Teledyne T803 User Manual

OPERATION MANUAL

MODEL T803

CO2/O2 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 07276B DCN 6418
Teledyne Advanced Pollution Instrumentation 14 January 2013

07276B 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

or contact [e-mail].

NOTICE OF COPYRIGHT

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

TRADEMARKS

, NOX and Ozone.

2

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

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.

For Technical Assistance regarding the use and maintenance of this instrument or any

other Teledyne API product, contact Teledyne API’s Technical Support Department:

or access any of the service options on our website at http://www.teledyne-api.com/

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)!

Note

Telephone: [phone]

Email: [e-mail]

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CONSIGNES DE SÉCURITÉ

Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter
des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes.
Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes
se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes
suivantes :

AVERTISSEMENT : Risque de choc électrique

DANGER : Oxydant puissant

AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne

complémentaire pour des renseignements spécifiques

MISE EN GARDE : Surface chaude

Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou

sans les outils appropriés pourrait entraîner des dommages aux pièces ou à
l’instrument.

Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent
être effectuées uniquement par du personnel de maintenance qualifié.

Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central
de la mise à la terre sécuritaire de l’instrument.

MISE EN GARDE

Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce
manuel. Si vous utilisez cet instrument d’une autre manière que celle pour
laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible
et entraîner des conséquences dangereuses.

NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!

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WARRANTY

WARRANTY POLICY (02024F)

Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne
Instruments, Inc., provides that:

Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should
equipment failure occur, TAPI assures its customers that prompt service and support
will be available.

COVERAGE

After the warranty period and throughout the equipment lifetime, TAPI stands ready
to provide on-site or in-plant service at reasonable rates similar to those of other
manufacturers in the industry. All maintenance and the first level of field
troubleshooting are to be performed by the customer.

NON-TAPI MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by TAPI is warranted and will be repaired
to the extent and according to the current terms and conditions of the respective
equipment manufacturer’s warranty.

PRODUCT RETURN

All units or components returned to Teledyne API should be properly packed for
handling and returned freight prepaid to the nearest designated Service Center.
After the repair, the equipment will be returned, freight prepaid.

The complete Terms and Conditions of Sale can be reviewed at

http://www.teledyne-api.com/terms_and_conditions.asp

CAUTION – Avoid Warranty Invalidation

Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and
packing instructions and Return Merchandise Authorization (RMA) procedures
when returning parts for repair or calibration may void your warranty. For anti­ESD handling and packing instructions please refer to “Packing Components for

Return to Teledyne API’s Technical Support” in the Primer on Electro-Static
Discharge section of this manual, and for RMA procedures please refer to our

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

under Customer Support > Return

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ABOUT THIS MANUAL

This T803 Operation Manual, PN 07276, is comprised of multiple documents in PDF
format, as listed below.

Part No. Rev Name/Description

06759 B T803 Operation Manual, top level assy

06763 C Appendix A Menu Trees, software version A.2 (E-Series), 1.0.0 (T-Series)

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

06532 B Warranty / Repair Form, Appendix C

Documents included in Appendix D

06294 A Interconnect Wire List

06407 A Interconnect Diagram

05803

06698

06882

06731

Note

B

D

B

A

ORGANIZATION

SCH, PCA 05802, MOTHERBOARD, GEN-5

SCH, PCA 06697, INTRFC, LCD TCH SCRN,

SCH, LVDS TRANSMITTER BOARD

SCH, AUXILLIARY-I/O BOARD

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

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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REVISION HISTORY

T803 Operation and Maintenance Manual, PN07276

Date Rev DCN Description

2013 January 14 B 6418 Administrative updates and Specs corrections
2011 March 11 A 6006 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

Revision History...............................................................................................................................................viii

1. INTRODUCTION, FEATUERES, AND OPTIONS ..............................................................17

1.1. T803 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 T803 Analyzer ......................................................................................................................23

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

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. Warm Up ...............................................................................................................................................50

3.5. Warning Messages....................................................................................................................................... 50

3.5.1. Functional Check...................................................................................................................................52

3.5.2. Initial Calibration .................................................................................................................................... 53

4. BASIC OPERATION...........................................................................................................57

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

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

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

4.4. Setup MODE................................................................................................................................................. 61

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

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

5.2. S ETUP  ACAL: [NOT USED] ...................................................................................................................63

5.3. SETUP  DAS: Internal Data Acquisition System ...................................................................................... 63

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

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

5.4.2. Analog Output Ranges for CO2 and O2 Concentration .........................................................................65

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

5.4.4. SETUP RNGE  DIL: Using the Optional Dilution Ratio Feature..................................................... 71

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

5.6. SETUP  CLK: Setting the T803 Analyzer’s Internal Clock........................................................................ 75

5.6.1. Setting the Internal Clock’s Time and Day ............................................................................................75

5.6.2. Adjusting the Internal Clock’s Speed..................................................................................................... 75

5.7. SETUP  MORE COMM .........................................................................................................................77

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5.8. SETUP  MORE  VARS: Internal Variables (VARS)............................................................................... 77

5.9. SETUP  MORE  DIAG: Using the Diagnostics Functions ....................................................................80

5.9.1. Accessing the Diagnostic Features ....................................................................................................... 81

5.10. Using the T803 Analyzer’s Analog Outputs................................................................................................ 82

5.10.1. Accessing the Analog Output Signal Configuration Submenu............................................................ 82

5.10.2. Analog Output Voltage / Current Range Selection.............................................................................. 84

5.10.3. Calibration of the Analog Outputs .......................................................................................................85

5.10.4. Turning an Analog Output Over-Range Feature ON/OFF ..................................................................94

5.10.5. Adding a Recorder Offset to an Analog Output................................................................................... 95

5.10.6. Selecting a Test Channel Function for Output A4............................................................................... 96

5.10.7. AIN Calibration ....................................................................................................................................98

5.10.8. Analog Inputs (XIN1…XIN8) Option Configuration .............................................................................99

