Teledyne T801 User Manual

OPERATION MANUAL

MODEL T801

NDIR CO2 ANALYZER

© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION

9480 CARROLL PARK DRIVE

SAN DIEGO, CA 92121-5201

USA

Toll-free Phone: [phone]

Phone: [phone]

Fax: [phone]

Email: [e-mail]

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

Copyright 2011-2013 07274B DCN6418
Teledyne Advanced Pollution Instrumentation 11 January 2013

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

[e-mail]

NOTICE OF COPYRIGHT

, NOX and Ozone.

2

.

or contact

TRADEMARKS

© 2011-2013 Teledyne Advanced Pollution Instrumentation. All rights reserved.

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: [phone] Email: [e-mail]
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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07274B DCN6418

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

–

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

2

.

2

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)

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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
[e-mail]

www.teledyne-api.com

Table 1-1. Analyzer Options

Option

Pumps

Rack Mount
Kits

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

29

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).

18

Sections 3.3.1.2
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Option

Current Loop Analog
Outputs

41

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.

61

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

62

USB COM Port

64A

Special Features Built in features, software activated

N/A

N/A

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

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

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

1

As defined by the USEPA

2

Defined as twice the zero noise level by the USEPA

1

1

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

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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: [e-mail]

Fax:

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

22

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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

e.

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.

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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.

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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.

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3.2.2. REAR PANEL

Figure 3-4: Rear Panel Layout

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Table 3-3: Rear Panel Component Descriptions

Component Function

cooling fan

AC power

connector

Model/specs label

SAMPLE

EXHAUST

SPAN 1

SPAN2/VENT

ZERO AIR

RX TX

COM 2

RS-232

DCE DTE

STATUS

ANALOG OUT

CONTROL IN

ALARM

ETHERNET

ANALOG IN

USB

Information Label

Pulls ambient air into chassis through side vents and exhausts through rear.

Connector for three-prong cord to apply AC power to the analyzer.

CAUTION! The cord’s power specifications (specs) MUST comply with the power
specs on the analyzer’s rear panel Model number/Volt/Freq information label

Identifies the analyzer model number and provides power specs
Inlet connection to be used for any one of the following:

 Sample gas
 Span gas
 Calibration gas
 Zero air

Connect an exhaust gas line of not more than 10 meters long here that leads outside
the shelter or immediate area surrounding the instrument.

Not used.
Not used.
Not used.
LEDs indicate receive (RX) and transmit (TX) activity on the when blinking.
Serial communications port for RS-232 or RS-485.
Serial communications port for RS-232 only.
Switch to select either data terminal equipment or data communication equipment

during RS-232 communication.
For ouputs to devices such as Programmable Logic Controllers (PLCs).
For voltage or current loop outputs to a strip chart recorder and/or a data logger.
For remotely activating the zero and span calibration modes.
Option for concentration alarms and system warnings.
Connector for network or Internet remote communication, using Ethernet cable
Option for external voltage signals from other instrumentation and for logging these

signals
Option for direct connection to personal computer, using USB com cable.
Includes voltage and frequency specifications

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3.2.3. INTERNAL CHASSIS LAYOUT

Figure 3-5: Internal Layout

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3.3. CONNECTIONS AND SETUP

This section presents the electrical (Section 3.3.1) and pneumatic (Section 3.3.2)
connections for setup and preparing for instrument operation.

3.3.1. ELECTRICAL CONNECTIONS

Note To maintain compliance with EMC standards, it is required that the

cable length be no greater than 3 meters for all I/O connections,
which include Analog In, Analog Out, Status Out, Control In,
Ethernet/LAN, USB, RS-232, and RS-485.

This section presents the electrical connections for AC power and
communications.

3.3.1.1. CONNECTING POWER

WARNING - ELECTRICAL SHOCK HAZARD

 High Voltages are present inside the analyzers case.
 Turn OFF analyzer power before disconnecting or connecting PCAs, wiring

harnesses or electrical subassemblies.

 Power connection must have functioning ground connection.
 Do not defeat the ground wire on power plug.

 Do not operate with cover off.

Attach the power cord to the analyzer and plug it into a power outlet capable of
carrying at least 10 A current at your AC voltage and that it is equipped with a
functioning earth ground.

CAUTION

GENERAL SAFETY HAZARD

The T801 analyzer can be configured for both 100-130 V and 210-240 V at either
47 or 63 Hz.

To avoid damage to your analyzer, make sure that the AC power voltage
matches the voltage indicated on the Analyzer’s serial number label (See
Figure 3-4) before plugging the T801 into line power.

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3.3.1.2. CONNECTING ANALOG INPUTS (OPTION 64)

The Analog In connector is used for connecting external voltage signals from
other instrumentation (such as meteorological instruments) and for logging these
signals in the analyzer’s internal DAS. The input voltage range for each analog
input is 0-10 VDC, and the input impedance is nominally 20kΩ in parallel with

0.1µF.

Figure 3-6. Analog In Connector

Pin assignments for the Analog In connector are presented in Table 3-4.

Table 3-4: Analog Input Pin Assignments

PIN DESCRIPTION

1 Analog input # 1 AIN 1
2 Analog input # 2 AIN 2
3 Analog input # 3 AIN 3
4 Analog input # 4 AIN 4
5 Analog input # 5 AIN 5
6 Analog input # 6 AIN 6
7 Analog input # 7 AIN 7
8 Analog input # 8 AIN 8

GND Analog input Ground N/A

1

See Section 7 for details on setting up the DAS.

3.3.1.3. CONNECTING ANALOG OUTPUTS

The T801 is equipped with several analog output channels accessible through the
ANALOG OUT connector on the rear panel of the instrument. The standard
configuration for these outputs is VDC. An optional current loop output is
available for each (Section 3.3.1.4).

When the instrument is in its default configuration, channel A1 ou
that is proportional to the CO

range is configured, channels A1 and A2 each output a signal proportional to the

concentration of the sample gas. Please refer to Section 5.4.3 for details.

CO

2

DAS

PARAMETER

1

tputs a signal

concentration of the sample gas. If Dual or Auto

2

Channel A3 is not used.

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A

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Channel A4 is special. It can be set by the user (see Section 5.9.3.10) to output
any one of the parameters accessible through the <TST TST> buttons of the

unit’s front panel menu.

To access these signals attach a strip chart recorder and/or data-logger to the
appropriate analog output connections on the rear panel of the analyzer.

NALOG OUT

A1 A2 A3 A4
+ - + - + - + -

Figure 3-7: Analog Output Connector

Table 3-5: Analog Output Pin-Outs

PIN

1 V Out I Out +
2
3 V Out I Out +
4
5 V Out I Out +
6
7 V Out NA
8

ANALOG

OUTPUT

A1

A2

A3

(not used)

A4

VOLTAGE SIGNAL CURRENT SIGNAL

Ground I Out -

Ground I Out -

Ground I Out -

Ground NA

3.3.1.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP

If your analyzer had this option installed at the factory, there are no further
connectons to be made. Otherwise, it can be installed as a retrofit for each of the
analog outputs of the analyzer . This option converts the DC voltage analog
output to a current signal with 0-20 mA output current. The outputs can be scaled
to any set of limits within that 0-20 mA range. However, most current loop
applications call for either 2-20 mA or 4-20 mA range. All current loop outputs
have a +5% over-range. Ranges with the lower limit set to more than 1 mA (e.g.,
2-20 or 4-20 mA) also have a -5% under-range.

Figure 3-8 provides installation instructions and illustrates a sample combination
of one current output a

nd two voltage outputs

configuration. The section
following this provides instructions for converting current loop analog outputs to
standard 0-to-5 VDC outputs. Information on calibrating or adjusting these
outputs can be found in Section 5.9.3.7.

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Figure 3-8: Current Loop Option Installed

CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD
VOLTAGE OUTPUTS

CAUTION – Avoid Invalidating Warranty

Servicing or handling of circuit components requires electrostatic discharge
(ESD) protection, i.e. ESD grounding straps, mats and containers. Failure to
use ESD protection when working with electronic assemblies will void the
instrument warranty. See Section 12 for more information on preventing ESD
damage.

To convert an output configured for current loop operation to the standard 0 to 5
VDC output operation:

1. Turn off power to the analyzer.

2. If a recording device was connected to the output being modified, disconnect

it.

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3. Remove the top cover as follows:

a) Remove the set screw located at the top center of the rear panel
b) Remove the screws fastening the top cover to the unit (two per side).
c) Slide cover back.
d) Lift the cover straight up.

4. Remove the screw holding the current loop option to the motherboard.

5. Disconnect the current loop option PCA from the appropriate connector on

the motherboard (see Figure 3-8).

a)

Each conn
on the two left most pins.

b) Place the second shunt on the two pins next to it (refer to Figure 3-8 for an

example

6. Reattach the top case to the analyzer.

7. The analyzer is now ready to have a voltage-sensing, recording device

attached to that output.

ector, J19, J21 and J23, requires two shunts: Place one shunt

.

)

3.3.1.5. CONNECTING THE STATUS OUTPUTS

The status outputs report analyzer conditions via optically isolated NPN
transistors, which sink up to 50 mA of DC current. These outputs can be used to
interface with devices that accept logic-level digital inputs, such as programmable
logic controllers (PLCs). Each status bit is an open collector output that can
withstand up to 40 VDC. All of the emitters of these transistors are tied together
and connected at Pin D.

Note

Most PLCs have internal provisions for limiting the current that the input will
draw from an external device. When connecting to a unit that does not have
this feature, an external dropping resistor must be used to limit the current
through the transistor output to less than 50 mA.

At 50 mA, the transistor will drop approximately 1.2V from its collector to
emitter.

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The status outputs are accessed via a 12-pin connector on the analyzer’s rear
panel labeled STATUS (see Figure 3-4). Pin-outs for this connector are:

STATUS

1 2 3 4 5 6 7 8 D +

SYSTEM OK

Figure 3-9: Status Output Connector

Table 3-6: Status Output Signals

Rear Panel Label Status Definition Condition

1

2

3

4

5

6

7 & 8

D

SYSTEM

OK/ALARM

CONC

VALID/CONC

INVALID

CAL MODE/

MEAS MODE

SPAN/ZERO

CAL

RANGE2 CAL
RANGE1 CAL

CO2 Sensor CAL

SPARE

EMITTER BUS The emitters of the transistors on Pins 1-8 are bussed together.

SPARE

ON if no faults are present.
OFF if alarm condition

ON if concentration measurement is valid.
OFF any time the HOLD OFF feature is active, such as during calibration or when

any faults exist invalidating the measurement.
ON whenever the instrument is in Calibration Mode

OFF when instrument in Measure Mode
ON whenever the instrument’s SPAN point is being calibrated.

OFF whenever the instrument’s ZERO point is being calibrated.
ON if unit is in high range of either the DUAL or AUTO range modes.

OFF if unit is in default low, single range mode
ON when CO2 sensor is in calibration mode.

OFF when calibration mode is exited.

CONC VALID

CAL MODE – RANGE 2

SPAN CAL / ZERO MODE

CAL MODE / MEAS MODE

+

DC POWER + 5 VDC, 300 mA source (combined rating with Control Output, if used).

Digital Ground The ground level from the analyzer’s internal DC power supplies

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3.3.1.6. CONNECTING THE CONTROL INPUTS

If you wish to use the analyzer to remotely activate the zero and span calibration
modes, several digital control inputs are provided through a 10-pin connector

labeled CONTROL IN on the analyzer’s rear panel.

There are two methods for energizing the control inputs. The internal +5V
available from the pin labeled “+” is the most convenient method (Figure 3-10,
left). However, if full isolation is required, an external 5 VDC power supply
should

be used (Figure 3-10, right).

CONTROL IN

CONTROL IN

A B C D E F U

SPAN/ZERO CAL

CAL/SMPL MODE

RANGE SELECTION

Table 3-7: Control Input Signals

Input # Status Definition

A

B

C

D

E & F

CALIBRATION MODE or

SAMPLE MODE

REMOTE SPAN or REMOTE

ZERO CALIBRATION

RANGE2 or RANGE1

CALIBRATION

CO2 SENSOR

CALIBRATION

SPARE

Digital Ground

CO2 CAL

Local Power Connections

+

A B C D E F U

CO2 CAL

SPAN/ZERO CAL

CAL/SMPL MODE

RANGE SELECTION

5 VDC

Power Supply

-

External Power Connections

+

+

Figure 3-10: Control Input Connector

Open/Closed Condition Description
Closed: initiates Calibration mode. Front panel display Mode field will read

CAL CO2 R or CAL CO2 ZR.

Open: initiates Sample (Measure) mode. Front panel display Mode field will
read SAMPLE.

Closed: initiates remote SPAN calibration mode as part of performing a low
span calibration. Front panel display Mode field will read CAL CO2 SR.

Open: initiates remote ZERO calibration mode. Front panel display Mode
field will read ZERO MODE.

Closed: selects High Range for calibration (C2H).
Open: selects Low Range (C2L), default range in single range mode.

Closed: Initiates CO
read CAL CO2 R or CAL CO2 ZR.

Open: Exits CO

The ground level from the analyzer’s internal DC power supplies (same as
chassis ground)

sensor calibration. Front panel display Mode field will

2

sensor calibration and returns to SAMPLE mode.

2

U

External Power input

Input pin for +5 VDC required to activate Pins A – F.

Internally generated 5V DC power. To activate inputs A – F, place a jumper

+

5 VDC output

between this pin and the “U” pin. The maximum amperage through this port
is 300 mA (combined with the analog output supply, if used).

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3.3.1.7. CONCENTRATION ALARM RELAY (OPTION 61)

The Teledyne API T-Series analyzers have an option for 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.
The relays have three pins that have connections on the rear panel (refer Figure
3-11). They

are a Common (C), a Normally Open (NO), and a Normally Closed

(NC) pin.

Figure 3-11: Concentration Alarm Relay

Alarm 1 “System OK 2”
Alarm 2 “Conc 1”
Alarm 3 “Conc 2”
Alarm 4 “Range Bit”

“ALARM 1” RELAY

Alarm 1 which is “System OK 2” (system OK 1, is the status bit) is in the
energized state when the instrument is “OK” & there are no warnings. If there is
a warning active or if the instrument is put into the “DIAG” mode, Alarm 1 will
change states. This alarm has “reverse logic” meaning that if you put a meter
across the Common and Normally Closed pins on the connector you will find that
it is OPEN when the instrument is OK. This is so that if the instrument should
turn off or lose power, it will change states & you can record this with a data
logger or other recording device.

“ALARM 2” RELAY AND “ALARM 3” RELAY

The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration
Alarm 1” set point in the software and the “Alarm 3 Relay” on the rear panel is
associated with the “Concentration Alarm 2” set point in the software.

Alarm 2 Relay CO2 Alarm 1 = xxx %
Alarm 3 Relay CO

The Alarm 2 Relay will be turned on any time the concentration set-point is
exceeded and will return to its normal state when the concentration value goes
back below the concentration set-point.

Even though the relay on the rear panel is a NON-Latching alarm and resets when
the concentration goes back below the alarm set point, the warning on the front
panel of the instrument will remain latched until it is cleared. You can clear the
warning on the front panel by either pushing the CLR button on the front panel or
through the serial port.

Alarm 2 = xxx %

2

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The software for this instrument is flexible enough to allow you to configure the
alarms so that you can have 2 alarm levels.

CO2 Alarm 1 = 5%

Alarm 2 = 10 %

CO

2

Another likely configuration for this would be to disable “Alarm 1” relay and set
the other concentration on the “Alarm 2” relay.

CO2 Alarm 1 = Disabled

Alarm 2 = 10%

CO

2

“ALARM 4” RELAY

This relay is connected to the “range bit”. If the instrument is configured for
“Auto Range” and the instrument goes up into the high range, it will turn this
relay on.

3.3.1.8. CONNECTING THE COMMUNICATIONS INTERFACES

The T-Series analyzers are equipped with connectors for remote communications
interfaces: Ethernet, USB, RS-232, optional RS-232 Multidrop, and optional RS-

485. In addition to using the appropriate cables (Table 1-1 describes the cable
options, 60A

through 60D), each type of communication m

ethod must be

configured using the SETUP>COMM menu (Section 5.7).

ETHERNET CONNECTION

For network or Internet communication with the analyzer, connect an Ethernet
cable from the analyzer’s rear panel Ethernet interface connector to an Ethernet
port. Although the analyzer is shipped with DHCP enabled by default, it should
be manually assigned a static IP address.

Configuration: Section 6.3

USB OPTION CONNECTION

For direct communication between the analyzer and a personal computer (PC),
connect a USB cable between the analyzer and desktop or laptop USB ports.
Setup instructions include downloading the USB driver and ensuring that the
baud rate of the PC and the analyzer match.

Configuration: Section 6.4.

Note If this option is installe

for anything other than Multidrop communication.

RS-232 CONNECTION

For RS-232 communications with data terminal equipment (DTE) or with data
communication equipment (DCE) connect the applicable cable option (Table 1-1:

either a DB9-fe
female cable, Option 60B) from the analyzer’s rear panel RS-232 port to the

male-to-DB25-male cable, Option 60A, or a DB9-female-to-DB9-

d, the rear panel COM2 port cannot be used

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device. Adjust the DCE-DTE switch (Figure 3-4) to select DTE or DCE as

appropriate.
Configuration: Section 6.1 and Section 6.5.2 (for Hessen protocol).

IMPORTANT

IMPACT ON READINGS OR DATA
Cables that appear to be compatible because of matching
connectors may incorporate internal wiring that makes the link
inoperable. Check cables acquired from sources other than
Teledyne API for pin assignments before using.

Received from the factory, the analyzer is set up to emulate a DCE or modem,
with Pin 3 of the DB-9 connector designated for receiving data and Pin 2
designated for sending data..

 COM1: RS-232 (fixed) DB-9 male connector

 Baud rate: 115200 bits per second (baud)
 Data Bits: 8 data bits with 1 stop bit
 Parity: None

 COM2: RS-232 (configurable to RS 485), DB-9 female connector

 Baud rate:19200 bits per second (baud)
 Data Bits: 8 data bits with 1 stop bit
 Parity: None

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

The signals from these two connectors are routed from the motherboard via a
wiring harness to two 10-pin connectors on the CPU card, J11 and J12.

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

To assist in properly connecting the serial ports to either a computer or a modem,
there are activity indicators just above the RS-232 port. Once a cable is
connected between the analyzer and a computer or modem, both the red and
green LEDs should be on.

 If the lights are not lit, use the small switch on the rear panel to switch it

between DTE and DCE modes

 If both LEDs are still not illuminated, make sure the cable is properly

constructed.

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RS-232 MULTIDROP OPTION CONNECTION

When the RS-232 Multidrop option is installed, connection adjustments and
configuration through the menu system are required. This section provides
instructions for the internal connection adjustments, then for external
connections, and ends with instructions for menu-driven configuration.

Note Because the RS-232 Multidrop option uses both the RS232 and

COM2 DB9 connectors on the analyzer’s rear panel to connect the
chain of instruments, COM2 port is no longer available for separate
RS-232 or RS-485 operation.

ATTENTION

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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

In each instrument with the Multidrop option there is a shunt jumpering two pins
on the serial Multidrop and LVDS printed circuit assembly (PCA), as shown in
Figure 3-14. This shunt must be removed from all instruments except that
designated as last in th
requires powering off and opening each instrument and making the following
adjustments:

1. With NO power to the instrument, remove its top cover and lay the rear

panel open for access to the Multidrop/LVDS PCA, which is seated on the
CPU.

2. On the Multidrop/LVDS PCA’s JP2 connector, remove the shunt that jumpers

Pins 21  22 as indicated in Figure 3-14. (Do this for all but the last

ment in

instru

3. Check that the following cable connections are made in all instruments

(again refer to Figure 3-14):

 J3 on the Multidrop/LVDS PCA to the CPU’s COM1 connector

(Note that the CPU’s COM2 connector is not used in Multidrop)

the chain where the shunt should remain at Pins 21  22).

e.

e multidrop chain, which must remain terminated. This

 J4 on the Multidrop/LVDS PCA to J12 on the motherboard
 J1 on the Multidrop/LVDS PCS to the front panel LCD

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Figure 3-14: Jumper and Cables for Multidrop Mode

(Note: If you are adding an instrument to the end of a previously configured chain,
remove the shunt between Pins 21  22 of JP2 on the Multidrop/LVDS PCA in
the instrument that was previously the last instrument in the chain.)

4. Close the instrument.

5. Referring to Figure 3-15 use straight-through DB9 male  DB9 female

cabl

es to inte

rconnect the host RS232 port to the first analyzer’s RS232 port;
then from the first analyzer’s COM2 port to the second analyzer’s RS232
port; from the second analyzer’s COM2 port to the third analyzer’s RS232
port, etc., connecting in this fashion up to eight analyzers, subject to the
distance limitations of the RS-232 standard.

6. On the rear panel of each analyzer, adjust the DCE DTE switch so that the
green and the red LEDs (RX and TX) of the COM1 connector (labeled
RS232) are both lit. (Ensure you are using the correct RS-232 cables
internally wired specifically for RS-232 communication; see Table 1-1,
“Co

mmuni

cation Cables” and the preceding subsection, “RS-232

Connection”).

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Host

RS-232 port

Analyzer Analyzer Analyzer Last Analyzer

COM2

RS-232

COM2

RS-232

Figure 3-15: RS-232-Multidrop PCA Host

COM2

RS-232

Ensure jumper is

installed between

JP2 pins 21

last instrument of

multidrop chain.

/Analyzer Interconnect Diagram

Female DB9

Male DB9

COM2

RS-232



22 in

Note

Note

7. BEFORE communicating from the host, power on the instruments and check
that the Machine ID is unique for each (Section 5.7.1).

a. In the SET

UP Mode menu go to SETUP>MORE>COMM>ID. The default

ID is typically the model number or “0”.

b. to change the identification number, press the button below the digit to be

changed.

c. Press/select ENTER to accept the new ID for that instrument.

8. Next, in the SETUP>MORE>COMM>COM1 menu (do not use the COM2
menu for multidrop), edit the COM1 MODE parameter as follows:
press/select EDIT and set only QUIET MODE, COMPUTER MODE, and
MULTIDROP MODE to ON. Do not change any other settings.

9. Press/select ENTER to accept the changed settings, and ensure that COM1
MODE now shows 35.

10. Press/select SET> to go to the COM1 BAUD RATE menu and ensure it
reads the same for all instruments (edit as needed so that all instruments are
set at the same baud rate).

Teledyne API recommends setting up the first link, between the Host and the
first analyzer, and testing it before setting up the rest of the chain.

The (communication) Host instrument can address only one instrument at a
time, each by its unique ID (see step 7 above).

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RS-485 CONNECTION

As delivered from the factory, COM2 is configured for RS-232 communications.

This port can be reconfigured for operation as a non-isolated, half-duplex RS-485
port. Using COM2 for RS-485 communication will disable the USB port. To
reconfigure this port for RS-485 communication, please contact the factory.

3.3.2. PNEUMATIC CONNECTIONS

This section presents information about gases and pneumatic connections.

CAUTION

GENERAL SAFETY HAZARD: CO2

While CO2 itself is not toxic, in sufficient concentrations it can be an irritant and
an asphyxiant.

Obtain a Material Safety Data Sheet for CO2 and any other hazardous components
of sample and calibration gases, and follow the prescribed safety guidelines.

Do not vent sample gases into the immediate vicinity of the analyzer nor into any
enclosed areas.

3.3.2.1. CALIBRATION GASES

ZERO GAS

Zero gas is similar in chemical composition to the earth’s atmosphere but
scrubbed of all components that might affect the analyzer’s readings. Teledyne
API recommends using pure N
sensor.

Rapid release of pure N2 gas into an enclosed space can displace oxygen, and
therefore represents an asphyxiation hazard. This may happen with few
warning symptoms.

Do not vent calibration gases into enclosed areas.

when calibrating the zero point of your CO

2

CAUTION

GENERAL SAFETY HAZARD

2

SPAN GAS

Span gas is specifically mixed to match the chemical composition of the type of
gas being measured at near full scale of the desired measurement range. Teledyne
API recommends the following when calibrating the span point of the CO
sensor:

 16% CO2 in N2

Cylinders of calibrated gas traceable to NIST-Standard Reference Material
specifications (also referred to as SRMs or EPA protocol calibration gases) are
commercially available.

46

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INTERFERENTS

Some gases, if present in the sample stream in high concentrations, could
potentially interfere with the analyzer. For example, if the Sample Gas to be
measured contains high levels of nitrogen dioxide (NO
(NO), the gases used for both the zero point calibration and the span calibration
should contain the same components in the same proportion in order to cancel
any interference effects.

3.3.2.2. BASIC PNEUMATIC CONNECTIONS

) and/or nitrous oxide

2

IMPORTANT

ATTENTION

IMPACT ON READINGS OR DATA
Sample and calibration gases should only come into contact with
Stainless Steel, PTFE (Teflon) tubing, glass or electroless nickel.

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

Remove dust plugs from rear panel exhaust and supply line fittings

before powering on/operating instrument. These plugs should be
kept for reuse in the event of future storage or shipping to prevent
debris from entering the pneumatics.

CAUTION - GENERAL SAFETY HAZARD

The exhaust from the analyzer’s internal or customer supplied external
pump MUST be vented outside the immediate area or shelter surrounding
the instrument.

See Figure 3-4 for the location and descriptions of the various pneumatic
inlets/outlets referred to in this section

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2

100%

Calibrated N

Concentration

at 16%

2

(CO

Calibrated gas

Span Concentration)

VENT

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

3.3.2.3. SAMPLE GAS SOURCE

Attach a sample inlet line to the SAMPLE inlet port. The SAMPLE input line

should not be more than two (2) meters long.

 Maximum pressure of any gas at the SAMPLE inlet should not exceed 1.5 in-

hg above ambient pressure and ideally should equal ambient atmospheric
pressure.

 In applications where the sample gas is received from a pressurized

manifold, a vent must be placed on the sample gas before it enters the
analyzer. Please refer to Figure 3-16.

3.3.2.4. CALIBRATION GAS SOURCES

The source of calibration gas is also attached to the SAMPLE inlet, but only

when a calibration operation is actually being performed.

Note

Zero air and span gas flows should be supplied in excess of the 120 cm
demand of the analyzer.

3.3.2.5. INPUT GAS VENTING

The span gas, zero air supply and sample gas (if pressurized) line MUST be
vented (Figure 3-16) for two reasons: in order to ensure that the gases input do
not exceed the m

aximum inlet pressure of the analyzer, and to prevent back

diffusion and pressure effects. These vents should be:

3

/min

 At least 0.2m long;

 No more than 2m long and;

 Vented outside the shelter or at least into a well-ventilated area and away

from the immediate area surrounding the instrument

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3.3.2.6. EXHAUST OUTLET

Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust
line should be:

 PTEF tubing; minimum O.D ¼”

 A maximum of 10 meters long.

 Vented outside the T801 analyzer’s enclosure, preferably outside the shelter

or at least into a well-ventilated area.

Figure 3-17: T801 Internal Gas Flow

IMPORTANT

Leak Check:
Run a leak check once the appropriate pneumatic connections

have been made; check all pneumatic fittings for leaks using the
procedures defined in Section 10.3.3.

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3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL
CALIBRATION

IMPORTANT

IMPACT ON READINGS OR DATA
The analyzer’s cover must be installed to ensure that the
temperatures of the internal components are properly controlled.

If you are unfamiliar with the theory of operation, we recommend that you read
Section 12. For information on navigating the analyzer’s software menus, see the
menu trees de

scribed in Appendix A.1.

3.4.1. STARTUP

After the electrical and pneumatic connections are made, an initial functional
check is in order. Turn on the instrument. The pump and exhaust fan should start
immediately. The display will show a splash screen and other information during
the initialization process while the CPU loads the operating systems, the
firmware, and the configuration data.

The analyzer should automatically switch to Sample Mode after completing the
boot-up sequence and start monitoring CO
period of about 60 minutes before reliable gas measurements can be taken.
During the warm-up period the front panel display may behave as described in
Table 3-8.

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

FIELD

Conc
(Concentration)

Mode N/A

Param
(Parameters)

STATUS LEDS

Sample Green On

Cal Yellow Off The instrument’s calibration is not enabled.
Fault Red Blinking

COLOR BEHAVIOR SIGNIFICANCE

N/A

N/A

Displays current,
compensated H
concentration

Displays blinking
“SAMPLE”

Displays menus,
parameters, and
messages.

This is normal operation, but deemed inaccurate during the

S

warm-up period.

2

Instrument is in sample mode but is still in the process of
warming up.

Use any warning messages as a means of diagnosing problems.

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

The analyzer is warming up and hence out of specification for a
fault-free reading. various warning messages appear in the
Param field.

gas. However, there is a warm-up

2

3.4.1.1. WARNING MESSAGES

Because internal temperatures and other conditions may be outside the specified
limits during the analyzer’s warm-up period, the software will suppress most
warning conditions for 30 minutes after power up. If warning messages persist

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after the 60-minute warm up period, investigate their cause using the
troubleshooting guidelines in Section 11.1.1.

To view and clear w

arning messages, press:

Figure 3-18: Viewing and Clearing WARNING Messages

Table 3-9 lists brief descriptions of the warning messages that may occur during
startup.

Table 3-9 : Warning Messages

MESSAGE DEFINITION

ANALOG CAL WARNING

BOX TEMP WARNING

CANNOT DYN SPAN2

CANNOT DYN ZERO3

CONFIG INITIALIZED

CO2 ALRM1 WARNING

CO2 ALRM2 WARNING

CO2 CELL TEMP WARN

DATA INITIALIZED

REAR BOARD NOT DET

RELAY BOARD WARN

SAMPLE FLOW WARN

The instrument's A/D circuitry or one of its analog outputs is not calibrated.

The temperature inside the T801 chassis is outside the specified limits.

Remote span calibration failed while the dynamic span feature was set to ON

Remote zero calibration failed while the dynamic zero feature was set to ON

Configuration was reset to factory defaults or was erased.

4

CO2 concentration alarm limit 1 exceeded

4

CO2 concentration alarm limit 2 exceeded

CO
CO2_CELL_SET variable.

DAS data storage was erased.

CPU unable to communicate with the motherboard.

CPU is unable to communicate with the relay PCA.

The flow rate of the sample gas is outside the specified limits.

sensor cell temperature outside of warning limits specified by

2

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MESSAGE DEFINITION

SAMPLE PRESS WARN

SYSTEM RESET1

1

Does not clear after power up.

2

Clears the next time successful span calibration is performed.

3

Clears the next time successful zero calibration is performed.

4

Only active if the Concentration Alarm Option is installed

Sample gas pressure outside of operational parameters.

The analyzer was rebooted or the CPU was reset.

3.4.2. FUNCTIONAL CHECKS

After the analyzer’s components have warmed up for at least 60 minutes, verify
that the software properly supports any hardware options that were installed. For
information on navigating through the analyzer’s software menus, see the menu
trees described in Appendix A.1.

Check to make sure that the analyzer is functioning within allowable operating
parameters. Appendix C includes a list of test functions, viewable from the
analyzer’s front panel, and their expected values. These functions are also useful
tools for diagnosing performance problems (Section 11.1.2) with your analyzer.

The enclosed Final Test and Validation Data Sheet (PN 068340
values before the instrument left the factory. To view the current values of these
parameters, press the front panel button sequence for TEST functions. Remember
until the unit has completed its warm up these parameters may not have
stabilized.

000) lists these

If your local area network (LAN) is running a dynamic host configuration
protocol (DHCP) software package, the Ethernet will automatically configure its
interface with your LAN. However, it is a good idea to check these settings to
make sure that the DHCP has successfully downloaded the appropriate network
settings from your network server (see Section 6.3.1).

ur network is not running DHCP, see your network administrator or

If yo
configure the Ethernet interface manually (see Section 6.3.2).

3.4.3. INITIAL CALIBRATION

To perform the calibration you must have sources for zero air and span gas
available for input into the SAMPLE port on the back of the analyzer. See
Section 3.3.2.1 for instructions for connecting these gas sources.

The initial calibration should be carried out
as used during the analyzer’s factory calibration. This will allow you to compare

your calibration results to the factory calibration as listed on the Final Test and
Validation Data Sheet.

If both available DAS parameters for a specific gas type are being reported via

the instrument’s analog outputs e.g. CONC1 and CONC2 when the DUAL

range mode is activated, separate calibrations should be carried out for each
parameter.

using the same reporting range set up

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 Use the RNG1 button when calibrating for CONC1 (equivalent to LOW

RANGE).

 Use the RNG2 button when calibrating for CONC2 (equivalent to HIGH

RANGE).

The calibration procedures assume:

 that the zero point and span gases have been adjusted for known interferents

(Section 3.3.2.1)

Note

 that the calibration gas will

be supplied through the SAMPLE port

 that the pneumatic setup matches that described in Section 3.3.2

Perform the following outline of procedures for each sensor:

1. Verify the Reporting Range settings as presented in Section 5.4.3. We
recommend that you perform this initial checkout using the following reporting
range settings:

 Mode Setting: SNGL

 Analog Output Reporting Range: 16% for CO

2

2. If the Dilution Ratio Option is enabled on your T801, perform the Dilution
Ratio set up as presented in Section 5.4.4

3. Set the expe

9.2.3.1. This should be 80% of concen

cted Span Gas Concentration for CO

tration range for which the analyzer’s

as presented in Section

2

analog output range is set.

4. Perform the Zero/Span point calibration presented in Section 9.2.3.2

The analyzer is now ready for operation.

Once you have completed the above set-up procedures, please fill out the
Quality Questionnaire that was shipped with your unit and return it to
Teledyne API. This information is vital to our efforts in continuously
improving our service and our products. THANK YOU.

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PART II

–

OPERATING INSTRUCTIONS

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4. BASIC OPERATION OF THE T801 ANALYZER

The T801 analyzer is a computer-controlled analyzer with a dynamic menu
interface that allows all major operations to be controlled from the front panel
touchscreen through user-friendly menus (A complete set of menu trees is located
in Appendix A of this manual)

This section includes step-by-step instructions for using the display/touchscreen
to set up and operate the analyzer's CO
modes.

4.1. OVERVIEW OF OPERATING MODES

The T801 software has several operating modes (Table 6-1), and most commonly

operates in SAMPLE mode. In this mode a continuous read-out of the gas

concentration is displayed on the front panel. SAMPLE mode is used to:

measurement features and functional

2

 perform calibrations

 run test functions

 read and clear warning messages

 output analog data (when enabled)

The next most commonly used operating mode is SETUP mode, which is used

to:

 perform certain configuration operations, such as programming the DAS

system or the configurable analog output channels

 set up the analyzer’s serial communication channels (RS-232, RS-485,

Ethernet)

 perform various diagnostic tests during troubleshooting

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Figure 4-1: Front Panel Touchscreen and Display

The mode field of the front panel display indicates to the user which operating
mode the unit is currently running.

In addition to SAMPLE and SETUP, other modes the analyzer can be operated

in are:

Table 4-1: Analyzer Operating Modes

MODE DESCRIPTION

SAMPLE Sampling normally, flashing text indicates adaptive filter is on.
SAMPLE A
CO2 M-P CAL This is the basic calibration mode of the instrument and is activated by pressing the CAL key.

SETUP [X.X]
CAL CO2 Z[type]

CAL CO2 S[type]
DIAG Mode One of the analyzer’s diagnostic modes is active (Section 5.9).

[type:]

2

3

Indicates that unit is in Sample Mode while AUTOCAL feature is active.

SETUP mode is being used to configure the analyzer. The gas measurement will continue during this
process. The revision of the T801 firmware being run will appear after the word “SETUP”

2 & 3

Unit is performing CO2 ZERO calibration procedure.

2 & 3

Unit is performing CO2 SPAN calibration procedure.

M: initiated manually by the user via the front panel touchscreen.

R: initiated remotely through the COM ports or digital control inputs

4.2. SAMPLE MODE

This is the analyzer’s standard operating mode. In this mode the instrument is
analyzing the gas in the sample chamber, calculating CO
reporting this information to the user via the front panel display, the analog
outputs and, if set up properly, the RS-232/485/Ethernet ports.

concentrations and

2

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4.2.1. TEST FUNCTIONS

A series of TEST functions are available for viewing at the front panel whenever

the analyzer is SAMPLE MODE. These functions provide information about the
various functional parameters related to the analyzer’s operation, its current
operating status, and its measurement of gas concentrations. This information is
particularly useful when troubleshooting a performance problem (see Section

11.1.2). They can also be recorded in one of the DAS channels (Section 7) for

s

data analy

To view these TEST functions, press,

is.

Figure 4-2: Viewing Test Functions

Note

Note

59

A value of “Warnings” displayed for any of the TEST functions indicates an
out-of-range reading or the analyzer’s inability to calculate it.

All pressure measurements are represented in terms of absolute pressure.
Absolute, atmospheric pressure is 29.92 in-Hg-A at sea level. It decreases
about 1 in-Hg per 300 m gain in altitude. A variety of factors such as air
conditioning and passing storms can cause changes in the absolute
atmospheric pressure.

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Table 4-2: Test Functions Defined

PARAMETER DISPLAY TITLE UNITS DEFINITION

Range

Stability

Sample Pressure

Sample Flow

CO2 Sensor

Slope

CO2 Sensor

Offset

CO2 Cell

Temperature

Box Temperature

Current Time

RNG

RN1
RN2

STABIL

PRES

SAMP FL

CO2 SLOPE

CO2 OFST

CO2 CELL

TEMP

BOX TEMP

TIME

%

%

In-Hg-A

3

/min

cm

- CO

- CO

C

C

-

The full scale limit at which the reporting range of the analyzer is
currently set. THIS IS NOT the Physical Range of the instrument.
See Section 5.4.1 for more information.

Standard deviation of CO
recorded every ten seconds using the last 25 data points.

The absolute pressure of the Sample gas as measured by a
pressure sensor located inside the sample chamber.

Sample mass flow rate as measured by the flow rate sensor in the
sample gas stream.

slope, computed during zero/span calibration.

2

offset, computed during zero/span calibration.

2

The current temperature of the CO

The temperature inside the analyzer chassis.
The current time. This is used to create a time stamp on DAS

readings, and by the AUTOCAL feature to trigger calibration events.

concentration readings. Data points are

2

sensor measurement cell.

2

4.3. CALIBRATION MODE

The T801 will switch into calibration mode when the user presses the CAL
button. In this mode the user can, in conjunction with introducing zero or span
gases of known concentrations into the analyzer, cause it to adjust and recalculate
the slope (gain) and offset of the its measurement range. This mode is also used
to check the current calibration status of the instrument.

Section 9 provides more information about setting up and perform
calibration operations or checks.

Note

It is recommended that span calibration be performed at 80% of full scale of
the analyzer’s currently selected reporting range.

EXAMPLE: If the reporting range is set for 0 to 10%, an appropriate span
point would be 8%.

4.4. SETUP MODE

The SETUP mode is used to configure the analyzer’s hardware and software

features, perform diagnostic procedures, gather information on the instrument’s
performance and configure or access data from the internal data acquisition
system (DAS) (Section 7). SETUP Mode has a Primary and a Secondary setup
menu.

ing standard

Note

Any changes made to a variable during one of the SETUP procedures are not
acknowledged by the instrument until the ENTR button is pressed. If the EXIT
button is pressed before the ENTR button, the analyzer will beep to notify the
user that the newly entered value has been lost.

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Setup Mode can be protected by password security through the SETUP>PASS
menu (Section 5.5) to prevent unauthorized or inadvertent configuration
adjustm

ents.

4.4.1. PRIMARY SETUP MENU

For a visual representation of the software menu trees, refer to Appendix A-1.

The areas accessible under the SETUP mode are shown below:

Table 4-3: Primary Setup Mode Features and Functions

MODE OR FEATURE

Analyzer Configuration

MENU

ITEM

CFG

DESCRIPTION

Lists key hardware and software configuration information 5.1

MANUAL
SECTION

Auto Cal Feature

Internal Data Acquisition

(DAS)

Analog Output Reporting

Range Configuration

Calibration Password

Security

Internal Clock Configuration

Advanced SETUP features

ACAL

DAS

RNGE

PASS

CLK

MORE

(Special configuration; consult factory). n/a

Used to set up the DAS system and view recorded data 7
Used to configure the output signals generated by the

instruments Analog outputs.
Turns the calibration password feature ON/OFF 5.2

Used to Set or adjust the instrument’s internal clock 5.6

This button accesses the instrument’s secondary setup
menu

4.4.2. SECONDARY SETUP MENU (SETUP>MORE)

Table 4-4: Secondary Setup Mode Features and Functions

MODE OR FEATURE

External Communication
Channel Configuration

System Status Variables

System Diagnostic Features
and
Analog Output Configuration

Alarm Limit Configuration

1

Alarm warnings only present when optional concentration alarm relay package is installed.

1

MENU

ITEM

COM

VARS

DIAG

ALRM

DESCRIPTION

Used to set up and operate the analyzer’s various external I/O
channels including RS-232, RS-485, modem communication
and/or Ethernet access.

Used to view various variables related to the instruments current
operational status

 Changes made to any variable will not be recorded in the

instrument’s memory until the ENTR key is pressed.

 Pressing the EXIT key ignores the new setting.
Used to access a variety of functions that configure, test or

diagnose problems with a variety of the analyzer’s basic
systems.
Most notably, the menus to configure the output signals
generated by the instruments Analog outputs are located here.
Used to turn the instrument’s two alarms on and off as well as
set the trigger limits for each.

5.4

See

Table 6-5

MANUAL
SECTION

5.7

5.8

5.9

5.10

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5. SETUP MENU

The SETUP menu is used to set instrument parameters for performing
configuration, calibration, reporting and diagnostics operations.

5.1. SETUP  CFG: CONFIGURATION INFORMATION

Pressing the CFG button displays the instrument’s configuration information.

This display lists the analyzer model, serial number, firmware revision, software
library revision, CPU type and other information.

 Special instrument or software features or installed options may also be listed

here.

 Use this information to identify the software and hardware installed in your

T801 analyzer when contacting Technical Support.

To access the configuration table, press:

Press NEXT or PREV to scroll through the

following list of Configuration information:

MODEL TYPE, NUMBER AND NAME
PART NUMBER
SERIAL NUMBER
SOFTWARE REVISION
LIBRARY REVISION
OS REVISION

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X SUPPORT: TELEDYNE-API.COM

PREV NEXT EXIT

Press EXIT at

any time to

return to the

SETUP menu

5.2. SETUP  ACAL: [NOT USED]

ACAL on the primary SETUP menu is a special configuration. Contact factory.

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5.3. SETUP  DAS: INTERNAL DATA ACQUISITION SYSTEM

Use the SETUP>DAS menu to capture and record data. Refer to Section 7 for
configuration and operation details.

5.4. SETUP  RNGE: ANALOG OUTPUT REPORTING RANGE
CONFIGURATION

Use the SETUP>RNGE menu to configure output reporting ranges, including
scaled reporting ranges to handle data resolution challenges. This section
describes configuration for Single, Dual, and Auto Range modes.

5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING

RANGES

Functionally, the T801 analyzers have one hardware PHYSICAL RANGE that is
capable of determining concentrations from 0.00 % to 20.00 % (the full range of
the sensor).

This architecture improves reliability and accuracy by avoiding the need for
extra, switchable, gain-amplification circuitry. Once properly calibrated, the
analyzer’s front panel will accurately report concentrations along the entire span
of its physical range.

Note

Because many applications use only a small part of the analyzer’s full physical
range, data resolution problems can occur for most analog recording devices. For
example, in a typical application where an T801 is being used to measure low
levels CO
instrument’s full measurement range. Unmodified, the corresponding analog
output signal would also be recorded across only 10% of the range of the
recording device.

The T801 analyzers solve this problem by allowing the user to select a scaled
reporting range for the analog outputs that only includes that portion of the
physical range relevant to the specific application.

Only this REPORTING RANGE of the analog outputs is scaled, the physical
range of the analyzer and the readings displayed on the front panel remain
unaltered.

Both the DAS values stored in the CPU’s memory and the concentration
values reported on the front panel are unaffected by the settings chosen for
the reporting range(s) of the instrument.

concentration, the full scale of expected values could be 10% of the

2

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5.4.2. ANALOG OUTPUT RANGES FOR CO2 CONCENTRATION

The analyzer has several active analog output signals accessible through a
connector on the rear panel (see Figure 3-4).

NALOG OUT

CO2 concentration outputs

A1 A2 A3 A4
+ - + - + - + -

LOW range when DUAL

or AUTO mode is selected

Not Used

Test Channel

HIGH range when DUAL

or AUTO mode is selected

Figure 5-1: Analog Output Connector Pin Out

All three outputs can be configured either at the factory or by the user for full
scale outputs of 0.1 VDC, 1VDC, 5VDC or 10VDC.

Additionally A1 and A2 may be equipped with optional 0-20 mA current loop

drivers and configured for any current output within that range (e.g. 0-20, 2-20,
4-20, etc.). (Please contact Sales for the Current Loop option) The user may also
adjust the signal level and scaling of the actual output voltage or current to match
the input requirements of the recorder or datalogger (See Section 5.9.3.9).

When the instrument is in
Auto range) output a signal proportional to the CO

its default configuration, channels A1 and A2 (Dual or

concentration of the sample

2

gas. (See Section 5.4.3). A3 is not used.

The output, l

abeled A4 is special. It can be set by the user (See Section 5.9.3.10)

to output several of the test functions accessible through the <TST TST> men

buttons.

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5.4.3. REPORTING RANGE MODES

The T801 provides three analog output range modes to choose from.

 Single range (SNGL) mode sets a single maximum range for the analog

output. If single range is selected, all three outputs are slaved together and
will represent the same measurement span (e.g. 0-20 %); however, their
electronic signal levels may be configured for different ranges (e.g. 0-10
VDC vs. 0-.1 VDC).

 Dual range (DUAL) allows the A1 and A2 outputs to be configured with

different measurement spans as well as separate electronic signal levels.

 Auto range (AUTO) mode gives the analyzer the ability to output data via a

low range and high range. When this mode is selected the analyzer will
automatically switch between the two ranges dynamically as the
concentration value fluctuates.

Range status is also output via the external digital I/O status outputs (See Section

3.3.1.4).

To select the Analog Output Range Type press:

Upper span limit setting for the individual range modes are shared. Resetting the
span limit in one mode also resets the span limit for the corresponding range in
the other modes as follows:

SNGL DUAL AUTO
Range  Range1  Low Range
Range2  High Range

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5.4.3.1. RNGE  MODE  SNGL: CONFIGURING THE T801 ANALYZER FOR SINGLE

RANGE MODE

Single Range Mode (SNGL) is the default reporting range mode for the analyzer.

When the single range mode is selected (SNGL), all concentration outputs (A1,
A2) are slaved together and set to the same reporting range limits (e.g. 0- 20.00

%). The span limit of this reporting range can be set to any value within the
physical range of the analyzer.

Although the outputs share the same concentration reporting range, the electronic
signal ranges of the analog outputs may still be configured for different values
(e.g. 0-5 VDC, 0-10 VDC, etc; see Section 5.9.3.1)

To select SNGL range m

ode and to set the upper limit of the range, press:

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

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5.4.3.2. RNGE  MODE  DUAL: CONFIGURING THE T801 ANALYZER FOR DUAL

RANGE MODE

Selecting the DUAL range mode allows the A1 and A2 outputs to be configured

with different reporting ranges. The analyzer software calls these two ranges
RNG1 (low) and RNG2 (high).

 The C2L RANGE 1 setting corresponds with the analog output labeled A1 on

the rear panel of the instrument.

 The C2H RANGE 2 setting corresponds with the A2 output.

In DUAL range mode the RANGE test function displayed on the front panel will

be replaced by two separate functions:

 CO2 RN1: The range setting for the A1 output.
 CO2 RN2: The range setting for the A2 output.

To select the DUAL range mode press following menu button sequence:

When the instrument’s range mode is set to Dual the concentration field in the
upper right hand corner of the display alternates between displaying the low
range value and the high range value. The concentration that would be displayed,

is identified as follows: ”C2L” = LOW (or A1) and ”C2H” = HIGH (or A2).

Note

68

In DUAL range mode C2L and C2H have separate slopes and offsets for
computing CO2 concentrations. The two ranges must be independently
calibrated.

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To set the upper range limit for each independent reporting range, press:

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

5.4.3.3. RNGE  MODE  AUTO: CONFIGURING THE T801 ANALYZER FOR AUTO

RANGE MODE

In AUTO range mode, the analyzer automatically switches the reporting range

between two user-defined ranges (low and high).

 The unit will switch from low range to high range when the CO2 concentration

exceeds 98% of the low range span.

 The unit will return from high range back to low range once the CO

concentration falls below 75% of the low range span.

In AUTO Range mode the instrument reports the same data in the same range on
both the A1 and A2 outputs and automatically switches both outputs between

ranges as described above.

Also the RANGE test function displayed on the front panel will be replaced by

two separate functions:

 CO2 RNG1: The LOW range setting for all analog outputs.
 CO2 RNG2: The HIGH range setting for all analog outputs.

The high/low range status is also reported through the external, digital status bits
(See Section 3.3.1.4).

2

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To set individual ranges press the following menu sequence:

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

5.4.4. SETUP RNGE  DIL: USING THE OPTIONAL DILUTION RATIO

FEATURE

This feature is an optional software utility that is used to compensate for any
dilution of the sample gas that may occur before it enters the sample inlet.
Typically this occurs in continuous emission monitoring (CEM) applications
where the sampling method used to remove the gas from the stack, dilutes the
sample.

To set up and use the dilution ratio option:

1. In the DIAG menu, use the 929 password and navigate to Factory Options
and enable the Dilution Ratio feature. (Press ENTER to save setting, and
then return to SETUP menu).

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2. Select the reporting range mode and set the reporting range upper limit (see
Section 5.4.3).

3. Ensu

re that the upper span limit entered for the reporting range is the

maximum expected concentration of the non-diluted gas.

4. Set the dilution factor as a gain (e.g., a value of 20 means 20 parts diluent
and 1 part of sample gas):

5. Calibrate the analyzer.

 Make sure that the calibration span gas is either supplied through the

same dilution system as the sample gas or has an appropriately lower
actual concentration.

EXAMPLE: If the reporting range limit is set for 20 % and the dilution ratio
of the sample gas is 20, either:

 a span gas with the concentration of 20 % can be used if the span gas

passes through the same dilution steps as the sample gas, or;

 a 1 % span gas must be used if the span gas IS NOT routed through the

dilution system.

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5.5. SETUP  PASS: PASSWORD PROTECTION

The menu system provides password protection of the calibration and setup
functions to prevent unauthorized adjustments. When the passwords have been
enabled in the PASS menu item, the system will prompt the user for a password
anytime a password-protected function (e.g., SETUP) is selected. This allows
normal operation of the instrument, but requires the password (101) to access to
the menus under SETUP. When PASSWORD is disabled (SETUP>PASS>OFF),
any operator can enter the Primary Setup (SETUP) and Secondary Setup
(SETUP>MORE) menus. Whether PASSWORD is enabled or disabled, a
password (default 818) is required to enter the VARS or DIAG menus in the
SETUP>MORE menu.

Table 5-1: Password Levels

PASSWORD LEVEL MENU ACCESS ALLOWED

Null (000) Operation All functions of the main menu (top level, or Primary, menu)

101

818

Configuration/Maintenance

Configuration/Maintenance

Access to Primary and Secondary SETUP Menus when PASSWORD is
enabled

Access to Secondary SETUP Submenus VARS and DIAG whether
PASSWORD is enabled or disabled.

IMPORTANT

IMPACT ON READINGS OR DATA
There are more VARS available when using the password, 929, for
configuration. Use caution when pressing any buttons while in this
setup. Any changes made may alter the performance of the
instrument or cause the instrument to not function properly. To
discard an accidental change to a setup parameter, press EXIT.

To enable or disable passwords, press:

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Example: If all passwords are enabled, the following menu sequence would be

required to enter the SETUP menu:

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

Press individual

buttons to set

number

EXAMPLE: This

password enables the

SETUP mode

Note

SYSTEM ENTER PASSWORD:0

0 0 0 ENTR EXIT

SYSTEM ENTER PASSWORD:101

1 0 1 ENTREXIT

Analyzer enters selected menu

When PASSWORD ENABLE is set to OFF, the instrument still prompts for a
password when entering the VARS and DIAG menus, but it displays the
default password (818). Press ENTR to continue.

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5.6. SETUP  CLK: SETTING THE ANALYZER’S INTERNAL
CLOCK

The analyzer has an internal clock for setting the time and day; it’s speed can be
adjusted to compensate for faster or slower CPU clocks. Press SETUP>CLK to
access the clock.

5.6.1. SETTING THE INTERNAL CLOCK’S TIME AND DAY

The T801 has a time of day clock that supports the time of day TEST function,
the time stamps for the DAS feature and most COM port messages.

To set the clock’s time and day, press:

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X TIME-OF-DAY CLOCK

TIME DATE EXIT

SETUP X.X TIME: 12:00

1 2 :0 0 ENTR EXIT

Toggle these

HOUR MINUTE DAY MONTH YEAR

SETUP X.X TIME: 22:30

2 2:3 0 ENTREXIT

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

buttons to enter

current hour

SETUP X.X TIME-OF-DAY CLOCK

TIME DATE EXIT

SETUP X.X DATE: 01-OCT-09

0 1OCT0 9 ENTREXIT

SETUP X.X DATE: 15-OCT-09

1 5OCT0 9 ENTREXIT

Toggle these buttons

to change day, month

and/or year.

EXIT returns to

SETUP X.X

display

5.6.2. ADJUSTING THE INTERNAL CLOCK’S SPEED

In order to compensate for CPU clocks that run faster or slower, you can adjust a

variable called CLOCK_ADJ to speed up or slow down the clock by a fixed

amount every day.

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The CLOCK_ADJUST variable is accessed via the VARS submenu: To change

the value of this variable, press:

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

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5.7. SETUP  MORE COMM: COMMUNICATION PORTS

This section introduces the communications setup menu; Section 6 provides the
setup instructions and operation information. To arrive at the communications
menu, press SETUP>ENTR>MORE>COMM.

5.7.1. ID (MACHINE IDENTIFICATION)

Each type of Teledyne API’s analyzer is configured with a default ID code. The
default ID code for T801 analyzers is either 0 or 801.

The ID number is only important if more than one of the same model analyzer is

connected to the one communications channel, such as when several analyzers
are:

 in an RS-232 multidrop chain (Section 3.3.1.8)

 on the same Ethernet LAN (Section 6.3)

 whe

 when applying HESSEN protocol (S

n applying MODBUS protocol (Section 6.5.1)

ection 6.5.2)

If two analyzers of the same model type are used on one channel, the ID codes of

one or both of the instruments needs to be changed.

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To edit the instrument’s ID code, press:

The ID can also be used for to identify any one of several analyzers attached to
the same network, e.g., by location number, company asset number, etc.).

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

5.7.2. INET (ETHERNET)

Use SETUP>COMM>INET to configure Ethernet communications, whether
manually or via DHCP. Please see Section 6.3 for configuration details.

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5.7.3. COM1[COM2] (MODE, BAUDE RATE AND TEST PORT)

Use the SETUP>COMM>COM1[COM2] menus to:

 configure communication modes (Section 6.2.1)
 view/set the baud rate (Section 6.2.2)
 test the con

nections of the com ports (Section 6.2.3).

Configuring COM1 or COM2 requires setting the DCE DTE switch on the rear
panel. Section 6.1 provides DCE DTE information.

5.8. SETUP  VARS: VARIABLES SETUP AND DEFINITION

Through the SETUP>MORE>VARS menu there are several user-adjustable
software variables, which define certain operational parameters. Usually, these
variables are automatically set by the instrument’s firmware, but can be manually

re-defined using the VARS menu.

Table 5-2 lists variables that are available within the 818 password protected
level. See Appendix A2
accessible through the remote interface.

for a detailed listing of the T801 variables that are

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Table 5-2: Variable Names (VARS)

0 Sec/Day

VARS

Default

settings

15 min.

ON

[OFF]

[OFF]

AUTO

OFF

NO. VARIABLE DESCRIPTION

Changes the Internal Data Acquisition System (DAS) HOLD
OFF timer:

DAS_HOLD_OFF

0

1

2

3

4

5

6

TPC_ENABLE

DYN_ZERO

Special configuration;

consult factory

DYN_SPAN

Special configuration;

consult factory

CONC_PRECISION

CLOCK_ADJ

SERVICE_CLEAR

No data are stored in the DAS channels during situations
when the software considers the data to be questionable
such as during warm up or just after the instrument returns
from one of its calibration modes to SAMPLE Mode.

NOTE: It is strongly recommended that this variable

NOT be changed.

ON enables, OFF disables temperature and pressure
compensation

[Automatically adjusts offset and slope of the CO2 response
when performing a zero point calibration during an AutoCal.]

[Automatically adjusts offset and slope of the CO
when performing a zero point calibration during an AutoCal.]

Allows the user to set the number of significant digits to the
right of the decimal point display of concentration and
stability values.

Adjusts the speed of the analyzer’s clock. Choose the +
sign if the clock is too slow, choose the - sign if the clock is
too fast. Toggle keys to change the number of seconds.

Pressing the OFF button to display SERVICE_CLEAR:ON,
followed by pressing ENTR resets the service interval timer
and returns this Var back to its default setting, ready for the
next reset.

response

2

ALLOWED
SETTINGS

May be set for

intervals
between

0.5 – 20 min

ON, OFF

[ON, OFF]

[ON, OFF]

AUTO, 1, 2,

3, 4

-60 to +60
s/day

ON, OFF

TIME_SINCE_SVC

7

SVC_INTERVAL

8

Displays time in hours since last service (restarted by the
SERVICE_CLEAR Variable).

Sets the interval in hours between service reminders.

0-50,000

0-100,000

0

0

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To access and navigate the VARS menu, use the following key sequence.

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL MSG SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

Toggle these

buttons to enter

the correct

PASSWORD

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

SETUP X.X ENTER PASSWORD:818

8 1 8 ENTR EXIT

SETUP X.X 0) DAS_HOLD_OFF=15.0 Minutes

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 2) TPC_ENABLE=ON

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 3) DYN_ZERO=OFF

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 4) DYN_SPAN=OFF

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 5) CONC_PRECISION=AUTO

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 6) CLOCK_ADJUST=0 Sec/Day

PREV NEXT JUMP EDIT ENTR EXIT

In all cases:

EXIT discards the new

setting

ENTR accepts the

new setting

SETUP X.X DAS_HOLD_OFF=15.0 Minutes

1 5 .0 ENTR EXIT

SETUP X.X TPC_ENABLE:ON

ON ENTR EXIT

SETUP X.X CONC_PRECISION=AUTO

AUTO1234 ENTREXIT

SETUP X.X CLOCK_ADJUST=0 Sec/Day

+0 0 ENTR EXIT

Toggle these buttons to set

the DAS HOLDOFF time

period in minutes

(MAX = 20 minutes).

Toggle to turn on or turn

OFF temperature pressure

compensation.

Use these buttons to select

the precision of the gas

concentration display

Enter sign and number of

seconds per day the clock

gains (-) or loses(+)

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5.9. SETUP  MORE  DIAG: DIAGNOSTICS FUNCTIONS

A series of diagnostic tools is grouped together under the

SETUPMOREDIAG menu. These tools can be used in a variety of

troubleshooting and diagnostic procedures and are referred to in many places of
the maintenance and trouble-shooting sections of this manual.

The various operating modes available under the DIAG menu are:

Table 5-3: Diagnostic Mode (DIAG) Functions

DIAG SUBMENU SUBMENU FUNCTION

Allows observation of all digital and analog signals in
the instrument. Allows certain digital signals such as

SIGNAL I/O

heaters to be toggled ON and OFF.

parameters are dependent on firmware revision, (see
Appendix A).

When entered, the analyzer performs an analog

ANALOG OUTPUT

output step test. This can be used to calibrate a
chart recorder or to test the analog output accuracy.

This submenu allows the user to configure the
analyzer’s analog output channels, including
choosing what parameter will be output on each

ANALOG I/O

CONFIGURATION

channel. Instructions that appear here allow
adjustment and calibration of the voltage signals
associated with each output as well as calibration of
the analog to digital converter circuitry on the
motherboard.

PRESSURE

CALIBRATION

FLOW

CALIBRATION

This function is used to calibrate the Sample

1

Pressure sensor.

This function is used to calibrate the sample gas

1

flow.

These

Front Panel Mode

Indicator

DIAG I/O

DIAG AOUT

DIAG AIO

DIAG PCAL

DIAG FCAL

MANUAL
SECTION

11.1.3

11.6.9.2

5.9.3

9.4.1

9.4.2

TEST CHAN

OUTPUT

1

These settings are retained after exiting DIAG mode.

Selects one of the available test channel signals to
output over the A4 analog output channel.

DIAG TCHN

5.9.3.10

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To access the DIAG functions press the following menu sequence:

<TST TST> CAL MSG

SETUP X.X

CFG DAS ACAL RNGE PASS CLK EXIT

SETUP X.X

COMM VARS EXIT

SETUP X.X

EXIT

returns to the

Activates the

selected

submenu

PREV

PREV

PREV

PREV

PREV

PREV

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

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5.9.1. SIGNAL I/O

The signal I/O diagnostic mode allows a user to review and change the digital and
analog input/output functions of the analyzer. It can also be used for
troubleshooting purposes (Section 11.1.3). Refer to Appendix A for a complete
list of the para

meters available for review under this menu.

IMPORTANT

IMPACT ON READINGS OR DATA
Any changes of signal I/O settings will remain in effect only until the
signal I/O menu is exited. Exceptions are the ozone generator
override and the flow sensor calibration, which remain as entered
when exiting.

Access the Signal I/O test mode from the DIAG Menu and press ENTR to access

its parameters:

DIAG SIGNAL I / O

PREV NEXT JUMP ENTR EXIT

DIAG I / O 0) EXT_ZERO_CAL=OFF

PREV NEXT JUMP PRNT EXIT

EXAMPLE

DIAG I / O JUMP TO: 12

1 2 ENTR EXIT

Press NEXT & PREV to

move between signal

types.

Press JUMP to go

directly to a specific

signal

See Appendix A-4 for

a complete list of

available SIGNALS

EXAMPLE:

Enter 12 to Jump to

12) ST_SYSTEM_OK=ON

DIAG I / O 12) ST_SYSTEM_OK = ON

PREV NEXT JUMP ON PRNT EXIT

Toggle ON/(OFF) button to

change status.

Pressing the PRNT button will send a formatted

printout to the serial port and can be captured

with a computer or other output device.

Exit to return

to the

DIAG menu

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5.9.2. ANALOG OUTPUT

The T801 analyzer comes equipped with four analog outputs.

 The first two analog output (A1 & A2) signals represent the currently

measured CO

 The third analog output (A3) is not used.

 The fourth output (A4) outputs a signal that can be set to represent the

current value of one of several test functions (see Table 5-8).

concentration (see Section 5.4.2).

2

5.9.3. ANALOG I/O CONFIGURATION

The following lists the analog I/O functions that are available in the T801
analyzer.

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

SUB MENU FUNCTION

Initiates a calibration of the A1, A2, A3 and A4 analog output channels that determines the

AOUT

CALIBRATED

CONC_OUT_1

CONC_OUT_2

TEST OUTPUT

slope and offset inherent in the circuitry of each output.
These values are stored in the memory and applied to the output signals by the CPU

automatically.
Sets the basic electronic configuration of the A1 output (CO2 Concentration).

There are four options:

 RANGE
 REC OFS: Allows them input of a DC offset to let the user manually adjust the output

level

 AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature
 CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this one

channel only.

Same as for CONC_OUT_1 but for analog channel A2 and only if Auto or Dual range is
selected (CO

Not used.

 Same as for CONC_OUT_1 but for analog channel A4 (TEST CHANNEL)

1

: Selects the signal type (voltage or current loop) and level of the output

high range, RNG2)

2

AIN

CALIBRATED

XIN1

.
.
.

XIN8

1

Any changes made to RANGE or REC_OFS require recalibration of this output.

Initiates a calibration of the A-to-D Converter circuit located on the Motherboard.

For each of 8 external analog inputs channels, shows the gain, offset, engineering
units, and whether the channel is to show up as a Test function.

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To access the ANALOG I/O CONFIGURATION sub menu, press:

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL MSG SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

SETUP X.X ENTER PASSWORD:818

Toggle these

buttons to enter

the correct

PASSWORD

8 1 8 ENTR EXIT

DIAG SIGNAL I/O

NEXT ENTR EXIT

Continue pressing NEXT until ...

AIO Configuration Submenu

DIAG ANALOG I/O CONFIGURATION

PREV NEXT ENTR EXIT

DIAG AIO AOUTS CALIBRATED: NO

SET> CAL EXIT

DIAG AIO CONC_OUT_1: 5V, OVR, CAL

<SET SET> EDIT EXIT

DIAG AIO CONC_OUT_2: 5V, OVR, CAL

<SET SET> EDIT EXIT

DIAG AIO CONC_OUT_3: 5V, OVR, CAL

<SET SET> EDIT EXIT

DIAG AIO TEST_OUTPUT: 5V,OVR, CAL

<SET SET> EDIT EXIT

Adjusts the signal output

for Analog Output A1

Adjusts the signal output

for Analog Output A2

Adjusts the signal output

for Analog Output A3

(O2Sensor Only)

Selects the parameter to be

output on the TEST channel and

adjusts its signal output

DIAG AIO AIN CALIBRATED: YES

<SET CAL EXIT

(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

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5.9.3.1. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION

In its standard configuration the analog outputs are set to output a 0 – 5 VDC
signals. Several other output ranges are available. Each range is usable from ­5% to + 5% of the rated span.

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

RANGE NAME RANGE SPAN MINIMUM OUTPUT MAXIMUM OUTPUT

0.1V
1V
5V

10V

 The default offset for all VDC ranges is 0-5 VDC.

CURR

 While these are the physical limits of the current loop modules, typical applications use 2-20 or 4-20 mA for the lower and

upper limits. Please specify desired range when ordering this option.

 The default offset for all current ranges is 0 mA.

0-100 mVDC -5 mVDC 105 mVDC

0-1 VDC -0.05 VDC 1.05 VDC
0-5 VDC -0.25 VDC 5.25 VDC

0-10 VDC -0.5 VDC 10.5 VDC

0-20 mA 0 mA 20 mA

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To change the output type and range, select the ANALOG I/O
CONFIGURATION submenu (see Section 5.9.3) then press,

5.9.3.2. CALIBRATION OF THE ANALOG OUTPUTS

Analog output calibration should to be carried out on first startup of the analyzer
(performed in the factory as part of the configuration process) or whenever
recalibration is required. The analog outputs can be calibrated automatically,
either as a group or individually, or adjusted manually.

In its default mode, the instrument is configured for automatic calibration of all
channels, which is useful for clearing any analog calibration warnings associated
with channels that will not be used or connected to any input or recording device,
e.g., datalogger.

Manual calibration should be used for the 0.1V range or in cases where the
outputs must be closely matched to the characteristics of the recording device.
Manual calibration requires the AUTOCAL feature to be disabled.

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5.9.3.3. ENABLING OR DISABLING THE AUTOCAL FOR AN INDIVIDUAL ANALOG
OUTPUT

To enable or disable the AutoCal feature for an individual analog output, elect
the ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

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5.9.3.4. AUTOMATIC GROUP CALIBRATION OF THE ANALOG OUTPUTS

IMPORTANT

IMPACT ON READINGS OR DATA

Manual calibration should be used for any analog output set for a

0.1V output range or in cases where the outputs must be closely
matched to the characteristics of the recording device.

Before performing this procedure, ensure that the AUTO CAL for
each analog output is enabled. (See Section 5.9.3.3).

To calibrate the outputs as a group with the AOUTS
CALIBRATION command, select the ANALOG I/O CONFIGURATION

submenu (see Section 5.9.3) then press:

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5.9.3.5. AUTOMATIC INDIVIDUAL CALIBRATION OF THE ANALOG OUTPUTS

To use the AUTO CAL feature to initiate an automatic calibration for an
individual analog output, select the ANALOG I/O CONFIGURATION

submenu (see Section 5.9.3) then press:

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5.9.3.6. MANUAL CALIBRATION OF THE ANALOG OUTPUTS CONFIGURED FOR
VOLTAGE RANGES

For highest accuracy, the voltages of the analog outputs can be manually
calibrated.

Note

The menu for manually adjusting the analog output signal level will only
appear if the AUTO-CAL feature is turned off for the channel being adjusted
(See Section 5.9.3.3).

Calibration is performed with a voltmeter connected across the output terminals
and by changing the actual output signal level using the front panel touchscreen
in 100, 10 or 1 count increments. See Figure 3-7 for pin assignments and
diagram of the analog outp

ut connector.

V

+DC Gnd

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

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

FULL SCALE

0.1 VDC ±0.0005V 90 mV ±0.001V 0.02 mV
1 VDC ±0.001V 900 mV ±0.001V 0.24 mV
5 VDC ±0.002V 4500 mV ±0.003V 1.22 mV

10 VDC ±0.004V 4500 mV ±0.006V 2.44 mV

ZERO

TOLERANCE

SPAN

VOLTAGE

SPAN

TOLERANCE

MINIMUM

ADJUSTMENT

(1 count)

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To adjust the signal levels of an analog output channel manually, select the

ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

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5.9.3.7. MANUAL ADJUSTMENT OF CURRENT LOOP OPTION OUTPUT SPAN AND
OFFSET

A current loop option may be purchased for the A1 and A2 analog outputs of the

analyzer. This option places circuitry in series with the output of the A-to-D
converter on the motherboard that changes the normal DC voltage output to a 0­20 milliamp signal (See Section 3.3.1.4).

 The outputs can be ordered scaled to any set of limits within that 0-20 mA

range, however most current loop applications call for either 0-20 mA or 4-20
mA range spans.

 All current loop outputs have a + 5% over range. Ranges whose lower limit is

set above 1 mA also have a 5% under range.

To switch an analog output from voltage to current loop, follow the instructions

in Section 5.9.3.1 (select CURR fro

m the list of options on the “Output Range”
menu).
Adjustment of the signal zero and span levels of the current loop output is done
by raising or lowering the voltage output of the D-to-A converter circuitry on the
analyzer’s motherboard. This raises or lowers the signal level produced by the
current loop option circuitry.
The software allows this adjustment to be made in 100, 10 or 1 count increments.
Since the exact amount by which the current signal is changed per D-to-A count
varies from output-to-output and instrument–to–instrument, you will need to
measure the change in the signal levels with a separate, current meter placed in
series with the output circuit. See Figure 3-7 for pin assignments and diagram of
the analog output connector.

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

CAUTION

GENERAL SAFETY HAZARD

Do not exceed 60 V peak voltage between current loop outputs and instrument ground.

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To adjust the zero and span signal levels of the current outputs, select the

ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

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An alternative method for measuring the output of the Current Loop converter is
to connect a 250 ohm 1% resistor across the current loop output in lieu of the
current meter (see Figure 3-7 for pin assignments and diagram of the analog
output conne

ctor). This allows the use of a voltmeter connected across the

resistor to measure converter output as VDC or mVDC.

V

+DC Gnd

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

In this case, follow the procedure above but adjust the output for the following
values:

Table 5-7: Current Loop Output Check

% FS

Voltage across

Resistor for 2-20 mA

Voltage across

Resistor for 4-20 mA

0 500 mVDC 1000 mVDC

100 5000 mVDC 5000 mVDC

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5.9.3.8. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE ON/OFF

In its default configuration, a ± 5% over-range is available on each of the T801’s
analog outputs. This over-range can be disabled if your recording device is
sensitive to excess voltage or current.

To turn the over-range feature on or off, select the ANALOG I/O
CONFIGURATION submenu (see Section 5.9.3) then press

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5.9.3.9. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT

Some analog signal recorders require that the zero signal be significantly different
from the baseline of the recorder in order to record slightly negative readings
from noise around the zero point. This can be achieved in the T801 by defining a
zero offset, a small voltage (e.g., 10% of span).

To add a zero offset to a specific analog output channel, select the ANALOG I/O
CONFIGURATION submenu (see Section 5.9.3) then press:

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5.9.3.10. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4

The test functions available to be reported are:

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

TEST CHANNEL DESCRIPTION ZERO FULL SCALE

NONE

SAMPLE PRESSURE

SAMPLE FLOW

CO2 CELL TEMP

CHASSIS TEMP

Test Channel is turned off
The absolute pressure of the Sample gas as

measured by a pressure sensor located inside
the sample chamber.

Sample mass flow rate as measured by the
flow rate sensor in the sample gas stream.

The temperature of the gas inside the CO
sensor sample chamber.

The temperature inside the analyzer chassis.

2

0 "Hg 40 "Hg

3

/m 1000 cm3/m

0 cm

0C 70C

0C 70C

Once a function is selected, the instrument not only begins to output a signal on

the analog output, but also adds TEST to the list of test functions viewable via

the front panel display.

98