less than 15 PSI.

3. Pressurize the system and check for leaks by watching overall pressure.

The pressure should not drop more than 1"Hg (.5psi) in 5 minutes.

If the instrument fails the pressure test, each fitting needs to be leak checked to
find the location.

NOTE
Be careful that the system is always pressurized so as not to draw soap solution into the
plumbing system. Make sure you dry off any accumulated bubble solution. Start by
checking the external fittings first.

30 07303C DCN6646

7.0 TROUBLESHOOTING, ADJUSTMENTS

CAUTION!

The operations outlined in this section must be performed by qualified
maintenance personnel only!

This section of the manual contains information on diagnosing and repairing
instrument performance problems. It provides troubleshooting procedures that
address problems to the board level.

As a guide to troubleshooting, think of the T200U-NOy as two systems:
pneumatics and electronics.

 Pneumatics - Over 50% of all instrument problems are traced to pneumatic

leaks. Suspect a leak first.

 Electronics – external Converter temp control board or DC power supply for

the converter temperature readout.

Another trouble-shooting tip has to do with incorrect span gas concentration:

 This could come either from the calibrator itself or from incorrectly

entering the expected span gas concentration in the instrument.

 If the instrument does not respond to span gas, check troubleshooting

section in the T200 manual.

The above should get you started in diagnosing and repairing the most common
faults. If these reasons have been eliminated and there are still problems with the
unit, the next thing to do is a Factory Calibration covered in the T200 manual. If
difficulties persist, contact our service department. The 800 telephone number is
on the cover page of this manual.

7.1 Operation Verification – Diagnostic Techniques

This section provides guidance on diagnosing some possible problems.

7.1.1 Pneumatic System

Refer to Figure 5 for a diagram of this system’s pneumatics, to be used in
conjunction with diagnostics and troubleshooting.

7.1.2 Leak Check

Refer to Section 6.6 for the leak check procedure.

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Model T200U-NOy Option Manual Addendum

7.1.3 501Y Bypass Pump Diagnostic Procedures

The 501Y bypass pump is capable of maintaining a total bypass flow rate of ~2.2
lpm. If flow checks indicate a fall off in bypass flow, the pump may need
servicing. Check the pump, inlet fittings, and analyzer for leaks first. If other
causes have been eliminated, rebuild the pump.

7.1.4 Electrical Fault Isolation

115 VAC is supplied to:

 the bypass pump
 the +5 volt and +24 volt switcher supplies
 the input power to the converter temperature controller

Refer to Figure 7 to check the 115 VAC supply voltage to each of these
components.

The converter temperature is controlled by the FUJI controller located on the
501Y front panel. The controller cycles power to the external converter, thereby
maintaining the temperature at 315

O

C, using the solid state relay.

7.2 Setting the Converter Temperature

A front panel-mounted programmable controller maintains the temperature of the
remote external Converter. By pressing the PV/SV button in the lower left corner
of the controller, you can see the Present Value (actual temperature) or the Set
Value (temperature set point). The temperature and PID (proportional, integral
and derivative) control parameters have been set at the factory and no further
adjustment should be necessary. Should you need to adjust the temperature,
follow these steps:

1. Select SV with the PV/SV button.

2. Press the "up-arrow" under the digit you want to change (the digit will

flash),

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

scroll the digit to the desired value.

4. Repeat for the other two digits.

5. Press the ENTER button.

6. Select PV with the PV/SV button to observe the actual temperature.

7.2.1 Temperature Controller Setup

The FUJI temperature controller has been programmed at the factory and should
not need to be altered under normal usage.

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Indications that would require re-programming are:

 Failure / replacement of controller.
 Replacement of thermocouple element.
 Controller’s loss of PID parameters leading to instability of the temp

setpoint.

In the event that the control parameters are changed or in the event that a new
controller is installed, it must be reprogrammed to suit the thermal characteristics
of the instrument. The controller includes an Autotuning feature, which can be
used to properly set the PID factors.

To start the Autotune procedure:

1. Press SEL until A7 (AT) is displayed

2. Press Data until value = 1 (enable Autotune)

 While Autotuning, the decimal point LED will blink.
 NOTE: During the procedure, it is normal for the temp to

overshoot up to 100°C.

 When the decimal point LED turns off, Autotune is complete. No

further adjustment should be necessary.

Table 7 Temperature Controller Programming Guide

PRESS DISPLAY ACTION

SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
SEL

P PROP BAND

i INTEGRAL

d DERIVATIVE TIME

AL LOW ALARM SETP

AH HIGH ALARM SETP

7C CYCLE TIME
HYS HYSTERESIS
LOC LOCK

UP/DOWN SET TO 5.0 (ENTER)

SET TO 50

SET TO 15

SET TO 300

SET TO 330

SET TO 2 (FOR FAST SYSTEM)
SET TO 0.3

0 = OPEN 1 = LOCKED
2 = SV ONLY OPEN

NOTE: DO NOT SET THE TEMPERATURE (SV) HIGHER THAN 320oC.