5.11. SETUP MORE  ALRM: Using the Gas Concentration Alarms (Option 61)....................................... 100

5.11.1. Setting the T803 Option 61 Concentration Alarm Limits................................................................... 101

6. COMMUNICATIONS SETUP AND OPERATION.............................................................103

6.1. Data Terminal/Communication Equipment (DTE DCE) .................................................................................... 103

6.2. Communication Modes, Baud Rate and Port Testing ................................................................................103

6.2.1. COM Port Communication Modes....................................................................................................... 103

6.2.2. COM Port Baud Rate ..........................................................................................................................106

6.2.3. COM Port Testing................................................................................................................................107

6.2.4. Machine ID ..........................................................................................................................................108

6.3. Remote Access via the Ethernet ................................................................................................................109

6.3.1. Configuring the Ethernet using DHCP.................................................................................................109

6.3.2. Manually Configuring the Network IP Addresses................................................................................112

6.3.3. Changing the Analyzer’s HOSTNAME................................................................................................ 114

6.4. USB Port for Remote Access ..................................................................................................................... 115

6.5. Communications Protocols......................................................................................................................... 117

6.5.1. MODBUS Setup ..................................................................................................................................117

6.5.2. Hessen ................................................................................................................................................118

6.5.3. Setting Hessen Protocol Status Flags.................................................................................................126

6.5.4. Instrument ID Code .............................................................................................................................128

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

7.1. SETUP  DAS: Using the Data Acquisition System (DAS) ......................................................................129

7.1.1. DAS Status .......................................................................................................................................... 130

7.1.2. DAS Structure...................................................................................................................................... 130

7.1.3. Default DAS Channels.........................................................................................................................131

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

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

7.1.6. Disabling/Enabling Data Channels......................................................................................................147

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

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

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

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

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

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

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

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 of the T803 Analyzer............................................................. 162

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

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

9.2.3. Performing a Manual Calibration.........................................................................................................163

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

9.4. Calibration of the T803’s Electronic Subsystems .......................................................................................167

9.4.1. Pressure Calibration............................................................................................................................ 167

9.4.2. Flow Calibration...................................................................................................................................169

10. MAINTENANCE SCHEDULE & PROCEDURES...........................................................173

10.1. Maintenance Schedule .............................................................................................................................173

10.2. Predictive Diagnostics ..............................................................................................................................177

10.3. Maintenance Procedures.......................................................................................................................... 177

10.3.1. Replacing the Sample Particulate Filter ............................................................................................177

10.3.2. Rebuilding the Sample Pump............................................................................................................178

10.3.3. Performing Leak Checks ...................................................................................................................179

10.3.4. Performing a Sample Flow Check.....................................................................................................180

10.3.5. Cleaning Exterior Surfaces of the T803 ............................................................................................ 180

11. TROUBLESHOOTING AND SERVICE..........................................................................181

11.1. General Troubleshooting .......................................................................................................................... 181

11.1.1. Fault Diagnosis with WARNING Messages ......................................................................................182

11.1.2. Fault Diagnosis with TEST Functions ...............................................................................................185

11.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function .....................................................186

11.2. Using the Internal Electronic Status LEDs ...............................................................................................188

11.2.1. CPU Status Indicator......................................................................................................................... 188

11.2.2. Relay PCA Status Indicators ............................................................................................................. 188

11.3. Gas Flow Problems ..................................................................................................................................190

11.3.1. T803 Internal Gas Flow Diagrams.....................................................................................................190

11.3.2. Typical Sample Gas Flow Problems .................................................................................................191

11.4. Calibration Problems ................................................................................................................................ 192

11.4.1. Miscalibrated .....................................................................................................................................192

11.4.2. Non-Repeatable Zero and Span ....................................................................................................... 193

11.4.3. Inability to Span – No SPAN Button .................................................................................................. 193

11.4.4. Inability to Zero – No ZERO Button...................................................................................................193

11.5. Other Performance Problems...................................................................................................................193

11.5.1. Temperature Problems...................................................................................................................... 194

11.6. Subsystem Checkout................................................................................................................................ 194

11.6.1. AC Mains Configuration ....................................................................................................................194

11.6.2. DC Power Supply ..............................................................................................................................194

11.6.3. I2C Bus...............................................................................................................................................195

11.6.4. Touchscreen Interface....................................................................................................................... 195

11.6.5. LCD Display Module.......................................................................................................................... 196

11.6.6. Relay Board.......................................................................................................................................196

11.6.7. Sensor Assembly............................................................................................................................... 196

11.6.8. Pressure/Flow Sensor Assembly ......................................................................................................196

11.6.9. Motherboard ......................................................................................................................................198

11.6.10. CPU .................................................................................................................................................199

11.6.11. RS-232 Communications ................................................................................................................200

11.6.12. CO2 Sensor STATUS LED’s............................................................................................................201

11.7. Repair Procedures.................................................................................................................................... 201

11.7.1. Repairing Sample Flow Control Assembly........................................................................................ 201

11.7.2. Disk-On-Module Replacement Procedure ........................................................................................202

11.8. FRequently Asked Questions (FAQ’s)...................................................................................................... 203

11.9. Technical Assistance................................................................................................................................ 204

12. PRINCIPLES OF OPERATION ......................................................................................205

12.1. O2 Sensor .................................................................................................................................................205

12.1.1. Magnetic Properties of O2 Gas.......................................................................................................... 205

12.1.2. Paramagnetic Measurement of O2....................................................................................................205

12.2. CO2 Sensor ...............................................................................................................................................207

12.2.1. NDIR Measurement of CO2...............................................................................................................207

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12.3. Operation within the T803 Analyzer .........................................................................................................208

12.4. Pneumatic Operation................................................................................................................................ 209

12.5. Flow Rate Control..................................................................................................................................... 210

12.5.1. Critical Flow Orifice............................................................................................................................210

