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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Section 1 General Information Teledyne API T803 CO2/O2 Analyzer Operation Manual

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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

18

Teledyne API T803 CO2/O2 Analyzer Operation Manual Introduction, Featueres, and Options

07276B DCN6418

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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Introduction, Featueres, and Options Teledyne API T803 CO2/O2 Analyzer Operation Manual

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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

20

07276B DCN6418

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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Specifications, Approvals & Compliance Teledyne API T803 CO2/O2 Analyzer Operation Manual

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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

07276B DCN6418

3. GETTING STARTED

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

3.1. UNPACKING THE 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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Getting Started Teledyne API T803 CO2/O2 Analyzer Operation Manual

07276B DCN6418

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.

24

Teledyne API T803 CO2/O2 Analyzer Operation Manual Getting Started

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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

25

Getting Started Teledyne API T803 CO2/O2 Analyzer Operation Manual

07276B DCN6418

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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Getting Started Teledyne API T803 CO2/O2 Analyzer Operation Manual

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

28