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Model T200U-NOy Option Manual Addendum

SECONDARY MENU (The fixed characteristics of the system).

PRESS DISPLAY ACTION

SEL hold until
SEL hold until
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL
SEL

p-n1
p-n2
p-dF DIGITAL FILTER
P-SL LOWER LIMIT
P-SU UPPER LIMIT
P-AH ALARM
P-An HYTERESIS
P-dP PROG DECIMAL
PVOF PROCESS OFFSET
SVOF SET POINT OFFS
P-F
P-n1

SEL hold until RETURNS TO MAIN MENU
SEL
SEL hold until

PV/SV
P PROP BAND

SET TO 0 – REVERSE ACTION
SET TO 2 = TYPE J THERMOCOUPLE
SET TO 5
SET TO -40 (-40ºC)
SET TO 350 (350ºC)
SET TO 0
SET TO 5
SET TO 0
LEAVE AT 0
LEAVE AT 0
SET TO 0 (0 = oC, 1 = oF)
ALREADY CONFIGURED

SET DISPLAY TO 315 C
ALREADY CONFIGURED

SEL

SCROLL TO A7

SET TO 1 (AUTOTUNE )

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Figure 7 Electrical Diagram

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36 07303C DCN6646

8.0 T200U-NOY SPARE PARTS LIST

The following spare parts list supplements the spare parts list for the T200U analyzer.

Note
Use of replacement parts other than those supplied by API may result in non-compliance with
European Standard EN 61010-1.

Note
Due to the dynamic nature of part numbers, please refer to the TAPI Website at

http://www.teledyne-api.com or call Customer Service at 800-324-5190 for more recent updates

to part numbers.

Reference: 06848 11/8/2010 1:13:10 PM

PARTNUMBER DESCRIPTION

000940100 CD, ORIFICE, .003 GREEN
000940400 CD, ORIFICE, .004 BLUE
000941100 CD, ORIFICE, .014 ORG/VIOLET
001330001 SLEEVE, GOLD PLATED, NOX
001761800 ASSY, FLOW CTL, 90CC, 1/4" TEE-TMT, B
002270100 AKIT, GASKETS, WINDOW, (12 GASKETS = 1)
002730000 CD, FILTER, 665NM (KB)
004330000 ZERO AIR SCRUBBER (NO/NO2)
005960000 AKIT, EXP, 6LBS ACT CHARCOAL (2 BT=1)
005970000 AKIT, EXP, 6LB PURAFIL (2BT=1)
009690200 AKIT, TFE FLTR ELEM (FL19,100=1) 47mm
009690300 AKIT, TFE FLTR ELEM (FL19, 30=1) 47mm
011310000 ASSY, DRYER, NOX
011630000 HVPS INSULATOR GASKET (KB)
013140000 ASSY, COOLER FAN (NOX/SOX)
014030000 AKIT, NOX EXPENDABLES, IZS
014080200 ASSY, HVPS, NOX
016290000 WINDOW, SAMPLE FILTER, 47MM (KB)
016300900 ASSY, SAMPLE FILTER, 47MM, ANG BKT, 5UM
024600100 ASSY, PREREACTOR NO/NOX VALVE
024930000 CD, PMT, NOX
037860000 ORING, TEFLON, RETAINING RING, 47MM (KB)
039700100 HEATER, BAND, TYPE K, DUAL VOLTAGE(KB)
040010000 ASSY, FAN REAR PANEL
040030800 PCA, PRESS SENSORS (2X), FLOW, (NOX)
040400000 ASSY, HEATERS/THERMAL SWITCH, RX CELL
040410500 ASSY, VACUUM MANIFOLD
040420200 ASSY, O3 GEN BRK, HIGH-O/P
041510200 ASSY, PRESS/FLOW SENSOR, NOX
041800300 PCA, PMT PREAMP, (OBS)

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Reference: 06848 11/8/2010 1:13:10 PM