12.5.2. Particulate Filter.................................................................................................................................211

12.5.3. Pneumatic Sensors ...........................................................................................................................211

12.6. Electronic Operation .................................................................................................................................212

12.6.1. Overview............................................................................................................................................ 212

12.6.2. Central Processing Unit (CPU).......................................................................................................... 213

12.6.3. Relay Board.......................................................................................................................................215

12.6.4. Heater Control ...................................................................................................................................217

12.6.5. Motherboard ......................................................................................................................................218

12.6.6. I2C Data Bus...................................................................................................................................... 219

12.6.7. Power Supply / Circuit Breaker .........................................................................................................220

12.6.8. Front Panel Touchscreen/Display Interface ...................................................................................... 221

12.6.9. Software Operation............................................................................................................................222

12.6.10. Adaptive Filter.................................................................................................................................. 222

12.6.11. Calibration - Slope and Offset .........................................................................................................223

12.6.12. Temperature and Pressure Compensation .....................................................................................223

12.6.13. Internal Data Acquisition System (DAS) .........................................................................................223

13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................225

13.1. How Static Charges are Created..............................................................................................................225

13.2. How Electro-Static Charges Cause Damage ........................................................................................... 226

13.3. Common Myths About ESD Damage ....................................................................................................... 227

13.4. Basic Principles of Static Control.............................................................................................................. 228

13.4.1. General Rules....................................................................................................................................228

13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance.................................................. 229

INDEX............................................................................................................................................................ 237

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: T803 Internal Gas Flow .................................................................................................. 49

Figure 3-18: Viewing and Clearing T803 WARNING Messages ........................................................52

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

Figure 4-2: Viewing T803 Test Functions ......................................................................................... 59

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

Figure 5-2: Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 89

Figure 5-3: Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter ...... 91

Figure 5-4: Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels..... 93

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

Figure 10-1: Sample Particulate Filter Assembly.............................................................................. 178

Figure 11-1: Viewing and Clearing Warning Messages ................................................................... 184

Figure 11-2: Example of Signal I/O Function.................................................................................... 187

Figure 11-3: CPU Status Indicator .................................................................................................... 188

Figure 11-4: Relay PCA Status LEDs Used for Troubleshooting ..................................................... 189

Figure 11-5: T803 – Internal Gas Flow .............................................................................................190

Figure 11-6: Location of Diagnostic LEDs on CO2 Sensor PCA....................................................... 201

Figure 11-7: Critical Flow Restrictor Assembly / Disassembly .........................................................202

Figure 12-1: Paramagnetic O2 Sensor Design ................................................................................. 206

Figure 12-2: Paramagnetic O2 Sensor Block Diagram ..................................................................... 206

Figure 12-3. CO2 Sensor Theory of Operation .................................................................................207

Figure 12-4. CO2 Sensor PCA Layout and Electronic Connections................................................. 208

Figure 12-5: Internal Pneumatic Flow ............................................................................................... 209

Figure 12-6: Flow Control Assembly & Critical Flow Orifice ............................................................. 211

Figure 12-7: T803 Electronic Block Diagram .................................................................................... 213

Figure 12-8. CPU Card .....................................................................................................................214

Figure 12-9: Relay PCA Layout (PN 04135)..................................................................................... 215

Figure 12-10: Relay PCA with AC Relay Retainer in Place................................................................ 216

Figure 12-11: Status LED Locations – Relay PCA ............................................................................. 217

Figure 12-12: Power Distribution Block Diagram................................................................................ 220

Figure 12-13: Front Panel and Display Interface Block Diagram .......................................................221

Figure 12-14: Basic Software Operation............................................................................................. 222

Figure 13-1: Triboelectric Charging ..................................................................................................225

Figure 13-2: Basic Anti-ESD Workbench.......................................................................................... 228

LIST OF TABLES

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

Table 2-1: T803 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: Front Panel Display during System Warm-Up ............................................................... 50

Table 3-9: Warning Messages......................................................................................................... 51

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

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

Table 6-4: Primary Setup Mode Features and Functions................................................................ 61

Table 6-5: Secondary Setup Mode Features and Functions........................................................... 62

Table 5-6: Password Levels ............................................................................................................73

Table 5-1: Variable Names (VARS)................................................................................................. 78

Table 5-2: Diagnostic Mode (DIAG) Functions................................................................................ 80

Table 5-3: DIAG - Analog I/O Functions.......................................................................................... 82

Table 5-4: Analog Output Voltage Range Min/Max......................................................................... 84

Table 5-5: Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 89

Table 5-6: Current Loop Output Check ........................................................................................... 93

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Table 5-7: Test Channels Functions available on the T803’s Analog Output ................................. 96

Table 5-8: Concentration Alarm Default Settings .......................................................................... 100

Table 6-1: COM Port Communication Modes................................................................................ 104

Table 6-2: Ethernet Status Indicators ............................................................................................109

Table 6-3: LAN/Internet Configuration Properties .........................................................................110

Table 6-4: RS-232 Communication Parameters for Hessen Protocol........................................... 119

Table 6-5: Teledyne API Hessen Protocol Response Modes .......................................................122

Table 6-6: Default Hessen Status Flag Assignments.................................................................... 126

Table 7-1: SAMPLE LED Status Indicators for DAS .....................................................................130

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: NIST SRM's Available for Traceability of O2 Calibration Gases.................................... 161

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

Table 10-1: T803 Maintenance Schedule........................................................................................ 175

Table 10-2: T803 Test Function Record.......................................................................................... 176

Table 10-3: Predictive uses for Test Functions ............................................................................... 177

Table 11-1: Warning Messages - Indicated Failures....................................................................... 184

Table 11-2: Test Functions - Indicated Failures .............................................................................. 186

Table 11-3: Relay PCA Watchdog LED Failure Indications ............................................................ 188

Table 11-4: Relay PCA Status LED Failure Indications ..................................................................189

