Teledyne T360, T360M User Manual

MODEL T360/T360M

CARBON DIOXIDE ANALYZER

Operation Manual

Also supports operation of:

T360U/GFC 7000E CO2 Analyzer

(when used in conjunction with T360U/GFC 7000E Addendum, PN 07273)

9480 Carroll Park Drive

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/

07272B DCN6552

ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)

Teledyne Advanced Pollution Instrumentation, Inc. (TAPI) is a worldwide market leader in the design and manufacture of precision analytical instrumentation used for air quality monitoring, continuous emissions monitoring, and specialty process monitoring applications. Founded in San Diego, California, in 1988, TAPI introduced a complete line of Air Quality Monitoring (AQM) instrumentation, which comply with the United States Environmental Protection Administration (EPA) and international requirements for the measurement of criteria pollutants, including CO, SO2, NOX and Ozone.

Since 1988 TAPI has combined state-of-the-art technology, proven measuring principles, stringent quality assurance systems and world class after-sales support to deliver the best products and customer satisfaction in the business.

For further information on our company, our complete range of products, and the applications that they serve, please visit www.teledyne-api.com or contact sales@teledyne-api.com.

NOTICE OF COPYRIGHT

TRADEMARKS

All trademarks, registered trademarks, brand names or product names appearing in this document are the property of their respective owners and are used herein for identification purposes only.

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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 are placed throughout this manual; the safety symbols are also located inside the instrument.

descriptions of which are as follows:

It is imperative that you pay close attention to these messages, the

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 tha That for which it was intended, unpredictable behavior could ensue with possible hazardous consequences.

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

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.

MISE EN GARDE

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!

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WARRANTY

Warranty Policy (02024 F)

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

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

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” 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 Customer Support > Return Authorization.

under

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ABOUT THIS MANUAL

This manual, PN 07272, provides operation instructions for Models T360 and T360M, and supports operation of the Model T360U (when used in conjunction with the T360U/GFC7000E Addendum, PN 07273). This manual is comprised of multiple documents as listed below.

Part No. Rev Name/Description

07272 B T360 Carbon Dioxide Analyzer Operation Manual

05233 C Menu trees and software documentation (inserted as Appendix A of this manual)

06879

05235 C Repair Request Questionnaire (inserted as Appendix C of this manual)

0691201 B Interconnect Wire List (located in Appendix D of this manual)

06912 B Interconnect Wiring Diagram (located in Appendix D of this manual)

03297 K PCA, 03296, IR Photodetector Preamp and Sync Demodulator

03632 C PCA, 03631, 0-20mA driver

04003 N PCA, 04003, Pressure/Flow Transducer Interface

04089 A PCA, 04088, Opto Pickup Interface

04136 B PCA, 04135 Rev A, Relay

04468 B PCA, 04467, Analog Output Series Res

05803 B SCH, PCA 05802, MOTHERBOARD, GEN-5

06698 D SCH, PCA 06697, INTRFC, LCD TCH SCRN,

06882 B SCH, LVDS TRANSMITTER BOARD

06731 B SCH, AUXILLIARY-I/O BOARD

1/4/2011

Interconnects and Schematics included in Appendix D of this manual

Spare Parts List (located in Appendix B, this manual)

NOTE

Please read this manual in its entirety before making any attempt made to operate the instrument.

REVISION HISTORY

T360 Manual PN 07272

Date Rev DCN Change Summary

2012 Dec 13 B 6552 Administrative updates; minor technical updates 2011 Jan 12 A 5950 Initial Release

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TABLE OF CONTENTS

ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)................................................................. i

SAFETY MESSAGES .............................................................................................................................................. iii

CONSIGNES DE SÉCURITÉ................................................................................................................................... iv

WARRANTY.............................................................................................................................................................. v

ABOUT THIS MANUAL........................................................................................................................................... vii

TABLE OF CONTENTS ........................................................................................................................................... ix

1. INTRODUCTION......................................................................................................................................................17

1.1. Features ...........................................................................................................................................................17

1.2. Using This Manual............................................................................................................................................17

1.3. Options.............................................................................................................................................................18

2. SPECIFICATIONS AND APPROVALS...................................................................................................................21

2.1. Specifications ...................................................................................................................................................21

2.2. Approvals and Certifications.............................................................................................................................23

2.2.1. Safety .......................................................................................................................................................23

2.2.2. EMC..........................................................................................................................................................23

3. GETTING STARTED ...............................................................................................................................................25

3.1. Unpacking and Initial Set Up ............................................................................................................................25

3.2. Front Panel.......................................................................................................................................................27

3.3. Rear Panel .......................................................................................................................................................31

3.4. Internal Layout .................................................................................................................................................33

3.5. Electrical Connections......................................................................................................................................35

3.5.1. Power Connection ....................................................................................................................................35

3.5.2. Connecting Analog Inputs (Option 64B) ...................................................................................................36

3.5.3. Connecting Analog Outputs......................................................................................................................36

3.5.4. Connecting the Status Outputs.................................................................................................................38

3.5.5. Current Loop Analog Outputs (Option 41) ................................................................................................39

3.5.6. Connecting the Control Inputs ..................................................................................................................40

3.5.7. Connecting the Alarm Relay Option (OPT 61)..........................................................................................42

3.5.8. Connecting the Communications Interfaces .............................................................................................43

3.6. Pneumatic Connections ...................................................................................................................................44

