Teledyne T801 User Manual

OPERATION MANUAL

MODEL T801

NDIR CO2 ANALYZER

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/

07274B DCN6418

ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)

Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne Instruments, Inc., 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, SO

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

api-sales@teledyne.com

NOTICE OF COPYRIGHT

, NOX and Ozone.

or contact

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. It is imperative that you pay close attention to these messages, the descriptions of which are as follows:

WARNING: Electrical Shock Hazard

HAZARD: Strong oxidizer

GENERAL WARNING/CAUTION: Read the accompanying message for specific

information.

CAUTION: Hot Surface Warning

Note

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

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.

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

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

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

Telephone: 800-324-5190 Email: sda_techsupport@teledyne.com or access 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 (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

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 antiESD handling and packing instructions please refer to “Packing Components for Return to Teledyne API’s Technical Support” 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 Authorization.

under Customer Support > Return

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ABOUT THIS MANUAL

This operation manual, PN 07274, is comprised of multiple documents in PDF format, as listed below.

Part No. Rev Name/Description

07274 B T801 Operation manual

06843 B Menu Trees and Software Documentation (inserted as Appendix A in this manual)

07269 A Spare Parts List (located in Appendix B of this manual)

06532 C Repair Request Form (inserted as Appendix C in this manual)

Appendix D Documents:

0738001 A Interconnect List

07380 A Interconnect Diagram

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

Note

We recommend that this manual be read in its entirety before any attempt is made to operate the instrument.

ORGANIZATION

This manual is divided among three main parts and a collection of appendices at the end:

Part I contains introductory information that includes an overview of the

analyzer, specifications, descriptions of the available options, installation and connection instructions, and the initial calibration and functional checks.

Part II comprises the operating instructions, which include setup and calibration,

as well as remote operation, and ends with the specifics of calibrating for use in monitoring within EPA protocol.

Part III provides detailed technical information starting with maintenance,

troubleshooting and service, frequently asked questions, principles of operation, a primer on electrostatic discharge, and a glossary.

The appendices at the end of the manual provide support inoformation such as version-specific software documentation, lists of spare parts* and recommended stocking levels, and schematics.

*Part numbers do not reflect real-time updates – contact Sales or Technical Support).

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CONVENTIONS USED

In addition to the safety symbols as presented in the Important Safety Information page, this manual provides special notices related to the safety and effective use

of the analyzer and other pertinent information.

Special Notices appear as follows:

ATTENTION

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

This special notice provides information to avoid damage to your instrument and possibly invalidate the warranty.

IMPORTANT

IMPACT ON READINGS OR DATA Could either affect accuracy of instrument readings or cause loss of data.

Note Pertinent information associated with the proper care, operation or

maintenance of the analyzer or its parts.

REVISION HISTORY

T801 Operation and Maintenance Manual, PN07274

Date Rev DCN Description

2013 January 11 B 6418 Administrative and specs updates 2011 March30 A 6009 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

REVISION HISTORY ................................................................................................................................................viii

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

List of Figures .......................................................................................................................................................xii

List of Tables .......................................................................................................................................................xiii

List of Appendices ...............................................................................................................................................xiv

PART I – GENERAL INFORMATION and Setup ...............................................................................................15

1. INTRODUCTION, FEATURES, AND OPTIONS.................................................................17

1.1. T801 Overview..............................................................................................................................................17

1.2. Features........................................................................................................................................................ 17

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

2. SPECIFICATIONS, APPROVALS & COMPLIANCE ...........................................................21

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

2.2. Approvals and Certifications.........................................................................................................................22

2.2.1. Safety ....................................................................................................................................................22

2.2.2. EMC....................................................................................................................................................... 22

2.2.3. Other Type Certifications....................................................................................................................... 22

3. GETTING STARTED...........................................................................................................23

3.1. Unpacking the T801 Analyzer ......................................................................................................................23

3.1.1. Ventilation Clearance ............................................................................................................................24

3.2. Instrument Layout......................................................................................................................................... 25

3.2.1. Front Panel ............................................................................................................................................25

3.2.2. Rear Panel.............................................................................................................................................29

3.2.3. Internal Chassis Layout......................................................................................................................... 31

3.3. Connections and Setup ................................................................................................................................32

3.3.1. Electrical Connections........................................................................................................................... 32