Table 11-5: DC Power Test Point and Wiring Color Codes ............................................................ 194

Table 11-6: DC Power Supply Acceptable Levels........................................................................... 195

Table 11-7: Analog Output Test Function - Nominal Values Current Outputs ................................ 198

Table 11-8: Status Outputs Check .................................................................................................. 199

Table 12-1: Relay PCA Status LEDs............................................................................................... 216

Table 13-1: Static Generation Voltages for Typical Activities.......................................................... 225

Table 13-2: Sensitivity of Electronic Devices to Damage by ESD................................................... 226

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION v. A.4 (E-Series); 1.0.3 (T-Series)

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

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

®

Register Map

xiv

07276B DCN6418

PART I

–

GENERAL INFORMATION AND SETUP

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1. INTRODUCTION, FEATUERES, AND OPTIONS

1.1. T803 OVERVIEW

The Model T803 Carbon Dioxide/Oxygen Analyzer (T803 CO2/O2 Analyzer) is
a microprocessor-controlled analyzer that determines the concentration of
molecular carbon dioxide (CO2) and oxygen (O2) in the sample gas drawn
through the instrument. It uses infrared absorption to measure CO2 concentration
and paramagnetic technology to measure O2 concentration.

The Model T803 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 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.

1.2. FEATURES

Some of the exceptional features of your T803 CO2 / O2 Analyzer are:

 Non-depleting, CO2/O2 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, RS-232, and 10/100Base-T Ethernet (optional USB and

 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

RS-485) ports for remote operation

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HAZARD

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 this 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

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

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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 T803 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 5.10.8

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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Option

USB COM Port

64A

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

N/A

N/A

Section 5.4.4

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2. SPECIFICATIONS, APPROVALS & COMPLIANCE

2.1. SPECIFICATIONS

Table 2-1: T803 Specifications

Parameter Description

CO2

Ranges Min: 0-1% Full scale

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

Zero Noise

Span Noise

Lower Detectable Limit2 <0.04%

Zero Drift <± 0.02% (24 hours); <± 0.05% (7 days)

Span Drift (7 days) <± 0.1%

Accuracy <± (1.5% of range + 2% of reading)

Temperature Coefficient <± 0.01% /°C

O2

Ranges Min: 0-1% Full scale

Zero Noise

Lower Detectable Limit2 <0.04%

Zero Drift 3 <± 0.02% (24 hours); <± 0.05% (7 days)

Span Noise

Span Drift (7 days) <± 0.1%

Accuracy <± 0.1%

Linearity <± 0.1 %

Temperature Coefficient <± 0.01% /°C

1

1

1

1

<0.02% (RMS)

< 0.1% of reading (RMS)

Max: 0-100% Full scale (user selectable)

<0.02% (RMS)

< 0.05% of reading (RMS)

Rise and Fall Time <60 seconds to 95%

Sample Flow Rate 120ml ± 20ml/min

Humidity Range 0-95% RH, Non-Condensing

Pressure Range 25-31 in•Hg

Temperature Range

Dimensions (HxWxD) 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)

Weight 28 lb (12.7 kg)

AC Power 100-120V 60 Hz (82W); 220-240V 50 Hz (94W)

Analog Output Ranges

Recorder Offset ± 10%

Analog Output Resolution 1 part in 4096 of selected full-scale voltage

5 - 40C operating

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

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Parameter Description

Standard I/O

Optional I/O 1 USB com port

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% O

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

during the first 24 hrs of operation

2

2.2. APPROVALS AND CERTIFICATIONS

The Teledyne API Model T803 Carbon Dioxide/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

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

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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 T803 ANALYZER

CAUTION

GENERAL SAFETY HAZARD

To avoid personal injury, always use two persons to lift and carry the T803.

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.

Verify that there is no apparent external shipping damage. If damage has
occurred, please advise the shipper first, then Teledyne API. Keep the shipping
container/packaging intact for the shipper’s examination.

Included with your analyzer is a printed record of the final performance
characterization performed on your instrument at the factory.

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This record, Final Test and Validation Data Sheet, PN 068360000 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.

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.

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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.

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: Front Panel Layout

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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 com

ponent 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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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, 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.

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

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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

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 analyzer’s model number, and provides voltage and frequency specifications

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

Connector for direct connection to personal computer, using USB cable.

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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 0)
connections for setup and preparing for instrument operation.

3.3.1. ELECTRICAL CONNECTIONS

CAUTION

ELECTRICAL SHOCK HAZARD

Never disconnect PCAs, wiring harnesses or electronic subassemblies while the

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.

analyzer is under power.

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

3.3.1.1. CONNECTING POWER

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.

High Voltages are present inside the analyzers case.
Power connection must have functioning ground connection.
Do not defeat the ground wire on power plug.
Turn off analyzer power before disconnecting or connecting electrical
subassemblies.
Do not operate with cover off.

CAUTION

ELECTRICAL SHOCK HAZARD

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CAUTION

GENERAL SAFETY HAZARD

The T803 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 tag (See
Figure 3-4) before plugging the T803 into line power.

3.3.1.2. ANALOG INPUTS (OPTION 64) CONNECTIONS

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 7.1 for details on setting up the DAS.

DAS

PARAMETER

1

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A

07276B DCN6418

3.3.1.3. ANALOG OUTPUT CONNECTIONS

The T803 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

concentration of the sample gas. If Dual or Auto

2

tputs a signal

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

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

2

Channel A3 outputs a signal proportional to the O

concentration of the sample

2

gas.

Channel A4 is special. It can be set by the user (see Section 5.10.6) to output any
one of the parame

ters 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.

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

Figure 3-7: Analog Output Connector

Table 3-5: Analog Output Pin-Outs

PIN ANALOG OUTPUT VOLTAGE SIGNAL CURRENT SIGNAL

1 V Out I Out +

2

3 V Out I Out +

4

5 V Out I Out +

6

7 V Out NA

8

NALOG OUT

A1

A2

A3

A4

Ground I Out -

Ground I Out -

Ground I Out -

Ground NA

3.3.1.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP

This option adds isolated, voltage-to-current conversion circuitry to the
analyzer’s analog outputs. This option may be ordered separately for any of the
analog outputs; it can be installed at the factory or added later. Call TELEDYNE
API Sales for pricing and availability.

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Figure 3-8: Current Loop Option Installed

CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD
VOLTAGE OUTPUTS

CAUTION

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.

3. Remove the top cover:

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Getting Started Teledyne API T803 CO2/O2 Analyzer Operation Manual

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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).

Each

connector, J19, J21 and J23, requires two shunts. Place one shunt on
the two left most pins and the second shunt on the two pins next to it (refer to
Figure 3-8 for an example).

6. Reatta

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

ch the top case to the analyzer.

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.

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:

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Teledyne API T803 CO2/O2 Analyzer Operation Manual Getting Started

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07276B DCN6418

1 2 3 4 5 6 7 8 D +

SYSTEM OK

CONC VALID

CAL MODE / MEAS MODE

STATUS

CAL MODE – RANGE 2

SPAN CAL / ZERO MODE

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

O2/O2 Sensor CAL

SPARE

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

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 O

CAL

2

CO

sensor is in calibration mode.

2

+

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

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,

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left). However, if full isolation is required, an external 5 VDC power supply
should be used (Figure 3-10, right).

A B C D E F U

SPAN/ZERO CAL

CAL/MEAS MODE

CONTROL IN

O2/CO2 CAL

RANGE SELECTION

+

A B C D E F U

SPAN/ZERO CAL

CAL/MEAS MODE

CONTROL IN

O2/CO2 CAL

RANGE SELECTION

-

Local Power Connections

Figure 3-10: Control Input Connector

Table 3-7: Control Input Signals

Input # Status Definition Open/Closed Condition Description

Open: initiates Calibration mode. The mode field of the front panel display

A

B

C

D

CALIBRATION MODE or

MEASURE MODE

REMOTE SPAN or

REMOTE ZERO

CALIBRATION

RANGE2 or RANGE1

CALIBRATION

O2 SENSOR or CO

2

SENSOR CALIBRATION

will read CO2 CAL R, CO2 CAL ZR, O2 CAL R or O2 CAL ZR
Closed: initiates Measure mode. The mode field of the front panel display

will read CO2 R, CO2 ZR, O2 R, or O2 ZR

Open: initiates remote SPAN calibration mode as part of performing a low
span calibration. The mode field of the front panel display will read CO2 CAL

SR or O2 CAL SR.

Closed: initiates remote ZERO calibration mode. The mode field of the front
panel display will read ZERO MODE.

Open: selects Range 2 for calibration.
Closed: selects Range 1, default range in single range mode.

Open: initiates calibration of the O
display will read O2 CAL R or O2 CAL ZR.

Closed: Initiates calibration of the CO
panel display will read CO2 CAL R or CO2 CAL ZR

External Power Connections

sensor. The mode field of the front panel

2

+

5 VDC

Power Supply

+

sensor. The mode field of the front

2

E & F

U

SPARE

Digital Ground

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

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 & 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 & “ALARM 3” RELAY

The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration
Alarm 1” set point in the software & 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
Alarm 2 Relay O
Alarm 3 Relay O2 Alarm 2 = xxx %

Alarm 1 = xxx %

2

Alarm 2 = xxx %

2

The Alarm 2 Relay will be turned on any time the concentration set-point is
exceeded & 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 & 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.

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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 for each gas.

CO2 Alarm 1 = 20 %

Alarm 2 = 100 %

CO

2

Alarm 1 = 20 %

O

2

Alarm 2 = 100 %

O

2

In this example, O2 Alarm 1 & CO2 Alarm 1 will both be associated with the
“Alarm 2” relay on the rear panel. This allows you to have multiple alarm levels
for individual gases.

A more likely configuration for this would be to put one gas on the “Alarm 1”
relay and the other gas on the “Alarm 2” relay.

CO2 Alarm 1 = 20 %

Alarm 2 = Disabled

CO

2

Alarm 1 = Disabled

O

2

Alarm 2 = 80 %

O

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. COMMUNICATION CONNECTIONS

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
configured using the SETUP>COMM menu.

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. Please refer to Section 6.3 for a description of the default configuration and
setup instructions.

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. (If
this option is installed, the COM2 port can only be used for RS232 multidrop
communication). USB download is required (Section 6.4).

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
device. Adjust the DCE-DTE switch located on the rear panel (Figure 3-4) to
select DTE or DCE as appr

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

ethod must be

opriate (Section 6.1).

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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.

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.

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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,

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

mmuni

“Co
Connection”).

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Host

RS-232 port

Analyzer Analyzer Analyzer Last Analyzer

COM2

RS-232

COM2

RS-232

COM2

RS-232

Ensure jumper is

installed between

JP2 pins 21

last instrument of

multidrop chain.

Figure 3-15: RS-232-Multidrop PCA Host/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 6.2.4).

a. In the SETUP Mode men

u 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

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.

While O2 is itself not toxic, the sample gas measured by, and in some cases the
calibration gases used with the T803 can contain other components that are
hazardous (e.g. NO, NO2, SO2, CO, etc).

Obtain a Material Safety Data Sheet (MSDS) for each such gas. Read and
rigorously follow the safety guidelines described there.

Do not vent sample gases containing hazardous components into enclosed areas.

3.3.2.1. CALIBRATION GASES

3.3.2.2. 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

sensors.

CO

2

CAUTION

GENERAL SAFETY HAZARD: O2

when calibrating the zero point of your O2 and

2

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CAUTION

GENERAL SAFETY HAZARD

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

3.3.2.3. SPAN GAS

warning symptoms.
Do not vent calibration gases into enclosed areas.

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 each sensor:

 O2 sensor: 21% O2 in N2

 CO

sensor: 16% CO2 in N2

2

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

3.3.2.4. 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.

3.3.2.5. BASIC PNEUMATIC CONNECTIONS

See Figure 3-4 and Table 3-3 for the location and descriptions of the various
pneumati

c inlets/outlets referred to in this section.

GENERAL SAFETY HAZARD

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

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

CAUTION

) and/or nitrous oxide

2

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2

100%

Calibrated N

Concentration

at 16%

2

at 20.95% or

2

CO

(O

Calibrated gas

Span Concentration)

VENT

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

3.3.2.6. 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.

3.3.2.7. 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.

3.3.2.8. 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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3.3.2.9. 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 T803 analyzer’s enclosure, preferably outside the shelter

or at least into a well-ventilated area.

Figure 3-17: T803 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, turn on the instrument.
The pump and exhaust fan should start immediately. The analyzer should
automatically switch to Sample Mode after completing the boot-up sequence and
start monitoring CO

and O2 gases.

2

3.4.2. WARM UP

The T803 requires about 60 minutes warm-up time before reliable measurements
can be taken. During that time, various portions of the instrument’s front panel
will behave as follows. See Figure 3-1 for locations.

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
CO

2/O2

concentration

Displays blinking
“SAMPLE”

Displays menus,
parameters, and
messages.

This is normal operation, but deemed inaccurate during the
warm-up period.

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.

3.5. 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 is over, investigate their cause using the
troubleshooting guidelines in Section 11.

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

O2 ALRM1 WARNING

O2 ALRM2 WARNING

4

4

O2 CELL TEMP WARN

REAR BOARD NOT DET

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

The temperature inside the T803 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

sensor cell temperature outside of warning limits specified by

CO

2

CO2_CELL_SET variable.

DAS data storage was erased.

O2 concentration alarm limit 1 exceeded

O2 concentration alarm limit 2 exceeded

sensor cell temperature outside of warning limits specified by

O

2

O2_CELL_SET variable.

CPU unable to communicate with the motherboard.

RELAY BOARD WARN

SAMPLE FLOW WARN

SAMPLE PRESS WARN

SYSTEM RESET1

1

Does not clear after power up.

2

Clears the next time successful zero calibration is performed.

3

Clears the next time successful span calibration is performed.

4

Only active if the Concentration Alarm Option is installed

CPU is unable to communicate with the relay PCA.

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

Sample gas pressure outside of operational parameters.

The analyzer was rebooted or the CPU was reset.

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To view and clear warning messages:

Suppresses the

warning messages

If a warning message persists after

several attempts to clear it, the message

may indicate a real problem and not an

artifact of the warm-up period

NOTE:

Once the last warning has

been cleared, the RANGE

function will be displayed in

the analyzer’s main

MESSAGE FIELD.

SAMPLE SYSTEM RESET

TEST CAL MSG CLR SETUP

SAMPLE SYSTEM RESET

TEST CAL MSG CLR SETUP

SAMPLE SYSTEM RESET

TEST CAL MSG CLR SETUP

SYSTEM SYSTEM RESET

TEST CLR SETUP

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

Figure 3-18: Viewing and Clearing T803 WARNING Messages

3.5.1. FUNCTIONAL CHECK

MSG returns the active

warnings to the message

Press CLR to clear the current

active, the next message will take

field.

message.

If more than one warning is

its place.

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 068360

000) lists these
values before the instrument left the factory. To view the current values of these
parameters, press the front panel button sequence for TEST functions as shown in
Figure 6.2 in Section 6.2. Remember until the unit has completed its warm up
these parameters may not have stabilized.

If your local area network 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).
If your network is not runni



interface manually (see Section 6.3.2).

ng DHCP, you will have to configure the analyzer’s

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3.5.2. 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 0 for instructions for connecting these gas sources.

The initial calibration should be carried out

using the same reporting range set up

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.

 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 3.3.2.4)

 that the Calib

 that the pneumatic setup matches that described in Section 0.

ration gas will be supplied through the SAMPLE port

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:

Note

 Mode Setting: SNGL

 Analog Output Reporting Range: 16% for CO2 and 20.95% for O2

2. If the Dilution Ratio Option is enabled on your T803, perform the Dilution

Ratio set up as presented in Section 5.4.4

3. Set the exp

in Section 9.2.3.1. This should be 80% of concentration range for which the
analyzer’s an

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

ected Span Gas Concentration for CO

alog output range is set.

and for O2, as presented

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

The T803 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 basic CO
functional modes.

4.1. OVERVIEW OF OPERATING MODES

The T803 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:

 perform calibrations

 run test functions

and O2 measurement features and

2

 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 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 button.

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

CAL CO2 S[type]
CAL O2 Z[type]
CAL O2 S[type]
DIAG Mode One of the analyzer’s diagnostic modes is active (Section 5.9).

[type:]

2

3

2 & 3

Unit is performing CO2 ZERO calibration procedure.

2 & 3

Unit is performing CO2 SPAN calibration procedure.

2 & 3

Unit is performing O2 ZERO calibration procedure.

2 & 3

Unit is performing O2 SPAN calibration procedure.

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 T803 firmware being run will appear after the word “SETUP”

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
and 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.

58

and O2 concentrations

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A variety of TEST functions are available for viewing at the front panel
whenever the analyzer is at the MAIN MENU. These functions provide

information about the various functional parameters related to the analyzers
operation and its measurement of gas concentrations. This information is
particularly useful when troubleshooting a performance problem (see Section

11.1.2).

To view these TEST functions, press,

Note

Note

Figure 4-2: Viewing T803 Test Functions

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

Box Temperature

CO2 Cell

Temperature

O2 Cell

Temperature

O2 Sensor Slope

O2 Sensor Offset

Current Time

RNG

RN1
RN2

STB

PRES

SAMP FL

CO2 SLOPE

CO2 OFST

BOX TEMP

CO2 CELL

TEMP

O2 CELL TEMP

O2 SLOPE

O2 OFST

TIME

%

%

In-Hg-A

3

/min

cm

- CO

- CO

C

C

C

- O2 slope, computed during zero/span calibration.

- O2 offset, computed during zero/span calibration.

-

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. This
function can be reset to show O2 or CO2 stability.

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 temperature inside the analyzer chassis.

The current temperature of the CO

The current temperature of the O

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

sensor measurement cell.

2

4.3. CALIBRATION MODE

The T803 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.

EXAMPLES:
If the reporting range is set for 0 to 50%, an appropriate span point would

be 40%.
If the of the reporting range is set for 0 to 100%, an appropriate span point

would be 80%.

ing standard

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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).

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.

Table 6-4: Primary Setup Mode Features and Functions

MODE OR FEATURE

Analyzer Configuration

Auto Cal Feature

Internal Data Acquisition

(DAS)

Analog Output Reporting

Range Configuration

Calibration Password

Security

Internal Clock Configuration

Advanced SETUP features

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

The areas accessible under the SETUP mode are shown below:

MENU

ITEM

CFG

ACAL

DAS

RNGE

PASS

CLK

MORE

DESCRIPTION

Lists key hardware and software configuration information 5.1

(Special configuration; consult factory).

Used to set up the DAS system and view recorded data 7.1

Used to configure the output signals generated by the
instruments Analog outputs.

Turns the calibration password feature ON/OFF 5.5

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

This button accesses the instrument’s secondary setup
menu

MANUAL

SECTION

5.2

See

Table 6-5

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Table 6-5: 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.

MENU

ITEM

Used to set up and operate the analyzer’s various external

COM

VARS

DIAG

1

ALRM

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 button is
pressed.

 Pressing the EXIT button 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.

DESCRIPTION

MANUAL

SECTION

5.7

5.5

5.9

5.11

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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

T803 analyzer when contacting Technical Support.

To access the configuration table, 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

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

SETUP X.X SUPPORT: TELEDYNE-API.COM

PREV NEXT EXIT

5.2. S ETUP  ACAL: [NOT USED]

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

Press EXIT at

any time to

return to the

SETUP menu

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.

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5.4. SETUP  RNGE: ANALOG OUTPUT REPORTING
RANGE CONFIGURATION

5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING
RANGES

Functionally, the T803 analyzers have one hardware PHYSICAL RANGE that is
capable of determining concentrations from 0.00% to 100.00% for O
variable depending on the exact CO

sensor.

2

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.

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 a T803 is being used to measure
atmospheric O

concentration, the full scale of expected values is only 21% of the

2

instrument’s full measurement range. Unmodified, the corresponding output
signal would also be recorded across only 21% of the range of the recording
device.

; CO2 is

2

Note

The T803 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.

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5.4.2. ANALOG OUTPUT RANGES FOR CO2 AND O2
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

O2 concentration output

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, A2 and A3 may be equipped with optional 0-20 mA current

loop drivers and configured for any current output within that range (e.g. 0-20, 2­20, 4-20, etc.). 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 5.10.5).

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).

Channel A3 outputs a sign

al proportional to the O

concentration of the sample

2

gas.

EXAMPLE:

A1 OUTPUT: Output Signal = 0-5 VDC representing 0- 20 % CO2
concentration values

A3 OUTPUT: Output Signal = 0 – 10 VDC representing 0-100 % O

concentration

2

values.

The output, labeled A4 is special. It can be set by the user (See Section 5.10.6) to
output several of the test functions accessible through the <TST TST> buttons of

the units sample display.

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5.4.3. REPORTING RANGE MODES

The T803 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. 0-0.1 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 T803 ANALYZER FOR SINGLE

RANGE MODE

When the single range mode is selected (SNGL), all concentration outputs (A1,
A2 and A3) are slaved together and set to the same reporting range limits (e.g. 0-

22.00 %). 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 5.10.2)

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 T803 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 touchscreen button sequence

SAMPLE CO2RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

Note

SETUP X.X RANGE CONTROL MENU

MODE SET EXIT

SETUP X.X RANGE MODE:SNGL

SNGL DUAL AUTO ENTR EXIT

SETUP X.X RANGE MODE:DUAL

SNGL DUAL AUTO ENTR EXIT

SETUP X.X RANGE CONTROL MENU

MODE SET EXIT

.

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).

In DUAL range mode O2L and O2H have separate slopes and offsets for
computing O2 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).

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5.4.3.3. RNGE  MODE  AUTO: CONFIGURING THE T803 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

To set individual ranges press the following touchscree

n button sequence:

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(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.

Using the dilution ratio option is a 3-step process:

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

Ensure that the upp
maximum expected concentration of the non-diluted gas.

71

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

3. 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 100 % and the dilution ratio of the
sample gas is 20, either:

 a span gas with the concentration of 100 % can be used if the span gas

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

 a 5 % span gas must be used if the span gas IS NOT routed through the

dilution system.

5.5. SETUP  PASS: PASSWORD FEATURE

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.

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Table 5-6: 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

Toggle this

button to

enable, disable

password

feasture

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:

SAMPLE CO2 RNG=20.00 % CO2=XXX.XX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG DAS RNGE PASS CLK MORE EXIT

SYSTEM PASSWORD ENABLE: OFF

OFF ENTR EXIT

SETUP X.X PASSWORD ENABLE: ON

ON ENTR EXIT

EXIT discards the new

setting

ENTR accepts the

new setting

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Example: If all passwords are enabled, the following touchscreen button 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 T803 ANALYZER’S
INTERNAL CLOCK

5.6.1. SETTING THE INTERNAL CLOCK’S TIME AND DAY

The T803 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:

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

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.

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

the value of this variable, press:

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

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5.7. SETUP  MORE COMM

The communications setup menu is for setting up serial and Ethernet
communciations for remote operation; it includes changing the ID of the
instrument when more than one analyzer of the same model is connected to the
same communications channel, e.g., same Ethernet LAN, RS-232 multidrop
chain, or when applying MODBUS or HESSEN protocols.

5.8. SETUP  MORE  VARS: INTERNAL VARIABLES
(VARS)

The T803 has 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 redefined through the VARS menu.

The following table lists all variables that are available within the 818 password
protected level. See Appendix A2 for a detailed listing of all of the T803
variables that are accessible through the remote interface.

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Table 5-1: Variable Names (VARS)

0 Sec/Day

VARS

Default

settings

15 min.

CO2

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

7

STABIL_GAS

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.

Selects which gas measurement is displayed when the
STABIL test function is selected.

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 O2 response
when performing a zero point calibration during an AutoCal.]

[Automatically adjusts offset and slope of the O
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 buttons 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

3, 4

s/day

2

CO2; O

ON, OFF

[ON, OFF]

[ON, OFF]

AUTO, 1, 2,

-60 to +60

ON, OFF

TIME_SINCE_SVC

8

SVC_INTERVAL

9

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

78

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To access and navigate the VARS menu, use the following button 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 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 1) STABIL_GAS=CO2

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

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 STABIL_GAS=O2

O2 CO2 ENTR EXIT

SETUP X.X TPC_ENABLE:ON

ON ENTR EXIT

Toggle these keys to set

the iDAS HOLDOFF time

period in minutes

(MAX = 20 minutes).

Press to select which gas

will be reported by the

STABIL test function

Toggle to turn ON or OFF

temperature pressure

compensation.

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

SETUP X.X CONC_PRECISION=AUTO

AUTO1234 ENTREXIT

SETUP X.X CLOCK_ADJUST=0 Sec/Day

+0 0 ENTR EXIT

Press 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: USING THE 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 5-2: 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

5.10.1

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

5.10.6

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5.9.1. ACCESSING THE DIAGNOSTIC FEATURES

To access the DIAG functions press the following buttons:

<TST TST> CAL MSG

SETUP X.X

CFG DAS ACAL RNGE PASS CLK EXIT

SETUP X.X

COMM VARS EXIT

SETUP X.X

returns to the

Activates the

selected

submenu

EXIT

PREV

PREV

PREV

PREV

PREV

PREV

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

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5.10. USING THE T803 ANALYZER’S ANALOG OUTPUTS

The T803 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) measures the current O

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

current value of one of several test functions (see Table 5-7).

5.10.1. ACCESSING THE ANALOG OUTPUT SIGNAL CONFIGURATION

SUBMENU

The following lists the analog I/O functions that are available in the T803
analyzer.

Table 5-3: DIAG - Analog I/O Functions

SUB MENU FUNCTION

concentration (see Section 5.4.2).

2

concentration.

2

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

AOUT

CALIBRATED

CONC_OUT_1

CONC_OUT_2

CONC_OUT_3

TEST OUTPUT

AIN

CALIBRATED

XIN1

.
.
.

the 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 (CO2 high range, RNG2)

 Same as for CONC_OUT_1 but for analog channel A3 but only for the O2 sensor.

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

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

1

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

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.

XIN8

1

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

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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

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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5.10.2. 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 5-4: 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 5.10.1) then press,

5.10.3. 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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5.10.3.1. 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 5.10.1) then

press:

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5.10.3.2. AUTOMATIC 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 5.10.3.1)).

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

submenu (see Section 5.10.1) then press:

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5.10.3.3. INDIVIDUAL (SINGLE-CHANNEL) 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 5.10.1) then press:

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5.10.3.4. 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 5.10.3.1)).

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

connector.

V

+DC Gnd

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

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

FULL SCALE ZERO TOLERANCE SPAN VOLTAGE

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

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 5.10.1) then press:

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

A current loop option may be purchased for the A1, A2 and A3 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 5.10.2 (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 / Calibration 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 5.10.1) then press:

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

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current meter (see Figure 3-7 for pin assignments and diagram of the analog
output connector). 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 5-6: 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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5.10.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE

ON/OFF

In its default configuration, a ± 5% over-range is available on each of the T803’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 5.10.1) then press

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5.10.5. 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 T803 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 5.10.1) then press:

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5.10.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4

The test functions available to be reported are:

Table 5-7: Test Channels Functions available on the T803’s Analog Output

TEST CHANNEL DESCRIPTION ZERO FULL SCALE

NONE

SAMPLE PRESSURE

SAMPLE FLOW

CO2 CELL TEMP

O2 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 of the gas inside the O
sensor sample chamber.

The temperature inside the analyzer chassis.

2

2

0 "Hg 40 "Hg

3

/m 1000 cm3/m

0 cm

0C 70C

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.

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To activate the TEST Channel and select a function (in this example SAMPLE
PRESSURE), 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 SECONDARY SETUP MENU

COMM VARS DIAG EXIT

SETUP X.X ENTER PASSWORD:818

8 1 8 ENTR EXIT

Toggle to enter

the correct

PASSWORD

Toggle to choose a

TEST channel

parameter

DIAG SIGNAL I/O

PREV NEXT ENTR EXIT

Continue pressing NEXT until ...

DIAG TEST CHAN OUTPUT

PREV NEXT ENTR EXIT

DIAG TEST CHAN:NONE

PREV NEXT ENTR EXIT

DIAG TEST CHANNEL:SAMPLE PRESSURE

PREV NEXT ENTR EXIT

EXIT discards the new

setting

ENTR accepts the

new setting

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

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5.10.7. AIN CALIBRATION

This is the sub-menu to conduct a calibration of the T803 analyzer’s analog
inputs. This calibration should only be necessary after major repair such as a
replacement of CPU, motherboard or power supplies.

To perform an analog input calibration, select the ANALOG I/O
CONFIGURATION submenu (see Section 5.10.1) then press:

98