3.6.1. Basic Pneumatic Connections .................................................................................................................. 44

3.6.2. Connections with Ambient Zero/Ambient Span Valve...............................................................................48

3.6.3. Connections with Ambient Zero/Pressurized Span Valve Option .............................................................50

3.6.4. Pneumatic Connections in Multipoint Calibration Applications..................................................................53

3.6.5. Setting the Internal Purge Air Pressure ....................................................................................................53

3.7. Initial Operation ................................................................................................................................................54

3.7.1. Startup ......................................................................................................................................................54

3.7.2. Warm Up...................................................................................................................................................55

3.7.3. Warning Messages ...................................................................................................................................55

3.7.4. Functional Checks ....................................................................................................................................57

3.8. Initial Calibration Procedure .............................................................................................................................58

3.8.1. Initial O2 Sensor Calibration Procedure ....................................................................................................61

4. OPERATING INSTRUCTIONS................................................................................................................................67

4.1. Overview of Operating Modes..........................................................................................................................67

4.2. Sample Mode ...................................................................................................................................................68

4.2.1. Test Functions ..........................................................................................................................................69

4.2.2. Warning Messages ...................................................................................................................................70

4.3. Calibration Mode ..............................................................................................................................................72

4.4. Setup Mode......................................................................................................................................................73

4.5. Setup  CFG: Viewing the Analyzer’s Configuration Information.................................................................... 74

4.6. SETUP  ACAL: Automatic Calibration ..........................................................................................................74

4.7. SETUP  DAS: Using the Data Acquisition System (DAS).............................................................................75

4.7.1. DAS Structure...........................................................................................................................................76

4.7.2. Default DAS Channels..............................................................................................................................78

4.7.3. Remote DAS Configuration.......................................................................................................................94

4.8. SETUP  RNGE: Analog Output Reporting Range Configuration ..................................................................95

4.8.1. Physical Range versus Analog Output Reporting Ranges........................................................................ 96

4.8.2. Reporting Range Modes...........................................................................................................................96

4.8.3. Single Range Mode (SNGL) ..................................................................................................................... 98

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4.8.4. Dual Range Mode (DUAL)........................................................................................................................99

4.8.5. Auto Range Mode (AUTO)......................................................................................................................100

4.8.6. Range Units............................................................................................................................................101

4.8.7. Dilution Ratio ..........................................................................................................................................102

4.9. SETUP  PASS: Password Feature .............................................................................................................103

4.10. SETUP  CLK: Setting the Internal Time-of-Day Clock ..............................................................................105

4.11. SETUP  MORE COMM: Using the Analyzer’s Communication Ports....................................................107

4.11.1. Machine ID............................................................................................................................................107

4.11.2. COM Port Default Settings....................................................................................................................108

4.11.3. RS-485 Configuration of COM2............................................................................................................111

4.11.4. DTE and DCE Communication .............................................................................................................111

4.11.5. COM Port Communication Modes ........................................................................................................112

4.11.6. Remote Access via the Ethernet...........................................................................................................114

4.11.7. USB Port Setup ....................................................................................................................................120

4.11.8. Multidrop RS-232 Setup .......................................................................................................................122

4.11.9. MODBUS Setup....................................................................................................................................125

4.11.10. COM Port Baud Rate..........................................................................................................................127

4.11.11. COM Port Testing ...............................................................................................................................128

4.12. SETUP  MORE  VARS: Internal Variables (VARS)...............................................................................129

4.13. SETUP  MORE  DIAG: Using the Diagnostics Functions.....................................................................131

4.13.1. Accessing the Diagnostic Features.......................................................................................................132

4.13.2. Signal I/O..............................................................................................................................................133

4.13.3. Analog Output Step Test ......................................................................................................................134

4.13.4. Analog I/O Configuration ......................................................................................................................135

4.13.5. Electric Test..........................................................................................................................................146

4.13.6. Dark Calibration Test............................................................................................................................147

4.13.7. Pressure Calibration .............................................................................................................................148

4.13.8. Flow Calibration....................................................................................................................................149

4.13.9. Test Channel Output.............................................................................................................................150

4.14. SETUP MORE  ALRM: Using the Gas Concentration Alarms............................................................... 151

4.14.1. Setting the Concentration Alarm Limits................................................................................................. 151

4.15. Remote Operation of the Analyzer ...............................................................................................................152

4.15.1. Remote Operation Using the External Digital I/O..................................................................................152

4.15.2. Remote Operation Using the External Serial I/O ..................................................................................155

4.15.3. Additional Communications Documentation .........................................................................................161

4.15.4. Using the T360 with a Hessen Protocol Network..................................................................................162

5. CALIBRATION PROCEDURES ............................................................................................................................ 169

5.1. Before Calibration...........................................................................................................................................169

5.1.1. Zero Air and Span Gas ...........................................................................................................................169

5.1.2. Calibration Gas Traceability....................................................................................................................170

5.1.3. Data Recording Devices .........................................................................................................................170

5.2. Manual Calibration without Zero/Span Valves................................................................................................170

5.3. Manual Calibration Checks ............................................................................................................................173

5.4. Manual Calibration with Zero/Span Valves.....................................................................................................173

5.5. Manual Calibration Checks with Zero/Span Valves........................................................................................178

5.5.1. Zero/Span Calibration on Auto Range or Dual Ranges ..........................................................................179

5.5.2. Use of Zero/Span Valves with Remote Contact Closure ........................................................................180