PARTNUMBER DESCRIPTION

041800600 PCA, PMT PREAMP, VR,
041920000 ASSY, THERMISTOR

042680100 ASSY, VALVE (SS)
043420000 ASSY, HEATER/THERM, O2 SEN
044340000 ASSY, HTR, BYPASS MANIFOLD
044540000 ASSY, THERMISTOR, NOX
044600000 AKIT, SPARES, NOX
045230100 PCA, RELAY CARD
045230200 PCA, RELAY CARD
045430000 ASSY, DRYER, O3, W/RELAYS & BRKT *
04550010A ASSY, ORIFICE HOLDER, 4 MIL
04550030A ASSY, ORIFICE HOLDER, 10 MIL, (NOX) (KB)
045500400 ASSY, ORIFICE HOLDER, 3 MIL
046030000 AKIT, CH-43, 3 REFILLS
046480000 ASSY, DILUTION MANIFOLD, (KB)
046490000 OPTION, DILUTION MANIFOLD (KB)
047150000 AKIT, EXPENDABLES, NOX
049310100 PCA,TEC DRIVER,PMT,(KB)
049760300 ASSY, TC PROG PLUG, MOLY,TYP K, TC1
050700200 KIT, RELAY BD NOX CONFIGURATION
051210000 DESTRUCT w/FTGS, O3 *
051990000 ASSY, SCRUBBER, INLINE EXHAUST, DISPOS
052820000 ASSY, IZS, HEATER/THERM, NOX
052930200 ASSY, BAND HEATER TYPE K, NOX
055300000 AKIT, PUMP REBUILD, THOMAS 2688, DUAL HD
055740000 ASSY, PUMP, NOx PUMP PACK, 115V/60HZ
055740100 ASSY, PUMP, NOx PUMP PACK, 220V/60HZ
055740200 ASSY, PUMP, NOx PUMP PACK, 220V/50HZ
056490000 FILTER, DFU, DESORBER (SOAKED)
058021100 PCA, MOTHERBD, GEN 5-ICOP
058230000 ASSY, O3 CLEANSER, ALUMINUM
059940000 OPTION, SAMPLE GAS CONDITIONER, NOX*
062390000 ASSY, MOLY GUTS w/WOOL
064540000 ASSY, PUMP NOX INTERNAL, 115V/60HZ
064540100 ASSY, PUMP NOX INTERNAL, 230V/60HZ
064540200 ASSY, PUMP NOX INTERNAL, 230V/50HZ
066970000 PCA, INTRF. LCD TOUCH SCRN, F/P
067240000 CPU, PC-104, VSX-6154E, ICOP *
067300000 PCA, AUX-I/O BD, ETHERNET, ANALOG & USB
067300100 PCA, AUX-I/O BOARD, ETHERNET
067300200 PCA, AUX-I/O BOARD, ETHERNET & USB
067900000 LCD MODULE, W/TOUCHSCREEN
068250100 DOM, w/SOFTWARE, STD, T200U *
068810000 PCA, LVDS TRANSMITTER BOARD
069500000 PCA, SERIAL & VIDEO INTERFACE BOARD
072150000 ASSY. TOUCHSCREEN CONTROL MODULE
072820000 KIT, T200U MANUAL

38 07303C DCN6646

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Reference: 06848 11/8/2010 1:13:10 PM

PARTNUMBER DESCRIPTION

CN0000073 POWER ENTRY, 120/60 (KB)
FL0000001 FILTER, SS (KB)
FL0000003 FILTER, DFU (KB)
FM0000004 FLOWMETER (KB)
FT0000010 CONNECTOR-ORING, SS, 1/8" (HK)
HW0000005 FOOT
HW0000020 SPRING
HW0000030 ISOLATOR
HW0000036 TFE TAPE, 1/4" (48 FT/ROLL)
HW0000099 STANDOFF, #6-32X.5, HEX SS M/F
HW0000101 ISOLATOR
HW0000453 SUPPORT, CIRCUIT BD, 3/16" ICOP
KIT000051 AKIT, REBUILD, RX CELL AMBIENT
KIT000095 AKIT, REPLACEMENT COOLER
KIT000115 OPTION, SAMPLE GAS COND, (KB)
KIT000156 OPTION, CARRYING HANDLE
KIT000253 ASSY & TEST, SPARE PS37
KIT000254 ASSY & TEST, SPARE PS38
OR0000001 ORING, 2-006VT *(KB)
OR0000002 ORING, 2-023V
OR0000025 ORING, 2-133V
OR0000027 ORING, 2-042V
OR0000034 ORING, 2-011V FT10
OR0000039 ORING, 2-012V
OR0000044 ORING, 2-125V
OR0000046 ORING, 2-019V
OR0000083 ORING, 105M, 1MM W X 5 MM ID, VITON
OR0000086 ORING, 2-006, CV-75 COMPOUND(KB)
OR0000094 ORING, 2-228V, 50 DURO VITON(KB)
PU0000047 PUMP, THOMAS 2688VE44, 2 HEAD, 115V/60HZ
PU0000048 PUMP, THOMAS 2688VGH144, 230V 50/60HZ CE
PU0000083 KIT, REBUILD, PU80, PU81, PU82
RL0000015 RELAY, DPDT, (KB)
SW0000025 SWITCH, POWER, CIRC BREAK, VDE/CE *(KB)
WR0000008 POWER CORD, 10A(KB)

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40 07303C DCN6646