Teledyne T200U-NOy User Manual

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T200U-NOy ANALYZER
ADDENDUM
(for use with T200 Operators Manual, PN 06858
and with the T200U Addendum, PN 06861)
© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone: 800-324-5190
Phone: 858-657-9800
Fax: 858-657-9816
Email: api-sales@teledyne.com
Website: http://www.teledyne-api.com/
Copyright 2011-2013 07303C DCN6646 Teledyne Advanced Pollution Instrumentation 06 February 2013
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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: 800-324-5190
Email: sda_techsupport@teledyne.com
or access any of the service options on our website at http://www.teledyne-api.com/
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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
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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
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Model 200EU-NOy Option Manual Addendum
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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
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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
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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.
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Model T200EU-NOy Option Manual Addendum 1.0 Introduction
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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.)
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Model T200EU-NOy Option Manual Addendum 2.0 Specifications
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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.
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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
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Model T200U-NOy Option Manual Addendum
Figure 1. Rear Panels: T200U-NOy Analyzer (top) and 501Y (center); Converter (bottom)
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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)
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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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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
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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.
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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.
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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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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)
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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
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Model T200U-NOy Option Manual Addendum
Figure 3. Replacing the Particulate Filter
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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.
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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.
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Model T200U-NOy Option Manual Addendum
Figure 5. Pneumatics
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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
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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.
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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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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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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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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
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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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