5.6. Automatic Zero/Span Cal/Check (AutoCal) ....................................................................................................180

5.6.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected ..............................................................183

5.7. Calibration Quality..........................................................................................................................................184

6. MAINTENANCE SCHEDULE AND PROCEDURES.............................................................................................185

6.1. Maintenance Schedule...................................................................................................................................185

6.2. Predicting Failures Using the Test Functions .................................................................................................189

6.3. Maintenance Procedures ...............................................................................................................................190

6.3.1. Replacing the Sample Particulate Filter..................................................................................................190

6.3.2. Rebuilding the Sample Pump .................................................................................................................191

6.3.3. Performing Leak Checks ........................................................................................................................191

6.3.4. Performing a Sample Flow Check ..........................................................................................................192

6.3.5. Cleaning the Optical Bench ....................................................................................................................192

6.3.6. Cleaning the Chassis..............................................................................................................................192

7. PRINCIPLES OF OPERATION .............................................................................................................................193

7.1. Measurement Method ....................................................................................................................................193

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7.1.1. Beer’s Law..............................................................................................................................................193

7.1.2. Measurement Fundamentals .................................................................................................................. 194

7.1.3. Gas Filter Correlation..............................................................................................................................194

7.1.4. Interference and Signal to Noise Rejection.............................................................................................197

7.2. Oxygen Sensor (OPT 65)...............................................................................................................................198

7.2.1. Paramagnetic Measurement of O2..........................................................................................................198

7.3. Pneumatic Operation......................................................................................................................................200

7.3.1. Sample Gas Flow ...................................................................................................................................200

7.3.2. Flow Rate Control...................................................................................................................................201

7.3.3. Purge Gas Pressure Control................................................................................................................... 202

7.3.4. Particulate Filter......................................................................................................................................202

7.3.5. Pneumatic Sensors.................................................................................................................................202

7.3.6. Pneumatic Operation of the O2 Sensor................................................................................................... 203

7.4. Electronic Operation.......................................................................................................................................204

7.4.1. Overview.................................................................................................................................................204

7.4.2. CPU ........................................................................................................................................................206

7.4.3. Optical Bench & GFC Wheel ..................................................................................................................207

7.4.4. Synchronous Demodulator (Sync/Demod) Assembly.............................................................................210

7.4.5. Relay Board............................................................................................................................................212

7.4.6. Motherboard ...........................................................................................................................................215

7.4.7. I2C Data Bus...........................................................................................................................................217

7.4.8. Power Supply/ Circuit Breaker................................................................................................................218

7.5. Front Panel Touchscreen/Display Interface ...................................................................................................219

7.5.1. LVDS Transmitter Board.........................................................................................................................219

7.5.2. Front Panel Touchscreen/Display Interface PCA....................................................................................219

7.6. Software Operation ........................................................................................................................................220

7.6.1. Adaptive Filter.........................................................................................................................................220

7.6.2. Calibration - Slope and Offset................................................................................................................. 221

7.6.3. Measurement Algorithm..........................................................................................................................221

7.6.4. Temperature and Pressure Compensation .............................................................................................222

7.6.5. Internal Data Acquisition System (DAS) .................................................................................................222

8. TROUBLESHOOTING AND SERVICE ................................................................................................................. 223

8.1. General Troubleshooting Hints....................................................................................................................... 223

8.1.1. Interpreting WARNING Messages..........................................................................................................224

8.1.2. Fault Diagnosis with TEST Functions .....................................................................................................228

8.1.3. Using the Diagnostic Signal I/O Function ...............................................................................................230

8.1.4. Internal Electronic Status LEDs ..............................................................................................................231

8.2. Gas Flow Problems........................................................................................................................................235

8.2.1. T360 Internal Gas Flow Diagrams ..........................................................................................................236

8.2.2. Typical Sample Gas Flow Problems.......................................................................................................238

8.2.3. Poor or Stopped Flow of Purge Gas.......................................................................................................240

8.3. Calibration Problems ......................................................................................................................................241

8.3.1. Miscalibrated...........................................................................................................................................241

8.3.2. Non-Repeatable Zero and Span.............................................................................................................242

8.3.3. Inability to Span – Touchscreen SPAN Button Not Visible .....................................................................242

8.3.4. Inability to Zero – Touchscreen ZERO Button Not Visible ......................................................................243

8.4. Other Performance Problems.........................................................................................................................244

8.4.1. Temperature Problems ........................................................................................................................... 244

8.4.2. Excessive Noise .....................................................................................................................................246

8.5. Subsystem Checkout .....................................................................................................................................247

8.5.1. AC Mains Configuration..........................................................................................................................247

8.5.2. DC Power Supply ...................................................................................................................................247

8.5.3. I2C Bus....................................................................................................................................................248

8.5.4. Touchscreen Interface ............................................................................................................................248

8.5.5. LCD Display Module ...............................................................................................................................249

8.5.6. Relay Board............................................................................................................................................249

8.5.7. Sensor Assembly....................................................................................................................................249

8.5.8. Motherboard ...........................................................................................................................................252

8.5.9. CPU ........................................................................................................................................................254

8.5.10. RS-232 Communications......................................................................................................................255

8.6. Repair Procedures .........................................................................................................................................256

8.6.1. Repairing Sample Flow Control Assembly..............................................................................................256

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8.6.2. Removing/Replacing the GFC Wheel .....................................................................................................257