3.3.2. Pneumatic Connections ........................................................................................................................46

3.4. Startup, Functional Checks, and Initial Calibration....................................................................................... 50

3.4.1. Startup ...................................................................................................................................................50

3.4.2. Functional Checks................................................................................................................................. 52

3.4.3. Initial Calibration.................................................................................................................................... 52

Part II – OPERATING INSTRUCTIONS.............................................................................................................. 55

4. BASIC OPERATION OF THE T801 ANALYZER ...............................................................57

4.1. Overview of Operating Modes......................................................................................................................57

4.2. Sample Mode................................................................................................................................................58

4.2.1. Test Functions.......................................................................................................................................59

4.3. Calibration Mode...........................................................................................................................................60

4.4. Setup MODE.................................................................................................................................................60

4.4.1. Primary Setup Menu.............................................................................................................................. 61

4.4.2. Secondary Setup Menu (Setup>More).................................................................................................. 61

5. SETUP MENU ..................................................................................................................63

5.1. SETUP  CFG: Configuration Information.................................................................................................. 63

5.2. SETUP  ACAL: [NOT uSED]..................................................................................................................... 63

5.3. SETUP  DAS: Internal Data Acquisition System ......................................................................................64

5.4. SETUP  RNGE: Analog Output Reporting Range Configuration..............................................................64

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5.4.1. Physical Range versus Analog Output Reporting Ranges.................................................................... 64

5.4.2. Analog Output Ranges for CO2 Concentration......................................................................................65

5.4.3. Reporting Range Modes .......................................................................................................................66

5.4.4. SETUP RNGE  DIL: Using the Optional Dilution Ratio Feature.....................................................70

5.5. SETUP  PASS: Password Protection .......................................................................................................72

5.6. SETUP  CLK: Setting the Analyzer’s Internal Clock ................................................................................. 74

5.6.1. Setting the Internal Clock’s Time and Day ............................................................................................ 74

5.6.2. Adjusting the Internal Clock’s Speed.....................................................................................................74

5.7. SETUP  MORE COMM: Communication Ports.....................................................................................76

5.7.1. ID (Machine Identification)..................................................................................................................... 76

5.7.2. INET (Ethernet) .....................................................................................................................................77

5.7.3. COM1[COM2] (Mode, Baude Rate and Test Port) ...............................................................................78

5.8. SETUP  VARS: Variables Setup and Definition........................................................................................ 78

5.9. SETUP  MORE  DIAG: Diagnostics Functions.................................................................................... 81

5.9.1. Signal I/O............................................................................................................................................... 83

5.9.2. Analog Output........................................................................................................................................84

5.9.3. Analog I/O Configuration .......................................................................................................................84

5.10. SETUP MORE  ALRM: Using the Gas Concentration Alarms (Option 61)....................................... 102

5.10.1. Setting the T801 Option 61 Concentration Alarm Limits................................................................... 102

6. COMMUNICATIONS SETUP AND OPERATION.............................................................105

6.1. Data Terminal/Communication Equipment (DTE DCE)..................................................................................105

6.2. Communication Modes, Baud Rate and Port Testing ................................................................................105

6.2.1. Communication Modes........................................................................................................................ 106

6.2.2. COM Port Baud Rate ..........................................................................................................................108

6.2.3. COM Port Testing................................................................................................................................109

6.3. Remote Access via the Ethernet ................................................................................................................ 110

6.3.1. Configuring the Ethernet using DHCP.................................................................................................110

6.3.2. Manually Configuring the Network IP Addresses................................................................................113

6.4. USB Port for Remote Access ..................................................................................................................... 116

6.5. Communications Protocols......................................................................................................................... 118

6.5.1. MODBUS.............................................................................................................................................118

6.5.2. Hessen ................................................................................................................................................120

7. DATA ACQUISITION SYSTEM (DAS) & APICOM .............................................................129

7.1. DAS Structure.............................................................................................................................................130

7.1.1. DAS Channels..................................................................................................................................... 130

7.1.2. Default DAS Channels.........................................................................................................................131

7.1.3. SETUP DAS VIEW: Viewing DAS Channels and Individual Records.........................................134

7.1.4. SETUP DAS EDIT: Accessing the DAS Edit Mode ....................................................................135

7.2. Remote DAS Configuration ........................................................................................................................ 148

7.2.1. DAS Configuration via APICOM..........................................................................................................148

7.2.2. DAS Configuration via Terminal Emulation Programs ........................................................................ 150

8. REMOTE OPERATION.....................................................................................................151

8.1. Computer Mode.......................................................................................................................................... 151

8.1.1. Remote Control via APICOM ..............................................................................................................151

8.2. Interactive Mode .........................................................................................................................................152

8.2.1. Remote Control via a Terminal Emulation Program............................................................................152

8.3. Remote Access by Modem.........................................................................................................................155

8.4. COM Port Password Security.....................................................................................................................157

9. CALIBRATION PROCEDURES .......................................................................................159

9.1. Before Calibration....................................................................................................................................... 160

9.1.1. Required Equipment, Supplies, and Expendables.............................................................................. 160

9.1.2. Calibration Gases................................................................................................................................ 160

9.1.3. Data Recording Devices...................................................................................................................... 161

9.2. Manual Calibration Checks and Calibration ............................................................................................... 162

9.2.1. Setup for Calibration Checks and Calibration .....................................................................................162

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9.2.2. Performing a Manual Calibration Check..............................................................................................163

9.2.3. Performing a Manual Calibration.........................................................................................................164

9.3. Assessing Calibration Quality.....................................................................................................................166

9.4. Calibrating the Electronic Subsystems....................................................................................................... 166

9.4.1. Pressure Calibration............................................................................................................................ 166

9.4.2. Flow Calibration...................................................................................................................................168

Part III – Maintenance and Service ...................................................................................................................169

10. MAINTENANCE SCHEDULE & PROCEDURES...........................................................171

10.1. Maintenance Schedule .............................................................................................................................171

10.2. Predictive Diagnostics ..............................................................................................................................175

10.3. Maintenance Procedures.......................................................................................................................... 175

10.3.1. Replacing the Sample Particulate Filter ............................................................................................ 175

10.3.2. Rebuilding the Sample Pump............................................................................................................176

10.3.3. Performing Leak Checks ...................................................................................................................177

10.3.4. Performing a Sample Flow Check.....................................................................................................178

10.3.5. Cleaning Exterior Surfaces of the T801 ............................................................................................178

11. TROUBLESHOOTING AND SERVICE..........................................................................179

11.1. General Troubleshooting.......................................................................................................................... 179

11.1.1. Fault Diagnosis with WARNING Messages ......................................................................................180

11.1.2. Fault Diagnosis with TEST Functions ...............................................................................................183

11.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function ..................................................... 184

11.2. Using the Internal Electronic Status LEDs ...............................................................................................186

11.2.1. CPU Status Indicator......................................................................................................................... 186

11.2.2. Relay PCA Status Indicators .............................................................................................................186

11.3. Gas Flow Problems ..................................................................................................................................187

11.3.1. T801 Internal Gas Flow Diagrams.....................................................................................................188

11.3.2. Typical Sample Gas Flow Problems .................................................................................................188

11.4. Calibration Problems ................................................................................................................................ 190

11.4.1. Miscalibrated .....................................................................................................................................190

11.4.2. Non-Repeatable Zero and Span .......................................................................................................190

11.4.3. Inability to Span – No SPAN Button.................................................................................................. 191

11.4.4. Inability to Zero – No ZERO Button...................................................................................................191

11.5. Other Performance Problems...................................................................................................................191

11.5.1. Temperature Problems...................................................................................................................... 192

11.6. Subsystem Checkout................................................................................................................................ 192

11.6.1. AC Mains Configuration ....................................................................................................................192

11.6.2. DC Power Supply ..............................................................................................................................192

11.6.3. I2C Bus...............................................................................................................................................193

11.6.4. Touch Screen Interface .....................................................................................................................194

11.6.5. LCD Display Module.......................................................................................................................... 194

11.6.6. Relay Board.......................................................................................................................................194

11.6.7. Sensor Assembly...............................................................................................................................194

11.6.8. Pressure/Flow Sensor Assembly ......................................................................................................195

11.6.9. Motherboard ...................................................................................................................................... 196

11.6.10. CPU .................................................................................................................................................197

11.6.11. RS-232 Communications ................................................................................................................198

11.6.12. CO2 Sensor STATUS LED’s............................................................................................................199

11.7. Repair Procedures.................................................................................................................................... 199

11.7.1. Repairing Sample Flow Control Assembly........................................................................................ 199

11.7.2. Disk-On-Module Replacement Procedure ........................................................................................200

11.8. FRequently Asked Questions (FAQ’s)......................................................................................................201

11.9. Technical Assistance................................................................................................................................ 202

12. PRINCIPLES OF OPERATION ......................................................................................203

12.1. NDIR Measurement of CO2......................................................................................................................203

12.2. Operation within the T801 Analyzer .........................................................................................................204

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12.2.1. Electronic Operation of the CO2 Sensor............................................................................................ 204

12.3. Pneumatic Operation................................................................................................................................ 205

12.4. Flow Rate Control..................................................................................................................................... 206

12.4.1. Critical Flow Orifice............................................................................................................................206

12.4.2. Particulate Filter.................................................................................................................................207

12.4.3. Pneumatic Sensors ...........................................................................................................................208

12.5. Electronic Operation .................................................................................................................................208

12.5.1. Overview............................................................................................................................................208

12.5.2. Central Processing Unit (CPU).......................................................................................................... 209

12.5.3. Relay Board.......................................................................................................................................210

12.5.4. Motherboard ...................................................................................................................................... 213

12.5.5. Power Supply / Circuit Breaker .........................................................................................................215

12.5.6. Front Panel Touch Screen/Display Interface ....................................................................................216

12.5.7. Software Operation............................................................................................................................218

12.5.8. Adaptive Filter....................................................................................................................................218

12.5.9. Calibration - Slope and Offset ........................................................................................................... 219

12.5.10. Temperature and Pressure Compensation .....................................................................................219

12.5.11. Internal Data Acquisition System (DAS) .........................................................................................219

13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................221

13.1. How Static Charges are Created..............................................................................................................221

13.2. How Electro-Static Charges Cause Damage ...........................................................................................222

13.3. Common Myths About ESD Damage....................................................................................................... 223

13.4. Basic Principles of Static Control.............................................................................................................. 224

13.4.1. General Rules....................................................................................................................................224

13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance..................................................225

Glossary............................................................................................................................................................. 229

INDEX................................................................................................................................................................ 233

LIST OF FIGURES

Figure 3-1: Front Panel Layout ......................................................................................................... 25

Figure 3-2: Display Screen and Touch Control................................................................................. 26

Figure 3-3: Display/Touch Control Screen Mapped to Menu Charts................................................ 28

Figure 3-4: Rear Panel Layout.......................................................................................................... 29

Figure 3-5: Internal Layout................................................................................................................ 31

Figure 3-6. Analog In Connector....................................................................................................... 33

Figure 3-7: Analog Output Connector............................................................................................... 34

Figure 3-8: Current Loop Option Installed ........................................................................................35

Figure 3-9: Status Output Connector................................................................................................ 37

Figure 3-10: Control Input Connector ................................................................................................. 38

Figure 3-11: Concentration Alarm Relay ............................................................................................ 39

Figure 3-12: Default Pin Assignments, Rear Panel COM Port Connectors ....................................... 41

Figure 3-13. CPU Connector Pin-Outs for RS-232 Mode................................................................... 42

Figure 3-14: Jumper and Cables for Multidrop Mode ......................................................................... 44

Figure 3-15: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram........................................ 45

Figure 3-16: Pneumatic Connections, Using Bottled Span Gas......................................................... 48

Figure 3-17: T801 Internal Gas Flow .................................................................................................. 49

Figure 3-18: Viewing and Clearing WARNING Messages ................................................................51

Figure 4-1: Front Panel Touchscreen and Display ........................................................................... 58

Figure 4-2: Viewing Test Functions ..................................................................................................59

Figure 5-1: Analog Output Connector Pin Out.................................................................................. 65

Figure 5-2: Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 91

Figure 5-3: Setup for Checking / Calibrating Current Output Signal Levels Using an Ammeter ...... 93

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Figure 5-4: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels..... 95

Figure 7-1: Default DAS Channel Setup......................................................................................... 133

Figure 7-2: APICOM Remote Control Program Interface ............................................................... 148

Figure 7-3: APICOM User Interface for Configuring the DAS ........................................................149

Figure 7-4: DAS Configuration Through a Terminal Emulation Program ....................................... 150

Figure 9-1: Pneumatic Connections Using Bottled Span Gas........................................................ 162

Figure 10-1: Sample Particulate Filter Assembly.............................................................................. 176

Figure 11-1: Viewing and Clearing Warning Messages ................................................................... 182

Figure 11-2: Example of Signal I/O Function.................................................................................... 185

Figure 11-3: CPU Status Indicator.................................................................................................... 186

Figure 11-4: Relay PCA Status LEDS Used for Troubleshooting..................................................... 187

Figure 11-5: T801 – Internal Gas Flow ............................................................................................. 188

Figure 11-6: Location of Diagnostic LEDs on CO2 Sensor PCA....................................................... 199

Figure 11-7: Critical Flow Restrictor Assembly / Disassembly .........................................................200

Figure 12-1. CO2 Sensor Theory of Operation .................................................................................204

Figure 12-2. CO2 Sensor PCA Layout and Electronic Connections................................................. 205

Figure 12-3: Internal Pneumatic Flow............................................................................................... 206

Figure 12-4: Flow Control Assembly & Critical Flow Orifice ............................................................. 207

Figure 12-5: T801 Electronic Block Diagram.................................................................................... 209

Figure 12-6. CPU Card ..................................................................................................................... 210

Figure 12-7: Relay PCA Layout (PN 04135)..................................................................................... 211

Figure 12-8: Relay PCA with AC Relay Retainer in Place................................................................ 212

Figure 12-9: Status LED Locations – Relay PCA ............................................................................. 213

Figure 12-10: Power Distribution Block Diagram................................................................................ 216

Figure 12-11: Front Panel and Display Interface Block Diagram .......................................................217

Figure 12-12: Basic Software Operation............................................................................................. 218

Figure 13-1: Triboelectric Charging ..................................................................................................221

Figure 13-2: Basic anti-ESD Workbench .......................................................................................... 224

LIST OF TABLES

Table 1-1. Analyzer Options ............................................................................................................ 18

Table 2-1: T801 CO2 Specifications ................................................................................................21

Table 3-1: Ventilation Clearance .....................................................................................................24

Table 3-2: Display Screen and Touch Control Description .............................................................27

Table 3-3: Rear Panel Component Descriptions............................................................................. 30

Table 3-4: Analog Input Pin Assignments .......................................................................................33

Table 3-5: Analog Output Pin-Outs ................................................................................................. 34

Table 3-6: Status Output Signals..................................................................................................... 37

Table 3-7: Control Input Signals ...................................................................................................... 38

Table 3-8: Front Panel Display during System Warm-Up ...............................................................50

Table 4-1: Analyzer Operating Modes............................................................................................. 58

Table 4-2: Test Functions Defined .................................................................................................. 60

Table 4-3: Primary Setup Mode Features and Functions................................................................ 61

Table 4-4: Secondary Setup Mode Features and Functions........................................................... 61

Table 5-1: Password Levels ............................................................................................................72

Table 5-2: Variable Names (VARS)................................................................................................. 79

Table 5-3: Diagnostic Mode (DIAG) Functions................................................................................ 81

Table 5-4: DIAG - Analog I/O Functions.......................................................................................... 84

Table 5-5: Analog Output Voltage Range Min/Max......................................................................... 86

Table 5-6: Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 91

Table 5-7: Current Loop Output Check ...........................................................................................95

Table 5-8: Test Channels Functions available on the T801’s Analog Output ................................. 98

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Table 5-9: Concentration Alarm Default Settings .......................................................................... 102

Table 6-1: COM Port Communication Modes................................................................................ 106

Table 7-1: Front Panel LED Status Indicators for DAS ................................................................. 129

Table 7-2: DAS Data Channel Properties...................................................................................... 131

Table 7-3: DAS Data Parameter Functions................................................................................... 138

Table 8-1: Terminal Mode Software Commands........................................................................... 152

Table 8-2: Teledyne API Serial I/O Command Types ...................................................................153

Table 9-1: NISTSRM's Available for Traceability of CO2 Calibration Gases.................................. 161

Table 9-2: Calibration Data Quality Evaluation.............................................................................. 166

Table 10-1: T801 Maintenance Schedule........................................................................................ 173

Table 10-2: T801 Test Function Record.......................................................................................... 174

Table 10-3: Predictive Uses for Test Functions............................................................................... 175

Table 11-1: Warning Messages - Indicated Failures....................................................................... 182

Table 11-2: Test Functions - Indicated Failures .............................................................................. 184

Table 11-3: Relay PCA Watchdog LED Failure Indications ............................................................ 186

Table 11-4: Relay PCA Status LED Failure Indications ..................................................................187

Table 11-5: DC Power Test Point and Wiring Color Codes ............................................................193

Table 11-6: DC Power Supply Acceptable Levels........................................................................... 193

Table 11-7: Analog Output Test Function - Nominal Values Current Outputs ................................ 196

Table 11-8: Status Outputs Check .................................................................................................. 197

Table 12-1: Relay PCA Status LEDs............................................................................................... 212

Table 13-1: Static Generation Voltages for Typical Activities.......................................................... 222

Table 13-2: Sensitivity of Electronic Devices to Damage by ESD................................................... 222

LIST OF APPENDICES

APPENDIX A – MENU TREES AND SOFTWARE DOCUMENTATION APPENDIX B - SPARE PARTS LIST APPENDIX C –REPAIR QUESTIONNAIRE APPENDIX D –ELECTRONIC SCHEMATICS

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PART I

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GENERAL INFORMATION AND SETUP

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1. INTRODUCTION, FEATURES, AND OPTIONS

1.1. T801 OVERVIEW

The Model T801 NDIR CO2 Analyzer is a microprocessor-controlled analyzer that employs Non-Dispersive Infrared (NDIR) spectroscopy to determine the concentration of molecular carbon dioxide (CO through the instrument. It uses infrared absorption to measure CO

The Model T801 analyzer’s multi-tasking software gives the ability to track and report a large number of operational parameters in real time. These readings are compared to diagnostic limits kept in the analyzer’s memory where, should any fall outside of those limits, the analyzer issues automatic warnings.

Built-in data acquisition capability using the analyzer's internal memory allows logging of multiple parameters including averaged or instantaneous concentration values, calibration data, and operating parameters such as pressure and flow rate. Stored data are easily retrieved through rear panel communications ports via our APICOM software, allowing operators to perform predictive diagnostics and enhanced data analysis by tracking parameter trends. Multiple averaging periods of one minute to 365 days are available for over a period of one year.

) in the sample gas drawn

1.2. FEATURES

Some of the exceptional features of your T801 NDIR CO2 Analyzer are:

 Non-depleting, CO2 measurement technologies:

 Microprocessor controlled for versatility  LCD Graphical User Interface with capacitive touch screen  Multi-tasking software for viewing of test variables during operation  Continuous self checking with alarms  Bi-directional USB (option), RS-232, and 10BaseT/100BaseT Ethernet ports

 Front panel USB ports for peripheral devices  Digital status outputs to indicate instrument operating condition  Adaptive signal filtering to optimize response time  Internal data logging with 1 min to 365-day multiple average  Remote operation when used with Teledyne API’s APICOM software  Temperature and Pressure Compensation  Ranges, 0-1% to 0-20.0%, user adjustable

 Virtually no cross-sensitivities  Rapid response times  No consumable parts  Consistent performance over time

for remote operation (optional RS-485)

Introduction, Features, and Options Teledyne API T801 NDIR CO2 Analyzer Operation Manual

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1.3. OPTIONS

Table 1-1 presents the options available with the T801 analyzer. For assistance with ordering, please contact the Sales department of Teledyne API at:

PHONE (toll free, North America)

FAX: PHONE (Direct): E-MAIL: WEB SITE

800-324-5190

858-657-9816 858-657-9800 api-sales@teledyne.com

www.teledyne-api.com

Table 1-1. Analyzer Options

Option

Pumps

Rack Mount Kits

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

Option

Number

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

10A External Pump 100V - 120V @ 60 Hz N/A 10B External Pump 220V - 240V @ 50 Hz N/A 10C External Pump 220V - 240V @ 60 Hz N/A 10D External Pump 100V – 120V @ 50 Hz N/A 10E External Pump 100V @ 60 Hz N/A 14 Internal Pump N/A 13 High Voltage Internal Pump 240V @ 50Hz N/A

Options for mounting the analyzer in standard 19” racks

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

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.

Description/Notes Reference

N/A

CAUTION - GENERAL SAFETY HAZARD

THE T801 WEIGHS ABOUT 28 POUNDS (12.7 KG). TAKE CARE TO AVOID PERSONAL INJURY WHEN LIFTING/CARRYING THE ANALYZER.

ALSO, DISCONNECT ALL CABLES AND TUBING FROM THE ANALYZER BEFORE MOVING IT.

Analog Inputs w/USB port

64B

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

Also can be used for logging these signals in the analyzer’s internal DAS. (See Option 64A for USB port only).

Sections 3.3.1.2 and 5.9.3.12

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Option

Current Loop Analog Outputs

Parts Kits Spare parts and expendables

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

Type Description

60A RS-232

60B RS-232

60C Ethernet

60D USB

Concentration Alarm Relay Issues warning when gas concentration exceeds limits set by user.

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

USB COM Port

64A

Special Features Built in features, software activated

N/A

Option

Number

42A

42D

Description/Notes Reference

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

Can be configured for 0-20 mA or 4-20 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 with a pump, includes a recommended set of expendables for one year of operation.

Expendables Kit for analyzer without a pump, includes a recommended set of expendables for one year of operation.

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.

Shielded, straight-through DB-9F to DB-9F cable of about

1.8 m length. Patch cable, 2 meters long, used for Internet and LAN

communications. Cable for direct connection between instrument (rear

panel USB port) and personal computer.

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 requires this card and a

communications cable (Option 60B).

Separate option if instrument not configured with Option 64B (analog inputs). Disabled when using Multidrop or RS-485 communication.

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 Technical Support for activation.

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

Call Technical Support 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 Technical Support for activation.

Section 3.3.1.4

Appendix B

Sections 3.3.1.8 and 6

Section 3.3.1.7

Section 3.3.1.8

Sections 3.3.1.8 and

6.4

N/A

Section 5.4.4

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2. SPECIFICATIONS, APPROVALS & COMPLIANCE

This section presents specifications, agency approvals, and safety compliance details.

2.1. SPECIFICATIONS

Table 2-1: T801 CO2 Specifications

Parameter Description

Ranges

Zero Noise Span Noise Lower Detectable Limit2 <0.04%

Zero Drift

Span Drift <± 0.1% (7 days) Accuracy <± (1.5% of range + 2% of reading) Temperature Coefficient <± 0.01% /°C Rise and Fall Time <60 seconds to 95% Pressure Range 25-31 in•Hg Temperature Range Humidity Range 0-95% RH, Non-Condensing Sample Flow Rate 120ml ± 20ml/min Dimensions (HxWxD) 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm) Weight 28 lb (12.7 kg)

AC Power

Analog Output Ranges

Recorder Offset ± 10% Analog Output Resolution 1 part in 4096 of selected full-scale voltage

Standard I/O

Optional I/O

Alarm outputs (option) 2 opto-isolated alarm outputs with user settable alarm limits

As defined by the USEPA

Defined as twice the zero noise level by the USEPA

Min: 0-1% Full scale Max: 0-20% Full scale (selectable, dual ranges and auto-ranging supported).

<0.02% (RMS) <± 0.1% of reading (RMS)

<± 0.02% (24 hours) <± 0.05% (7 days)

5 - 40C operating

100-120V 60 Hz (79W) 220-240V 50 Hz (69W)

All Outputs: 0.1 V, 1 V, 5 V or 10 V (selectable) Three outputs convertible to 4-20 mA isolated current loop. All Ranges with 5% under/over-range

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 4 analog outputs

1 USB com port 1 RS485 8 analog inputs (0-10V, 12-bit) 4 digital alarm outputs Multidrop RS232 2 4-20mA current outputs

Specifications, Approvals & Compliance Teledyne API T801 NDIR CO2 Analyzer Operation Manual

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2.2. APPROVALS AND CERTIFICATIONS

The Teledyne API Model T801 NDIR 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

2.2.3. OTHER TYPE CERTIFICATIONS

For additional certifications, please contact Technical Support:

Toll-free Phone:

Phone:

Email: sda_techsupport@teledyne.com

Fax:

800-324-5190 858-657-9800 858-657-9816

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3. GETTING STARTED

This section addresses the procedures for unpacking the instrument and inspecting for damage, presents clearance specifications for proper ventilation, introduces the instrument layout, then presents the procedures for getting started: making electrical and pneumatic connections, and conducting an initial calibration check.

3.1. UNPACKING THE T801 ANALYZER

CAUTION

GENERAL SAFETY HAZARD

To avoid personal injury, always use two persons to lift and carry the T801.

ATTENTION

Printed Circuit Assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. Refer to Section 13 for more information on preventing ESD damag

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

CAUTION!

Do not operate this instrument until you’ve removed dust plugs from SAMPLE

Note Teledyne API recommends that you store shipping containers/materials

and EXHAUST ports on the rear panel.

for future use if/when the instrument should be returned to the factory for repair and/or calibration service. See Warranty section in this manual and shipping procedures on our Website at http://www.teledyne-api.com under Customer Support > Return Authorization.

Getting Started Teledyne API T801 NDIR CO2 Analyzer Operation Manual

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

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 068340000) is an important quality

assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument.

With no power to the unit, carefully removed the top cover of the analyzer and check for internal shipping damage by carrying out the following steps:

1. Carefully remove the top cover of the analyzer and check for internal shipping damage, as follows:

a) Remove the locking screw located in the top, center of the Front panel; b) Remove the two flat head, Phillips screws on the sides of the instrument

(one per side towards the rear); c) Slide the cover backwards until it clears the analyzer’s front bezel; d) Lift the cover straight up.

2. Inspect the interior of the instrument to ensure all circuit boards and other components are in good shape and properly seated.

3. Check the connectors of the various internal wiring harnesses and pneumatic hoses to ensure they are firmly and properly seated.

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

WARNING – ELECTRICAL SHOCK HAZARD

Never disconnect PCAs, wiring harnesses or electronic subassemblies while under power.

3.1.1. VENTILATION CLEARANCE

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

Table 3-1: Ventilation Clearance

AREA

Back of the instrument 4 in. Sides of the instrument 1 in. Above and below the instrument 1 in.

MINIMUM REQUIRED CLEARANCE

Various rack mount kits are available for this analyzer. See Table 1-1 of this manual for more information.

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3.2. INSTRUMENT LAYOUT

Instrument layout shows front panel and display, rear panel connectors, and internal chassis layout.

3.2.1. 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 3-2. 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

The front panel liquid crystal display screen includes touch control. Upon analyzer start-up, the screen 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 alarm). The lights on the display screen, herein referred to as LEDs, indicate the Sample, Calibration and 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 what mode the analyzer is currently in, as well as messages and data (Param). Along the bottom of the screen is a row of touch control buttons; only those that are currently applicable will have a label. Table 3-2 provides detailed information for each component

of the screen.

ATTENTION

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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

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Table 3-2: Display Screen and Touch Control Description

Field Description/Function

Status

Conc

Mode Displays the name of the analyzer’s current operating mode

Param

Control Buttons Displays dynamic, context sensitive labels on each button, some blank when inactive until applicable.

LEDs indicating the states of Sample, Calibration and Fault, as follows: Name Color State Definition

Off On

SAMPLE Green

CAL Yellow

FAULT Red

Displays the actual concentration of the sample gas currently being measured by the analyzer in the currently selected units of measure

Displays a variety of informational messages such as warning messages, operational data, test function values and response messages during interactive tasks.

Blinking

Off On Blinking

Off Blinking

Unit is not operating in sample mode, DAS is disabled. Sample Mode active; Front Panel Display being updated; DAS data

being stored. Unit is operating in sample mode, front panel display being updated,

DAS hold-off mode is ON, DAS disabled Auto Cal disabled

Auto Cal enabled Unit is in calibration mode

No warnings exist Warnings exist

Figure 3-3 shows how the front panel display is mapped to the menu charts illustrated in this manual. The Mode, Param (parameters), and Conc (gas concentration) fields in the display screen are represented across the top row of each menu chart. The eight touch control buttons along the bottom of the display screen are represented in the bottom row of each menu chart.

Getting Started Teledyne API T801 NDIR CO2 Analyzer Operation Manual

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

Note The menu charts in this manual contain condensed representations

of the analyzer’s display during the various operations being described. These menu charts are not intended to be exact visual representations of the actual display.

+ 243 hidden pages

Teledyne T801 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual