Teledyne T802 User Manual

OPERATION MANUAL

MODEL T802

PARAMAGNETIC OXYGEN 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 2010-2013 07275B DCN6418
Teledyne Advanced Pollution Instrumentation 14 January 2013

07275B DCN6418

ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)

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

TRADEMARKS

© 2010-2013 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

Do Not Touch: Touching some parts of the instrument without

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

Note

Technician Symbol: All operations marked with this symbol are to be

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.

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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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 anti-ESD 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

under Customer Support > Return Authorization.

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ABOUT THIS MANUAL

This operation manual, PN 07275, is comprised of multiple documents in
PDF format, as listed below.

Part No. Rev Name/Description

07275 B T802 Operation manual

06530 C Menu Trees and Software Documentation (inserted as Appendix A in this manual)

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

06535 A Expendables Kit (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 A 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 information 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

T802 Operation and Maintenance Manual, PN07275

Date Rev DCN Description

2013 January 14 B 6418 Administrative Updates and specs updates
2011 February 18 A 6005 Initial Release

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TABLE OF CONTENTS

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

A

Safety Messages ...................................................................................................................................................iii

Warranty ................................................................................................................................................................ v

About This Manual................................................................................................................................................vii

Table of Contents ................................................................................................................................................. ix

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

1.1. T802 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 T802 Analyzer ......................................................................................................................23

3.1.1. Ventilation Clearance ............................................................................................................................ 25

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

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

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....................................................................................... 52

3.4.1. Startup ...................................................................................................................................................52

3.4.2. Functional Checks ................................................................................................................................. 54

3.4.3. Initial Calibration .................................................................................................................................... 55

4. BASIC OPERATION...........................................................................................................63

4.1. Overview of Operating Modes ...................................................................................................................... 63

4.2. Sample Mode................................................................................................................................................ 65

4.3. Calibration Mode...........................................................................................................................................66

4.4. Setup Mode ..................................................................................................................................................67

4.4.1. Primary Setup Menu.............................................................................................................................. 67

4.4.2. Secondary Setup Menu (Setup>More).................................................................................................. 68

5. SETUP MENU 69

5.1. SETUP  CFG: Configuration Information.................................................................................................. 69

5.2. SETUP  ACAL: [NOT USED] ....................................................................................................................69

5.3. SETUP  DAS: Internal Data Acquisition System ...................................................................................... 69

5.4. SETUP  RNGE: Analog Output Reporting Range Configuration.............................................................. 70

5.4.1. Physical Range versus Analog Output Reporting Ranges.................................................................... 70

5.4.2. Analog Output Ranges for O2 Concentration ........................................................................................71

5.4.3. Reporting Range Modes .......................................................................................................................72

5.4.4. SETUP RNGE  DIL: Using the Optional Dilution Ratio Feature..................................................... 77

5.5. SETUP  PASS: Password Feature ........................................................................................................... 78

5.6. SETUP  CLK: Setting the T802 Analyzer’s Internal Clock........................................................................ 81

5.6.1. Setting the Internal Clock’s Time and Day ............................................................................................81

5.6.2. Adjusting the Internal Clock’s Speed..................................................................................................... 82

5.7. SETUP  MORE COMM: Communication Ports..................................................................................... 83

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5.7.1. ID (Machine Identification)..................................................................................................................... 83

5.7.2. INET (Ethernet) .....................................................................................................................................84

5.7.3. COM1[COM2] (Mode, Baude Rate and Test Port) ...............................................................................85

5.8. SETUP  MORE  VARS: Internal Variables (VARS)............................................................................... 85

5.9. SETUP  MORE  DIAG: Diagnostics Functions.................................................................................... 88

5.9.1. Signal I/O............................................................................................................................................... 90

5.9.2. Analog Output........................................................................................................................................ 91

5.9.3. Analog I/O Configuration .......................................................................................................................91

5.9.4. Turning an Analog Output Over-Range Feature ON/OFF ..................................................................103

5.9.5. Adding a Recorder Offset to an Analog Output................................................................................... 104

5.9.6. Selecting a Test Channel Function for Output A4............................................................................... 105

5.9.7. AIN Calibration ....................................................................................................................................107

5.9.8. Analog Inputs (XIN1…XIN8) Option Configuration .............................................................................108

5.10. SETUP MORE  ALRM: Using the Gas Concentration Alarms (Option 61)....................................... 109

5.10.1. Setting the T802 Option 61 Concentration Alarm Limits................................................................... 110

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6. COMMUNICATIONS SETUP AND OPERATION.............................................................113

6.1. Data Terminal/Communication Equipment (DTE DCE) ...................................................................................113

6.2. Communication Modes, Baud Rate and Port Testing ................................................................................113

6.2.1. COM Port Communication Modes....................................................................................................... 114

6.2.2. COM Port Baud Rate ..........................................................................................................................116

6.2.3. COM Port Testing................................................................................................................................117

6.3. Remote Access via the Ethernet ................................................................................................................118

6.3.1. Configuring the Ethernet Interface using DHCP .................................................................................118

6.3.2. Manually Configuring the Network IP Addresses................................................................................121

6.4. USB Port for Remote Access .....................................................................................................................124

6.5. Communications Protocols......................................................................................................................... 126

6.5.1. MODBUS Setup ..................................................................................................................................126

6.5.2. Hessen ................................................................................................................................................128

7. DATA ACQUISITION SYSTEM (DAS) & APICOM.............................................................138

7.1. DAS Structure.............................................................................................................................................139

7.1.1. DAS Channels ..................................................................................................................................... 139

7.1.2. Default DAS Channels.........................................................................................................................140

7.1.3. SETUP DAS VIEW: Viewing DAS Channels and Individual Records......................................... 143

7.1.4. SETUP DAS EDIT: Accessing the DAS Edit Mode ....................................................................144

7.2. Remote DAS Configuration ........................................................................................................................157

7.2.1. DAS Configuration via APICOM..........................................................................................................157

7.2.2. DAS Configuration via Terminal Emulation Programs ........................................................................159

8. REMOTE OPERATION.....................................................................................................160

8.1. Computer Mode.......................................................................................................................................... 160

8.1.1. Remote Control via APICOM ..............................................................................................................160

8.2. Interactive Mode .........................................................................................................................................161

8.2.1. Remote Control via a Terminal Emulation Program............................................................................ 161

8.3. Remote Access by Modem......................................................................................................................... 164

8.4. COM Port Password Security..................................................................................................................... 166

9. CALIBRATION PROCEDURES .......................................................................................169

9.1. Before Calibration....................................................................................................................................... 170

9.1.1. Required Equipment, Supplies, and Expendables.............................................................................. 170

9.1.2. Calibration Gases................................................................................................................................ 170

9.1.3. Data Recording Devices...................................................................................................................... 171

9.2. Manual Calibration Checks and Calibration ...............................................................................................172

9.2.1. Setup for Basic Calibration Checks and Calibration ...........................................................................172

9.2.2. Performing a Basic Manual Calibration Check.................................................................................... 173

9.2.3. Performing a Basic Manual Calibration............................................................................................... 174

9.3. Assessing Calibration Quality..................................................................................................................... 176

9.4. Calibration of the T802’s Electronic Subsystems .......................................................................................176

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9.4.1. Pressure Calibration............................................................................................................................ 176

9.4.2. Flow Calibration...................................................................................................................................178

9.5. Calibration of the Optional CO2 Sensor...................................................................................................... 179

9.5.1. CO2 Calibration Setup .........................................................................................................................179

9.5.2. Set CO2 Span Gas Concentration....................................................................................................... 179

9.5.3. Activate CO2 Sensor Stability Function ...............................................................................................180

9.5.4. CO2 Zero/Span Calibration:................................................................................................................. 181

10. MAINTENANCE SCHEDULE & PROCEDURES...........................................................185

10.1. Maintenance Schedule .............................................................................................................................185

10.2. Predictive Diagnostics ..............................................................................................................................189

10.3. Maintenance Procedures.......................................................................................................................... 189

10.3.1. Replacing the Sample Particulate Filter ............................................................................................189

10.3.2. Rebuilding the Sample Pump............................................................................................................190

10.3.3. Performing Leak Checks ...................................................................................................................191

10.3.4. Performing a Sample Flow Check.....................................................................................................192

10.3.5. Cleaning the Optical Bench............................................................................................................... 193

10.3.6. Cleaning Exterior Surfaces of the T802 ............................................................................................ 193

11. TROUBLESHOOTING AND SERVICE..........................................................................195

11.1. General Troubleshooting .......................................................................................................................... 195

11.1.1. Fault Diagnosis with WARNING Messages ......................................................................................196

11.1.2. Fault Diagnosis with TEST Functions ...............................................................................................199

11.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function .....................................................200

11.2. Using the Internal Electronic Status LEDs ...............................................................................................202

11.2.1. CPU Status Indicator......................................................................................................................... 202

11.2.2. Relay PCA Status Indicators .............................................................................................................202

11.3. Gas Flow Problems ..................................................................................................................................203

11.3.1. T802 Internal Gas Flow Diagrams.....................................................................................................204

11.3.2. Typical Sample Gas Flow Problems .................................................................................................205

11.4. Calibration Problems ................................................................................................................................207

11.4.1. Miscalibrated .....................................................................................................................................207

11.4.2. Non-Repeatable Zero and Span ....................................................................................................... 207

11.4.3. Inability to Span – No SPAN Button .................................................................................................. 208

11.4.4. Inability to Zero – No ZERO Button...................................................................................................208

11.5. Other Performance Problems................................................................................................................... 208

11.5.1. Temperature Problems...................................................................................................................... 208

11.6. Subsystem Checkout................................................................................................................................ 209

11.6.1. AC Mains Configuration ....................................................................................................................209

11.6.2. DC Power Supply ..............................................................................................................................209

11.6.3. I2C Bus...............................................................................................................................................210

11.6.4. Touchscreen Interface....................................................................................................................... 210

11.6.5. LCD Display Module.......................................................................................................................... 210

11.6.6. Relay Board.......................................................................................................................................211

11.6.7. Sensor Assembly............................................................................................................................... 211

11.6.8. Pressure/Flow Sensor Assembly ......................................................................................................211

11.6.9. Motherboard ......................................................................................................................................212

11.6.10. CPU .................................................................................................................................................213

11.6.11. RS-232 Communications ................................................................................................................214

11.6.12. Optional CO2 Sensor .......................................................................................................................215

11.7. Repair Procedures.................................................................................................................................... 215

11.7.1. Repairing Sample Flow Control Assembly........................................................................................ 215

11.7.2. Disk-On-Module Replacement Procedure ........................................................................................216

11.8. FAQ’s........................................................................................................................................................ 217

11.9. Technical Assistance................................................................................................................................ 218

12. PRINCIPLES OF OPERATION ......................................................................................219

12.1. Paramagnetic Oxygen Measurement....................................................................................................... 219

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12.1.1. Magnetic Properties of O2 Gas.......................................................................................................... 219

12.1.2. Principle of Measurement.................................................................................................................. 219

12.2. NDIR Measurement of CO2......................................................................................................................221

12.2.1. Operation within the T802 Analyzer ..................................................................................................222

12.3. Pneumatic Operation................................................................................................................................ 222

12.3.1. Pneumatic Operation of the CO2 Sensor ..........................................................................................223

12.4. Flow Rate Control..................................................................................................................................... 224

12.4.1. Critical Flow Orifice............................................................................................................................224

12.4.2. Particulate Filter.................................................................................................................................225

12.4.3. Pneumatic Sensors ...........................................................................................................................225

12.5. Electronic Operation .................................................................................................................................226

12.5.1. Overview............................................................................................................................................ 226

12.5.2. Electronic Operation of the CO2 Sensor............................................................................................ 227

12.5.3. Central Processing Unit (CPU).......................................................................................................... 228

12.5.4. Relay Board.......................................................................................................................................229

12.5.5. Heater Control ...................................................................................................................................232

12.5.6. Motherboard ......................................................................................................................................232

12.5.7. Front Panel Touch Screen/Display Interface ....................................................................................235

12.5.8. Software Operation............................................................................................................................237

12.5.9. Adaptive Filter....................................................................................................................................237

12.5.10. Calibration - Slope and Offset .........................................................................................................238

12.5.11. Temperature and Pressure Compensation .....................................................................................238

12.5.12. Internal Data Acquisition System (DAS) .........................................................................................238

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13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................239

13.1. How Static Charges are Created..............................................................................................................239

13.2. How Electro-Static Charges Cause Damage ...........................................................................................240

13.3. Common Myths About ESD Damage ....................................................................................................... 241

13.4. Basic Principles of Static Control.............................................................................................................. 242

13.4.1. General Rules....................................................................................................................................242

13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance.................................................. 244

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–Basic Configuration–Using Bottled Span Gas ....................... 48

Figure 3-17: T802 Internal Gas Flow (Basic Configuration) ............................................................... 50

Figure 3-18: T802 – Internal Gas Flow with CO2 Sensor Option........................................................ 51

Figure 3-19: Viewing and Clearing T802 WARNING Messages ........................................................ 53

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Figure 4-1: Front Panel Touchscreen and Display ...........................................................................64

Figure 4-2: Viewing Test Functions ..................................................................................................65

Figure 5-1: Analog Output Connector Pin Out.................................................................................. 71

Figure 5-2: Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 98

Figure 5-3: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter ....100

Figure 5-4: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels... 102

Figure 7-1: Default DAS Channel Setup......................................................................................... 142

Figure 7-2: APICOM Remote Control Program Interface ...............................................................157

Figure 7-3: APICOM User Interface for Configuring the DAS ........................................................ 158

Figure 7-4: DAS Configuration through a Terminal Emulation Program ........................................ 159

Figure 9-1: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................... 172

Figure 9-2: CO2 Sensor Calibration Set Up ....................................................................................179

Figure 10-1: Sample Particulate Filter Assembly.............................................................................. 190

Figure 11-1: Viewing and Clearing Warning Messages ................................................................... 198

Figure 11-2: Example of Signal I/O Function.................................................................................... 201

Figure 11-3: CPU Status Indicator.................................................................................................... 202

Figure 11-4: Relay PCA Status LEDS Used for Troubleshooting..................................................... 203

Figure 11-5: T802– Basic Internal Gas Flow .................................................................................... 204

Figure 11-6: T802 – Internal Pneumatics with CO2 Sensor Option 67 .............................................205

Figure 11-7: Location of Diagnostic LEDs on CO2 Sensor PCA....................................................... 215

Figure 11-8: Critical Flow Restrictor Assembly / Disassembly .........................................................216

Figure 12-1: Paramagnetic O2 Sensor Design ................................................................................. 220

Figure 12-2: Paramagnetic O2 Sensor Block Diagram ..................................................................... 220

Figure 12-3: CO2 Sensor Theory of Operation .................................................................................221

Figure 12-4: T802 – Internal Pneumatic Flow – Basic Configuration ............................................... 223

Figure 12-5: T802 – Internal Pneumatic Flow with CO2 Sensor Option ........................................... 224

Figure 12-6: Flow Control Assembly & Critical Flow Orifice ............................................................. 225

Figure 12-7: T802 Electronic Block Diagram.................................................................................... 227

Figure 12-8: CO2 Sensor Option PCA Layout and Electronic Connections .....................................228

Figure 12-9. CPU Card ..................................................................................................................... 229

Figure 12-10: Relay PCA Layout (PN 04135)..................................................................................... 230

Figure 12-11: Relay PCA with AC Relay Retainer in Place................................................................ 231

Figure 12-12: Status LED Locations – Relay PCA ............................................................................. 232

Figure 12-13: Power Distribution Block Diagram................................................................................ 235

Figure 12-14: Front Panel and Display Interface Block Diagram .......................................................236

Figure 12-15: Basic Software Operation............................................................................................. 237

Figure 13-1: Triboelectric Charging ..................................................................................................239

Figure 13-2: Basic Anti-ESD Workbench.......................................................................................... 242

LIST OF TABLES

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

Table 2-1: T802 Specifications ........................................................................................................21

Table 3-1: Ventilation Clearance .....................................................................................................25

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: NISTSRMs Available for Traceability of O2 Calibration Gases ....................................... 47

Table 3-9: Front Panel Display during System Warm-Up ............................................................... 52

Table 4-1: Analyzer Operating Modes............................................................................................. 64

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Table 4-2: Test Functions Defined .................................................................................................. 66

Table 6-4: Primary Setup Mode Features and Functions................................................................ 67

Table 6-5: Secondary Setup Mode Features and Functions........................................................... 68

Table 5-2: Variable Names (VARS)................................................................................................. 86

Table 5-3: Diagnostic Mode (DIAG) Functions................................................................................ 88

Table 5-4: DIAG - Analog I/O Functions.......................................................................................... 91

Table 5-5: Analog Output Voltage Range Min/Max......................................................................... 93

Table 5-6: Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 98

Table 5-7: Current Loop Output Check .........................................................................................102

Table 5-8: Test Channels Functions available on the T802’s Analog Output ...............................105

Table 5-9: O2 Concentration Alarm Default Settings .....................................................................109

Table 6-1: COM Port Communication Modes................................................................................ 114

Table 6-2: Ethernet Status Indicators ............................................................................................118

Table 6-3: LAN/Internet Configuration Properties .........................................................................119

Table 6-4: RS-232 Communication Parameters for Hessen Protocol........................................... 128

Table 6-5: Teledyne API Hessen Protocol Response Modes .......................................................131

Table 6-6: Default Hessen Status Flag Assignments.................................................................... 135

Table 7-1: Front Panel LED Status Indicators for DAS ................................................................. 138

Table 7-2: DAS Data Channel Properties...................................................................................... 140

Table 7-3: DAS Data Parameter Functions ...................................................................................147

Table 8-2: Teledyne API Serial I/O Command Types ...................................................................162

Table 9-1: NISTSRM's Available for Traceability of O2 Calibration Gases..................................... 171

Table 9-2: Calibration Data Quality Evaluation.............................................................................. 176

Table 10-1. T802 Maintenance Schedule........................................................................................ 187

Table 10-2: T802 Test Function Record ..........................................................................................188

Table 10-3: Predictive uses for Test Functions ...............................................................................189

Table 11-1: Warning Messages - Indicated Failures .......................................................................198

Table 11-2: Test Functions - Indicated Failures ..............................................................................200

Table 11-3: Relay PCA Watchdog LED Failure Indications ............................................................202

Table 11-4: Relay PCA Status LED Failure Indications .................................................................. 203

Table 11-5: DC Power Test Point and Wiring Color Codes ............................................................ 209

Table 11-6: DC Power Supply Acceptable Levels........................................................................... 210

Table 11-7: Analog Output Test Function - Nominal Values Current Outputs ................................ 212

Table 11-8: Status Outputs Check .................................................................................................. 213

Table 12-1: Relay PCA Status LEDs ...............................................................................................231

Table 13-1: Static Generation Voltages for Typical Activities.......................................................... 240

Table 13-2: Sensitivity of Electronic Devices to Damage by ESD................................................... 240

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION

A-1 - T802 Software Menu Trees
A-2 - T802 Setup Variables for Serial I/O
A-3 - T802 Warnings and Test Functions
A-4 - T802 Signal I/O Definitions
A-5 - T802 DAS Functions
A-6 - T802 Terminal Command Designators

A-7 - T802 MODBUS
APPENDIX B - T802 SPARE PARTS LIST
APPENDIX C – T802 REPAIR QUESTIONNAIRE
APPENDIX D – T802 ELECTRONIC SCHEMATICS

xiv

®

Register Map

07275B DCN6418

PART I

–

GENERAL INFORMATION AND SETUP

15

Section 1 General Information Teledyne API T802 Paramagnetic O

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Analyzer Operation Manual

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07275B DCN6418

1. INTRODUCTION, FEATURES AND OPTIONS

1.1. T802 OVERVIEW

The Model T802 (also referred to as T802) Paramagnetic Oxygen Analyzer is a
microprocessor-controlled analyzer that determines the concentration of
molecular oxygen (O
paramagnetic sensor that relies on the relatively high reactivity of O
to magnetic fields to generate a current that is proportional to the amount of O
present in the sensor chamber.

The T802 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
the 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 the serial port or optional
Ethernet port via our APICOM software or from the front panel, 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 a sample gas drawn through the instrument. It uses a

2

molecules

2

2

1.2. FEATURES

Some exceptional features of your T802 Paramagnetic Oxygen Analyzer are:

 Non-depleting, paramagnetic sensor for O2 specific measurement:

 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, RS-232, and 10BaseT/100BaseT Ethernet ports for

 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 0-100.0%, user adjustable

 Virtually no cross-sensitivities
 Rapid response times
 No consumable parts
 Consistent performance over time
 No susceptibility to CO2 poisoning (unlike electromechanical O2 sensors)

remote operation (optional RS-485)

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Introduction, Features and Options Teledyne API T802 Paramagnetic O

07275B DCN6418

HAZARD

Strong Oxidizer

OXYGEN IS A STRONG OXIDIZER.

This is a general purpose instrument designed for usage in nonhazardous areas. Ensure
that all safety precautions related combustible gases are followed.

Before working with the casing open, be sure to turn off power to the analyzer, and
perform air or N2 gas purging of not only the analyzer inside, but also the sample gas line.

In addition, carefully prevent oil and grease from adhering to any tubing. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.

1.3. OPTIONS

Table 1-1 presents the options available with the T802 analyzer. For assistance
with ordering, please contact the Sales department of Teledyne API at:

Analyzer Operation Manual

2

PHONE (toll free,
North America)

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

Table 1-1. Analyzer Options

Option

Pumps

Rack Mount
Kits

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

800-324-5190

858-657-9816

858-657-9800

[e-mail]

www.teledyne-api.com

Description/Notes Reference

18

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07275B DCN6418

Analyzer Operation Manual Introduction, Features and Options

2

Option

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

29

Option

Number

Description/Notes Reference

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.

N/A

CAUTION - GENERAL SAFETY HAZARD

THE T802 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

Current Loop Analog
Outputs

41

Parts Kits Spare parts and expendables

42A

42D

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

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).

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).

Sections 3.3.1.2
and 5.9.8

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

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Introduction, Features and Options Teledyne API T802 Paramagnetic O

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Analyzer Operation Manual

2

Option

USB COM Port

64A

Second Gas Sensor

67A Carbon Dioxide (CO2) Sensor 0-20%

Special Features Built in features, software activated

N/A

N/A

N/A

Option

Number

Description/Notes Reference

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.

Sections 3.3.1.8 and

6.4

Sections 9.5, 12.2,

12.2.1 and 12.3.1

N/A

N/A

Sections 3.4.3.2
and 5.4.4

20

07275B DCN6418

2. SPECIFICATIONS, APPROVALS & COMPLIANCE

2.1. SPECIFICATIONS

Table 2-1: T802 Specifications

PARAMETER SPECIFICATION

O2 Sensor

Ranges

Zero Noise1
Span Noise1
Lower Detectable Limit2
Zero Drift3
Span Drift
Accuracy
Linearity
Temperature Coefficient

CO2 Sensor Option

Ranges Min: 0-1% Full scale

Zero Noise1
Span Noise1
Lower Detectable Limit2
Zero Drift
Span Drift
Accuracy
Temperature Coefficient

Rise and Fall Time

Flow Rate

Humidity Range

Pressure Range
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 2 opto-isolated alarms outputs with user settable alarm limits

1

As defined by the USEPA.

2

Defined as twice the Zero Noise level by the USEPA.

3

Note: Zero Drift is typically < 0.1% O2 during the first 24 hours of operation.

Min: 0-1% Full scale
Max: 0-100% Full scale (user selectable)
< 0.02% (RMS)

< 0.05% of reading (RMS)
< 0.04%
< ±0.02%/24 hours; < ±0.05%/7 days
< ±0.1%/7 days
< ±0.1%
< ±0.1%
< ±0.01%/degree C

Max: 0-20% Full scale (user selectable; dual ranges and auto ranging supported)
< 0.02% (RMS)

< 0.1% of reading (RMS)
< 0.04%
< ±0.02%/24 hours; < ±0.05%/7 days
< ±0.1%/7 days
< ±(1.5% of range +2% of reading)
< ±0.01%/degree C
<60 seconds to 95%

120ml ±20ml/min

0-95% RH

25-31 in HG
100V – 120V 60 Hz (77W); 220V – 240 V 50 Hz (80W)

All Outputs: 0.1 V, 1 V, 5 V or 10 V

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
3 4-20mA current outputs

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Specifications, Approvals & Compliance Teledyne API T802 Paramagnetic O

07275B DCN6418

2.2. APPROVALS AND CERTIFICATIONS

The Teledyne API Model T802 Paramagnet Oxygen 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

Analyzer Operation Manual

2

2.2.3. OTHER TYPE CERTIFICATIONS

For additional certifications, please contact Technical Support:

Toll-free Phone:

Phone:

Email:

800-324-5190

858-657-9800

Fax:

858-657-9816

[e-mail]

22

07275B DCN6418

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 T802 ANALYZER

CAUTION

GENERAL SAFETY HAZARD

To avoid personal injury, always use two persons to lift and carry the T802.

CAUTION – AVOID WARRANTY INVALIDATION

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

See A Primer on Electro-Static Discharge in this manual for more information on

preventing ESD damage.

CAUTION!

Do not operate this instrument until removing dust plugs from SAMPLE and
EXHAUST ports on the rear panel!

Note Teledyne API recommends that you store shipping containers/materials

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

23

Section II Operating Instructions Teledyne API T802 Paramagnetic O

07275B DCN6418

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, Final Test and Validation Data Sheet, PN 068350000, is an

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

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 make sure all circuit boards and other
components are in good shape and properly seated.

Analyzer Operation Manual

2

3. Check that the connectors of the various internal wiring harnesses and
pneumatic hoses 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.

24

Teledyne API T802 Paramagnetic O

07275B DCN6418

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 MINIMUM REQUIRED CLEARANCE

Back of the instrument 4 in.

Sides of the instrument 1 in.

Above and below the instrument 1 in.

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

3.2. INSTRUMENT LAYOUT

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

Analyzer Operation Manual

2

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 3-3. 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

25

Section II Operating Instructions Teledyne API T802 Paramagnetic O

07275B DCN6418

Analyzer Operation Manual

2

ATTENTION

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 LEDs on the display screen 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.

COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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

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Teledyne API T802 Paramagnetic O

07275B DCN6418

Table 3-2. Display Screen and Touch Control Description

Field Description/Function

Analyzer Operation Manual

2

Status

Conc

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

Param

Control Buttons Displays dynamic, context sensitive labels on each button, which is 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.

27

Section II Operating Instructions Teledyne API T802 Paramagnetic O

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Analyzer Operation Manual

2

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

28