8.6.3. Disk-On-Module Replacement Procedure ..............................................................................................259

8.7. Frequently Asked Questions ..........................................................................................................................260

9. A PRIMER ON ELECTRO-STATIC DISCHARGE.................................................................................................263

9.1. How Static Charges are Created....................................................................................................................263

9.2. How Electro-Static Charges Cause Damage .................................................................................................264

9.3. Common Myths About ESD Damage.............................................................................................................265

9.4. Basic Principles of Static Control....................................................................................................................266

9.4.1. General Rules.........................................................................................................................................266

9.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ........................................................268

LIST OF APPENDICES

APPENDIX A - SOFTWARE DOCUMENTATION APPENDIX B - SPARE PARTS LIST APPENDIX C - REPAIR QUESTIONNAIRE APPENDIX D - ELECTRONIC SCHEMATICS

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LIST OF FIGURES

Figure 3-1: Front Panel Layout ...................................................................................................................... 27

Figure 3-2: Display Screen and Touch Control .............................................................................................28

Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts............................................................. 30

Figure 3-4: Rear Panel Layout....................................................................................................................... 31

Figure 3-5: Internal Chassis Layout...............................................................................................................33

Figure 3-6: Optical Bench Layout ..................................................................................................................34

Figure 3-7: Analog In Connector.................................................................................................................... 36

Figure 3-8: Current Loop Option Installed on the Motherboard..................................................................... 39

Figure 3-9: Control Inputs Power Connections.............................................................................................. 41

Figure 3-10: Alarm Relay Output Pin Assignments ......................................................................................... 42

Figure 3-11: Basic Internal Gas Flow ..............................................................................................................45

Figure 3-12: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ....................................46

Figure 3-13: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ............................46

Figure 3-14: Pneumatic Connections with Ambient Zero/Ambient Span Valves (OPT 50A) .......................... 48

Figure 3-15: Pneumatic Connections with Ambient Zero/Ambient Span Valves (Opt 50A) and

External Zero Air Scrubber..........................................................................................................48

Figure 3-16: Internal Pneumatic Flow – Ambient Zero/Ambient Span ............................................................49

Figure 3-17: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (OPT 50B) ....................50

Figure 3-18: Pneumatic Connections with Ambient Zero/Pressurized Span Valves (Opt 50B) and

External Zero Air Scrubber..........................................................................................................51

Figure 3-19: Internal Pneumatic Flow – Ambient Zero/Pressurized Span Valves...........................................52

Figure 3-20: Example of Pneumatic Set up for Multipoint Calibration.............................................................53

Figure 3-21: O2 Sensor Calibration Set Up..................................................................................................... 61

Figure 3-22: Internal Pneumatics with O2 Sensor Option 65 ..........................................................................62

Figure 4-1: Front Panel Display ..................................................................................................................... 67

Figure 4-2: Viewing TEST Functions ............................................................................................................. 70

Figure 4-3: Viewing and Clearing T360 WARNING Messages .....................................................................72

Figure 4-4: Default DAS Channels Setup......................................................................................................80

Figure 4-5: APICOM User Interface for DAS Configuration ..........................................................................94

Figure 4-6: Analog Output Connector Pin Out............................................................................................... 95

Figure 4-7: Rear Panel Connector Pin-Outs for COM1 & COM2 in RS-232 Mode..................................... 109

Figure 4-8: CPU Connector Pin-Outs for COM1 & COM2 in RS-232 Mode ...............................................110

Figure 4-9: Jumper and Cables for Multidrop Mode .................................................................................... 123

Figure 4-10: RS-232-Multidrop Host-to-Analyzer Interconnect Diagram....................................................... 124

Figure 4-11: Setup for Calibrating Analog Voltage Outputs ..........................................................................141

Figure 4-12: Setup for Calibrating Current Outputs.......................................................................................142

Figure 4-13: Status Output Connector...........................................................................................................152

Figure 4-14: Control Inputs ............................................................................................................................ 154

Figure 4-15: APICOM Remote Control Program Interface............................................................................ 161

Figure 5-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................................170

Figure 5-2: Pneumatic Connections–Basic Configuration–Using Gas Dilution Calibrator ..........................171

Figure 5-3: Pneumatic Connections – Ambient Zero/Pressurized Span Valves ........................................174

Figure 5-4: Pneumatic Connections – Ambient Zero/Pressurized Span Valves and External Zero Air

Scrubber.................................................................................................................................... 174

Figure 5-5: Pneumatic Connections – Ambient Zero/Ambient Span Valves............................................... 175

Figure 5-6: Pneumatic Connections – Ambient Zero/Ambient Span Valves with External Zero Air

Scrubber.................................................................................................................................... 175

Figure 6-1: Sample Particulate Filter Assembly ..........................................................................................190

Figure 7-1: Measurement Fundamentals.....................................................................................................194

Figure 7-2: GFC Wheel................................................................................................................................194

Figure 7-3: Measurement Fundamentals with GFC Wheel .........................................................................195

Figure 7-4: Affect of CO2 in the Sample on CO2 MEAS & CO2 REF.........................................................196

Figure 7-5: Effects of Interfering Gas on CO2 MEAS & CO2 REF.............................................................. 197

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Figure 7-6: Chopped IR Signal ....................................................................................................................197

Figure 7-7: Oxygen Sensor - Principle of Operation.................................................................................... 199

Figure 7-8: Internal Pneumatic Flow – Basic Configuration ........................................................................200

Figure 7-9: Flow Control Assembly & Critical Flow Orifice .......................................................................... 201

Figure 7-10: Gas Flow with O2 Sensor Option..............................................................................................203

Figure 7-11: T360 Electronic Block Diagram.................................................................................................205

Figure 7-12: CPU Board ................................................................................................................................206

Figure 7-13: GFC Light Mask ........................................................................................................................208

Figure 7-14: Segment Sensor and M/R Sensor Output................................................................................. 209

Figure 7-15: T360 Sync / Demod Block Diagram .......................................................................................... 210

Figure 7-16: Sample & Hold Timing...............................................................................................................211

Figure 7-17: Location of relay board Status LED’s........................................................................................214

Figure 7-18: Power Distribution Block Diagram............................................................................................. 218

Figure 7-19: Front Panel and Display Interface Block Diagram .................................................................... 219

Figure 7-20: Basic Software Operation..........................................................................................................220

Figure 8-1: Viewing and Clearing Warning Messages ................................................................................226

Figure 8-2: Example of Signal I/O Function.................................................................................................231

Figure 8-3: CPU Status Indicator.................................................................................................................232

Figure 8-4: Sync/Demod Board Status LED Locations ...............................................................................233

Figure 8-5: Relay Board Status LEDs.......................................................................................................... 233

Figure 8-6: T360 – Basic Internal Gas Flow ................................................................................................236

Figure 8-7: Internal Pneumatic Flow – Ambient Zero/Pressurized Span Valves.........................................237

Figure 8-8: Internal Pneumatic Flow – Ambient Zero/Ambient Span ..........................................................237

Figure 8-9: T360 – Internal Pneumatics with O2 Sensor Option 65A ..........................................................238

Figure 8-10: Critical Flow Restrictor Assembly Disassembly ........................................................................ 257

Figure 8-11: Opening the GFC Wheel Housing............................................................................................. 258

Figure 8-12: Removing the GFC Wheel ........................................................................................................258

Figure 9-1: Triboelectric Charging ...............................................................................................................263

Figure 9-2: Basic anti-ESD Work Station..................................................................................................... 266

LIST OF TABLES

Table 2-1: Model T360 Basic Unit Specifications.........................................................................................21

Table 2-2: Model T360M Basic Unit Specifications......................................................................................22

Table 3-1: Display and Touchscreen Control Description............................................................................ 29

Table 3-2: Rear Panel Description ...............................................................................................................32

Table 3-3: Analog Input Pin Assignments ....................................................................................................36

Table 3-4: T360 Analog Output Pin Outs .....................................................................................................37

Table 3-5: Status Output Pin-outs ................................................................................................................38

Table 3-6: Control Input Pin-outs..................................................................................................................41

Table 3-8: Concentration Alarm Relay Output Operation............................................................................. 42

Table 3-9: Ambient Zero/Ambient Span Valve Operating States.................................................................49

Table 3-10: Ambient Zero/Pressurized Span Valve Operating States ........................................................... 52

Table 3-11: Front Panel Display During System Warm-Up............................................................................ 55

Table 3-12: Possible Warning Messages at Start-Up ....................................................................................56

Table 4-1: Analyzer Operating Modes..........................................................................................................68

Table 4-2: Test Functions Defined ...............................................................................................................69

Table 4-3: List of Warning Messages........................................................................................................... 71

Table 4-4: Primary Setup Mode Features and Functions.............................................................................73

Table 4-5: Secondary Setup Mode Features and Functions........................................................................ 73

Table 4-6: Secondary Setup Mode Features and Functions........................................................................ 75

Table 4-7: DAS Data Channel Properties.....................................................................................................76

Table 4-8: DAS Data Parameter Functions..................................................................................................77

Table 6-9: Password Levels .......................................................................................................................103

Table 4-9: Com Port Communication Modes .............................................................................................112

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Table 4-10: Ethernet Status Indicators ................................................................................................................114

Table 4-11: LAN/Internet Configuration Properties.............................................................................................. 115

Table 4-12: Internet Configuration Touchscreen Functions.................................................................................119

Table 4-13: Variable Names (VARS) ................................................................................................................... 129

Table 4-14: T360 Diagnostic (DIAG) Functions...................................................................................................131

Table 4-15: DIAG - Analog I/O Functions ............................................................................................................135

Table 4-16: Analog Output Voltage Ranges ........................................................................................................135

Table 4-17: Analog Output Current Loop Range ................................................................................................. 136

Table 4-18: Analog Output Pin Assignments....................................................................................................... 136

Table 4-19: Voltage Tolerances for Analog Output Calibration ...........................................................................140

Table 4-20: Current Loop Output Calibration with Resistor................................................................................. 143

Table 4-21: Test Parameters Available for Analog Output A4.............................................................................150

Table 4-22: CO2 Concentration Alarm Default Settings ...................................................................................... 151

Table 4-23: Status Output Pin Assignments........................................................................................................153

Table 4-24: Control Input Pin Assignments .........................................................................................................154

Table 4-25: Terminal Mode Software Commands ...............................................................................................155

Table 4-26: Command Types ..............................................................................................................................156

Table 4-27: Serial Interface Documents ..............................................................................................................161

Table 4-28: RS-232 Com Parameters for Hessen Protocol.................................................................................162

Table 4-29: Teledyne API Hessen Protocol Response Modes............................................................................165

Table 4-30: Default Hessen Status Bit Assignments ...........................................................................................166

Table 5-1: AUTOCAL Modes ............................................................................................................................. 180

Table 5-2: AutoCal ATTRIBUTE Setup Parameters..........................................................................................180

Table 5-3 : Calibration Data Quality Evaluation.................................................................................................184

Table 6-1: T360 Maintenance Schedule............................................................................................................187

Table 6-2: T360 Test Function Record ..............................................................................................................188

Table 6-3: Predictive Uses for Test Functions...................................................................................................189

Table 7-1: Sync/Demod Status LED Activity...................................................................................................... 212

Table 7-2: Relay Board Status LED’s ................................................................................................................214

Table 8-1: Warning Messages - Indicated Failures .............................................................................................227

Table 8-2: Test Functions - Indicated Failures.....................................................................................................229

Table 8-3: Sync/Demod Board Status Failure Indications ................................................................................... 232

Table 8-4: I2C Status LED Failure Indications..................................................................................................... 233

Table 8-5: Relay Board Status LED Failure Indications ......................................................................................234

Table 8-6: DC Power Test Point and Wiring Color Codes................................................................................... 247

Table 8-7: DC Power Supply Acceptable Levels .................................................................................................248

Table 8-8: Relay Board Control Devices.............................................................................................................. 249

Table 8-9: Opto Pickup Board Nominal Output Frequencies............................................................................... 250

Table 8-10: Analog Output Test Function - Nominal Values Voltage Outputs ......................................................252

Table 8-11: Analog Output Test Function - Nominal Values Current Outputs.......................................................253

Table 8-12: Status Outputs Check.........................................................................................................................253

Table 9-1: Static Generation Voltages for Typical Activities ................................................................................ 264

Table 9-2: Sensitivity of Electronic Devices to Damage by ESD ......................................................................... 264

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1. INTRODUCTION

The Models T360 and T360M differ only in specifications; unless clearly differentiated, both models in this manual are referred to as the T360 for simplification. The T360/T360M measures carbon dioxide CO infrared energy absorbed by a sample to that absorbed by a reference according to the Beer-Lambert law. This is accomplished by using a Gas Filter Wheel which alternately allows a high energy infrared (IR) light source to pass through a CO filled chamber and a chamber with no CO

The IR light then travels through the sample cell, which has a folded path. Energy loss through the sample cell is compared with the zero reference signal provided by the gas filter to produce an output proportional to concentration, with little effect from interfering gases within the sample. A nitrogen purge system is pro-vided for the GFC wheel assembly to eliminate the effects of ambient CO

This design produces superior zero and span stability and a high signal-to-noise ratio, allowing excellent sensitivity. Multi-tasking software gives real time indication of numerous operating parameters and provides automatic alarms if diagnostic limits are exceeded.

present.

by comparing

, if necessary.

1.1. FEATURES

The Models T360 and T360M include the following features:

 Ranges,T360: 0-2 ppm to 0-2000 ppm, T360M: 0-4 ppm to 0-4000 ppm, user

selectable

 Gas Filter Wheel for CO2 specific measurement

 LCD Graphical User Interface with capacitive touch screen

 Multi-tasking software allows viewing of test variables during operation

 Continuous self checking with alarms

 Bi-directional RS-232 and 10/100Base-T Ethernet (optional USB and RS-

485) ports for remote operation

 Front panel USB ports for peripheral devices

 Digital status outputs to indicate instrument operating condition

 Adaptive signal filtering to optimize response time

 Temperature & Pressure compensation

 Internal data logging with 1 min to 24 hour averages

1.2. USING THIS MANUAL

The flowcharts in this manual contain typical representations of the analyzer’s display during the various operations being described. These representations are not intended to be exact and may differ slightly from the actual display of your instrument.

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1.3. OPTIONS

Option

Pumps

Rack Mount Kits

Carrying Strap/Handle Side-mounted strap for hand-carrying analyzer

Option Number

11 No pump (If one is standard either internal or external) 10A External Pump 100V – 120V/60Hz 10B External Pump 220V – 240V/50H 10C External Pump 220V – 240V/60Hz 10D External Pump 100V – 120V/50Hz 10E External Pump 100V /60Hz 13 High Voltage Internal Pump 240V/50Hz

Description/Notes

Pumps meet all typical AC power supply standards while exhibiting same pneumatic performance.

Options for mounting the analyzer in standard 19” racks

20A Rack mount brackets with 26 in. (660 mm) chassis slides 20B Rack mount brackets with 24 in. (610 mm) chassis slides 21 Rack mount brackets only (compatible with carrying strap, Option 29) 23 Rack mount for external pump pack (no slides)

Extends from “flat” position to accommodate hand for carrying. Recesses to 9mm (3/8”) dimension for storage. Can be used with rack mount brackets, Option 21. Cannot be used with rack mount slides.

CAUTION – GENERAL SAFETY HAZARD

THE T360 OR T360M ANALYZER WEIGHS ABOUT 18 KG (40 POUNDS).

TO AVOID PERSONAL INJURY WE RECOMMEND THAT TWO PERSONS LIFT AND CARRY

THE ANALYZER. DISCONNECT ALL CABLES AND TUBING FROM THE ANALYZER BEFORE

MOVING IT.

Analog Input and USB port

64B Also can be used for logging these signals in the analyzer’s internal DAS

Current Loop Analog Outputs

Parts Kits Spare parts and expendables

Calibration Valves

50A

50B

42A

Used for connecting external voltage signals from other instrumentation (such as meteorological instruments).

Adds isolated, voltage-to-current conversion circuitry to the analyzer’s analog outputs.

Can be configured for any output range between 0 and 20 mA. May be ordered separately for any of the analog outputs. Can be installed at the factory or retrofitted in the field.

Expendables Kit for analyzer includes a recommended set of expendables for one year of operation.

Expendables Kit for Internal Zero/Span, one year of operation. Used to control the flow of calibration gases generated from external sources,

rather than manually switching the rear panel pneumatic connections. AMBIENT ZERO AND AMBIENT SPAN VALVES

Zero Air and Span Gas input supplied at ambient pressure.

Gases controlled by 2 internal valves; SAMPLE/CAL & ZERO/SPAN.

AMBIENT ZERO AND PRESSURIZED SPAN VALVES

Zero Air supplied at ambient pressure. Span gas supplied from pressurized bottle of cal gas.

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Option

Communication Cables For remote serial, network and Internet communication with the analyzer.

Type Description

60A RS-232

60B RS-232 Shielded, straight-through DB-9F to DB-9F cable of about 1.8 m length. 60C Ethernet Patch cable, 2 meters long, used for Internet and LAN communications.

60D USB

USB Port For remote connection

64A

Concentration Alarm Relays

RS-232 Multidrop Enables communications between host computer and up to eight analyzers.

Other Gas Options Second gas sensor and gas conditioners

65A Oxygen (O2) Sensor

Special Features Built in features, software activated

N/A

Option Number

Description/Notes

Shielded, straight-through DB-9F to DB-25M cable, about 1.8 m long. Used to interface with older computers or code activated switches with DB-25 serial connectors.

Cable for direct connection between instrument (rear panel USB port) and personal computer.

For connection to personal computer. (Separate option only when Option 64B, Analog Input and USB Com Port, not elected).

Issues warning when gas concentration exceeds limits set by user.

Four (4) “dry contact” relays on the rear panel of the instrument. This relay option is different from and in addition to the “Contact Closures” that come standard on all TAPI instruments.

Multidrop card seated on the analyzer’s CPU card. Each instrument in the multidrop network requres this card and a communications cable (Option 60B).

Maintenance Mode Switch, located inside the instrument, places the analyzer in maintenance mode where it can continue sampling, yet ignore calibration, diagnostic, and reset instrument commands. This feature is of particular use for instruments connected to Multidrop or Hessen protocol networks.

Call Customer Service for activation.

Second Language Switch activates an alternate set of display messages in a language other than the instrument’s default language.

Call Customer Service for a specially programmed Disk on Module containing the second language.

Dilution Ratio Option allows the user to compensate for diluted sample gas, such as in continuous emission monitoring (CEM) where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas.

Call Customer Service for activation.

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2. SPECIFICATIONS AND APPROVALS

2.1. SPECIFICATIONS

Table 2-1: Model T360 Basic Unit Specifications

T360 Parameter T360 Specification

Ranges (Physical Analog Output)

Measurement Units ppb, ppm, µg/m3, mg/m3, % (user selectable) Zero Noise < 0.1 ppm (RMS) Span Noise < 1% of reading (RMS) Lower Detectable Limit < 0.2 ppm1 Zero Drift (24 hours) <0.25 ppm1 Span Drift (24 hours) <0.5% of reading 1 Lag Time 10 seconds Rise/Fall Time <60 seconds to 95% Linearity 1% of full scale Precision 0.5% of reading Sample Flow Rate

Temperature Coefficient < 0.1% of Full Scale per oC Voltage Coefficient < 0.05% of Full Scale per V AC Power Rating 100V-120V, 60 Hz, (142 W) ; 220V – 240 V, 50 Hz (147 W) Analog Output Ranges 10V, 5V, 1V, 0.1V (selectable) Analog Output Resolution 1 part in 4096 of selected full-scale voltage Recorder Offset

Standard I/O

Optional I/O

Environmental Installation category (over-voltage category) II; Pollution degree 2 Temperature Range 5-40oC Humidity Range 0 - 95% RH, non-condensing Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) Weight 40 lbs. (18.1 kg)

At constant temperature and voltage.

Min: 0-2 ppm Full scale Max: 0-2,000 ppm Full scale Selectable, dual ranges and auto ranging supported

800cm O

±10% 1 Ethernet: 10/100Base-T

2 RS-232 (300 – 115,200 baud) 2 USB device ports 8 opto-isolated digital status outputs 6 opto-isolated digital control inputs (3 defined, 3 spare)

4 analog outputs 1 USB com port

1 RS485 8 analog inputs (0-10V, 12-bit) 4 digital alarm outputs Multidrop RS232 3 4-20mA current outputs

/min. ±10%

Sensor option adds 110 cm³/min, ±20%, to total flow through when installed.

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Table 2-2: Model T360M Basic Unit Specifications

T360M Parameter T360M Specification

Ranges (Physical Analog Output)

Measurement Units ppb, ppm, µg/m3, mg/m3, (selectable) Zero Noise < 0.2 ppm (RMS) Span Noise < 1% of reading (RMS) Lower Detectable Limit < 0.4 ppm1 Zero Drift (24 hours) <0.5 ppm1 Span Drift (24 hours) <0.5% of reading1 Lag Time 10 seconds Rise/Fall Time <60 seconds to 95% Linearity 1% of full scale Precision 0.5% of reading Sample Flow Rate

Temperature Coefficient < 0.1% of Full Scale per oC or 0.1 ppm per oC, whichever is greater Voltage Coefficient < 0.05% of Full Scale per V AC Power Requirements 100V – 120V, 220V – 240V, 50/60 Hz Analog Output Ranges 10V, 5V, 1V, 0.1V Recorder Offset

Analog Output Resolution 1 part in 4096 of selected full-scale voltage Standard I/O

Optional I/O

Operating Temperature Range 5-40oC Humidity Range 0 - 95% RH, non-condensing Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) Weight 40 lbs. (18.1 kg) Environmental Installation category (over-voltage category) II; Pollution degree 2

At constant temperature and voltage.

Min: 0-4 ppm Full scale Max: 0-4000 ppm Full scale Selectable, dual ranges and auto ranging supported

800cm

/min. ±10%

O2 Sensor option adds 110 cm³/min, ±20%, to total flow though when installed

±10%

1 Ethernet: 10/100Base-T 2 RS232 (300-115,200 baud) 2 USB device ports 8 Status opto-isolated digital status outputs 6 Opto-isolated digital control inputs (3 defined, 3 spare) 4 Analog outputs

1 USB com port 1 RS485 8 Analog inputs (0-10V, 12-bit) 4 Digital alarm outputs Multidrop RS232 3 4-20mA current outputs

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2.2. APPROVALS AND CERTIFICATIONS

The Teledyne Instruments Model T360 Gas Filter Correlation CO2 Analyzer was tested and certified for Safety and Electromagnetic Compatibility (EMC). This section presents the compliance statements for those requirements and directives.

2.2.1. Safety

IEC 61010-1:2001, Safety requirements for electrical equipment for measurement, control, and laboratory use.

CE: 2006/95/EC, Low-Voltage Directive

North American:

cNEMKO (Canada): CAN/CSA-C22.2 No. 61010-1-04 NEMKO-CCL (US): UL No. 61010-1 (2nd Edition)

2.2.2. EMC

EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial Immunity EN 55011 (CISPR 11), Group 1, Class A Emissions FCC 47 CFR Part 15B, Class A Emissions

CE: 2004/108/EC, Electromagnetic Compatibility Directive

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3. GETTING STARTED

3.1. UNPACKING AND INITIAL SET UP

CAUTION

To avoid personal injury, always use two persons to lift and carry the

Never disconnect PCAs, wiring harnesses or electronic subassemblies

Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Damage resulting from failure to use ESD protection when working with electronic assemblies will void the instrument warranty.

while the instrument is under power.

CAUTION – Avoid Warranty Invalidation

Model T360.

WARNING

See A Primer on Electro-Static Discharge in this manual for more information on preventing ESD damage.

NOTE

It is recommended that you store shipping containers/materials for future use if/when the instrument should be returned to the factory for repair and/or calibration service. See Warranty page in this manual and shipping procedures on our Website at:

http://www.teledyne-api.com under Customer Support > Return Authorization.

1. Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne Instruments.

2. Included with your analyzer is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet (P/N 04596) is an important quality assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument.

3. Carefully remove the top cover of the analyzer and check for internal shipping damage.

 Remove the set-screw located in the top, center of the Front panel.  Remove the 2 screws fastening the top cover to the unit (one per side

towards the rear).

 Slide the cover backwards until it clears the analyzer’s front bezel.  Lift the cover straight up.

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4. Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated.

5. Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated.

6. Verify that all of the optional hardware ordered with the unit has been installed. These are listed on the paperwork accompanying the analyzer.

7. VENTILATION CLEARANCE: Whether the analyzer is set up on a bench or installed into an instrument rack, be sure to leave sufficient ventilation clearance.

AREA MINIMUM REQUIRED CLEARANCE

Back of the instrument

4 in.

Sides of the instrument

Above and below the instrument

1 in. 1 in.

Various rack mount kits are available for this analyzer – please see Section 1.3.

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3.2. FRONT PANEL

Figure 3-1 shows the analyzer’s front panel layout, followed by a close-up of the display screen in Figure 3-2, which is described in Table 3-1. The two USB ports on the front panel are provided for the connection of peripheral devices:

 plug-in mouse (not included) to be used as an alternative to the touchscreen

interface

 thumb drive (not included) to download updates to instruction software

(contact TAPI Technical Support for information).

Figure 3-1: Front Panel Layout

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Figure 3-2: Display Screen and Touch Control

CAUTION – Avoid Damaging Touchscreen

Do not use hard-surfaced instruments such as pens to operate the touchscreen.

The front panel liquid crystal display includes touch control. Upon analyzer startup, the display shows a splash screen and other initialization indicators before the main display appears, similar to Figure 3-2 above (may or may not display a Fault

). The LEDs on the display screen indicate the Sample, Calibration and

alarm Fault states; also on the screen is the gas concentration field (Conc), which displays real-time readouts for the primary gas and for the secondary gas if installed. The display screen also shows which mode the analyzer is currently in (Mode field), as well as messages and data (Param field). Along the bottom of the screen is a row of touch control buttons; only those that are currently applicable will have a label. Table 3-1 provides detailed information for each com

ponent of

the screen.

+ 289 hidden pages

Teledyne T360, T360M User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual