Toll-free Phone:
800-324-5190
Phone:
+1 858-657-9800
Fax:
+1 858-657-9816
Email:
api-sales@teledyne.com
Website:
http://www.teledyne-api.com/
Copyright 2011-2018
07303E DCN7996
Teledyne API
10 October 2018
T200U NOy ANALYZER
ADDENDUM
(for use with T200 Operators Manual, PN 06858
and with T200U Addendum, PN 06861)
© TELEDYNE API
9970 CARROLL CANYON ROAD
SAN DIEGO, CA 92131-1106
USA
Safety Messages
CAUTION
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 placed throughout
this manual and inside the instrument. The symbols with messages are defined as
follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message for specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without protection or proper tools
could result in damage to the part(s) and/or the instrument.
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.
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
NEVER use any gas analyzer to sample combustible gas(es)!
Note
For Technical Assistance regarding the use and maintenance of this instrument or any other Teledyne
API product, contact Teledyne API’s Technical Support Department:
Telephone: 800-324-5190
Email: api-techsupport@teledyne.com
or access any of the service options on our website at http://www.teledyne-api.com/
.
07303E DCN7996 i
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne
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
Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central
MISE EN GARDE
NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!
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:
complémentaire pour des renseignements spécifiques
l’instrument.
être effectuées uniquement par du personnel de maintenance qualifié.
de la mise à la terre sécuritaire de l’instrument.
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.
ii 07303E DCN7996
Model T200U NOy Option Manual Addendum
Static Discharge (ESD) handling and packing
Warranty
WARRANTY POLICY (02024J)
Teledyne API (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.
(For the instrument-specific warranty period, please refer to the “Limited Warranty” section
in the Terms and Conditions of Sale on our website at the following link:
http://www.teledyne-api.com/terms_and_conditions.asp).
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
api.com/terms_and_conditions.asp
Failure to comply with proper anti-Electroinstructions and Return Merchandise Authorization (RMA) procedures when returning parts
for repair or calibration may void your warranty. For anti-ESD handling and packing
instructions please refer to the manual, Fundamentals of ESD, PN 04786, in its “Packing
Components for Return to Teledyne API’s Customer Service” section. The manual can be
downloaded from our website at http://www.teledyne-api.com. RMA procedures can also be
found on our website.
http://www.teledyne-
CAUTION – Avoid Warranty Invalidation
07303E DCN7996 iii
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Model T200U NOy Option Manual Addendum
Table of Contents
1.0 INTRODUCTION ...................................................................................................... 7
2.0 SPECIFICATIONS ................................................................................................... 9
2.1 Specifications ................................................................................................................................ 9
3.0 GETTING STARTED .............................................................................................. 11
3.1 Unpacking and Inspection ........................................................................................................... 11
3.2 Electrical and Pneumatic Connections........................................................................................ 12
3.3 Initial Operation .......................................................................................................................... 16
4.0 PRINCIPLE OF OPERATION ................................................................................ 17
5.0 CALIBRATION AND CAL CHECKS ...................................................................... 19
5.1 Calibration or Cal Check Procedure ............................................................................................ 20
6.0 MAINTENANCE ..................................................................................................... 23
6.1 Maintenance Schedule ............................................................................................................... 23
6.2 Replacing the Sample Particulate Filters .................................................................................... 24
6.3 Checking Analyzer Flow Rate ...................................................................................................... 25
6.4 Replacing the Converter ............................................................................................................. 26
6.5 Inspecting Pneumatic Lines ........................................................................................................ 27
6.6 Checking for Leaks ...................................................................................................................... 29
7.0 TROUBLESHOOTING AND ADJUSTMENTS ....................................................... 31
7.1 Operation Verification – Diagnostic Techniques ........................................................................ 31
7.1.1 Pneumatic System............................................................................................................ 31
7.1.2 Leak Check ....................................................................................................................... 31
7.1.3 501 NOy Bypass Pump Diagnostic Procedures ............................................................... 31
7.1.4 Electrical Fault Isolation ................................................................................................... 32
7.2 Setting the Converter Temperature ............................................................................................ 32
7.2.1 Temperature Controller Setup .......................................................................................... 32
07303E DCN7996 v
Model T200U NOy Option Manual Addendum
List of Figures
Figure 1. Rear Panels: T200U NOy Analyzer (top) and 501 NOy (center); Converter (bottom) ................................ 14
Figure 2. Rear Panel Pneumatic Connections ............................................................................................................. 15
Figure 3. Replacing the Particulate Filter ................................................................................................................... 25
Figure 4. NOy Converter Interior Assembly Location ............................................................................................... 26
Figure 5. Pneumatics ................................................................................................................................................... 28
Figure 6. Location of O3 Generator Air Inlet .............................................................................................................. 29
Figure 7. Thermocouples, J-Type and K-Type ............................................................................................................ 35
Figure 8. Electrical Diagram ...................................................................................................................................... 36
List of Tables
Table 1 Specifications for the External Converter and the 501 NOy Bypass Pump .................................................... 9
Table 2 Manual Zero Calibration Procedure .............................................................................................................. 20
Table 3 Enter Expected Span Gas Concentrations Procedure For NO & NOy .......................................................... 20
Table 4 Span Calibration Procedure ........................................................................................................................... 21
Table 5 Preventative Maintenance Calendar .............................................................................................................. 23
Table 6 Temperature Controller Programming Guide ................................................................................................ 33
vi 07303E DCN7996
Model T200U NOy Option Manual Addendum
1.0 INTRODUCTION
The T200U NOy analyzer consists of an external thermal converter designed to
support a NOx analyzer by converting multiple, unstable compounds grouped
under the name NOy. The converter is mounted externally at the sample inlet to
minimize flow time between sample in and converter, thereby optimizing
measurement accuracy. The sample is pulled through the converter box by the 501
NOy pump pack.
The 501 NOy pump pack contains a temperature control unit for the converter and
an internal pump. The pump pack pulls ambient air into the converter box via the
sample port; the sample port’s cross-fitting splits the sample between two paths:
one bypasses the heated converter and flows directly into the pump pack via the
tubing for NO, while the other path flows through the heated converter assembly
first, and then flows into the pump pack via the tubing for the converted NOy. From
the pump pack the separate samples flow to the analyzer.
This manual addendum is to be used in conjunction with two additional documents
with operation instructions:
• T200 operation manual (part number 06858)
• T200U addendum (part number 06861).
It is recommended that you read/familiarize yourself with all sets of instructions in
order to use the analyzer and converter correctly.
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Model T200U NOy Option Manual Addendum
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8 07303E DCN7996
Model T200U NOy Option Manual Addendum
Converter
Remotely mounted molybdenum external Converter with
Converter Temperature
315oC ± 7oC with read-out on front panel of bypass pump chassis.
Tube/Electrical Cable
Up to 50 feet (15 m) maximum length
Power, 501 NOy Bypass Pump
120V~ 50/60 Hz, 230V~ 50/60 Hz 360 watts
Power, Converter Assembly
120V~ 50/60 Hz, 230V~ 50/60 Hz, 60 watts
Converter Efficiency
>96% for NO2
Weight, 501 NOy Bypass
35 lbs (16 kg)
Weight, Remote Converter with
42 lbs (19 kg)
501 NOy Bypass Pump
9" x 17" x 23.6" (23cm x 43cm x 61cm)
Remote Converter Assy
12" x 19" x 7" (31cm x 48cm x 18cm)
Environmental
Installation Category (Over-voltage Category) II
Bypass Flow rate
800 cc/min ± 10%, each channel
2.0 SPECIFICATIONS
2.1 Specifications
Table 1 Specifications for the External Converter and the 501 NOy Bypass Pump
temperature controller in a NEMA – 4 enclosure.
Assembly
Assembly
Pump Assembly
umbilical
Chassis Dimensions HxWxD
Dimensions HxWxD
Cal gas Flow rate
Pollution Degree 2
4000 cc/min (approx.)
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Model T200U NOy Option Manual Addendum
3.0 GETTING STARTED
The NOy converter has been designed to operate with the T200U low level NOx
analyzer, with some additional modifications. The combination is referred to as the
T200U NOy analyzer.
3.1 Unpacking and Inspection
CAUTION!
Avoid personal injury: use two persons each to lift and carry the analyzer and the
Model 501 NOy Pump Pack chassis.
The T200U NOy, comprised of four components, comes in three boxes:
• The analyzer with AC power cord
• The 501 NOy Bypass Pump Chassis 501 with AC power cord
• External Converter housed in a stainless steel NEMA 4 enclosure, and an
umbilical cable assembly (herein referred to as “Converter” or “external
Converter”)
• External Pump (herein referred to as “external Pump” not to be confused with
the 501 NOy Bypass Pump or Pump Pack)
1. Verify that there is no apparent shipping damage. If damage has occurred
please advise shipper first, then TAPI. (Keep original container and packaging
for shipper’s inspection).
2. Follow the unpacking instructions in the T200 Manual.
3. Please check the voltage and frequency label on the rear panel of the
instrument for compatibility with the local power before connecting the
instruments to a power source.
07303E DCN7996 11
Model T200U NOy Option Manual Addendum
to a grounded structure, using a grade of metal fasteners,
3.2 Electrical and Pneumatic Connections
NOTE
To maintain compliance with EMC standards, it is required that the cable length (at the
rear of the analyzer) 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.
1. Ensure that the location allows sufficient space to disconnect the AC power
cable from the rear of the unit.
2. Mount the Converter (Figure 1, bottom) on a suitable mast that is grounded.
IMPORTANT
The metal NEMA box must be secured by its four mounting holes
including locking washers and/or nuts, that are resistant to both
corrosion and vibration.
ADHERE TO NATIONAL ELECTRIC CODE (NEC)
The umbilical cable assembly installation must follow local and
national electrical code standards.
3. Uncoil and arrange the TAPI-provided umbilical cable assembly to avoid
twisting or kinks, while protecting both ends of the exposed tubing and
electrical fittings to prevent scuffing or any dirt and debris from entering.
4. Route the umbilical cable assembly into the instruments’ shelter.
5. Locate the analyzer and the 501 NOy Bypass Pump Chassis in close proximity
to each other, preferably mounting one over the other in a 19” rack.
6. Connect the T200U NOy analyzer rear panel electrical connectors per the
T200 operation manual.
7. Connect the pneumatic cable fittings from the analyzer rear panel (Figure 1,
top) to the 501 NOy rear panel (Figure 1, center) and from Converter Figure
1, bottom) to the 501 NOy rear panel.
Refer to Figure 2 for an illustration of the pneumatic connections; refer to the
tags on each tube to match up the correct tube with the appropriate rear panel
fitting.
12 07303E DCN7996
Model T200U NOy Option Manual Addendum
8. Connect the pneumatic cable fitting from the calibrator to the 501 NOy rear
panel (Figure 2).
9. Also, connect the EXHAUST port of the analyzer rear panel to the external
Pump.
10. Connect the circular power and signal cable from the external Converter’s
umbilical cable assembly to the CONVERTER POWER connection on the rear
of the 501 NOy.
11. Connect the three-prong thermocouple connector from the umbilical cable
assembly to the THERMOCOUPLE connection on the rear of the 501 NOy.
12. Connect the analyzer and 501 NOy AC power cords from their AC power
receptacles to the correct line voltage (refer to power specs on the respective
rear panel label).
WARNING!
• Lethal voltages are present inside the chassis.
• Do not operate with cover off during normal operation.
• Before operation, check for correct input voltage and frequency.
• Do not operate without proper chassis grounding.
• Do not defeat the ground wire on power plug.
• Turn off power before disconnecting electrical subassemblies.
07303E DCN7996 13
Model T200U NOy Option Manual Addendum
Figure 1. Rear Panels: T200U NOy Analyzer (top) and 501 NOy (center); Converter
(bottom)
14 07303E DCN7996
Model T200U NOy Option Manual Addendum
CONNECTIONS: Analyzer to Pump to Converter and Calibrator to Pump
Calibrator
Analyzer
Pump Chassis
Converter
NO IN (1)
NO OUT (1)
NOY IN (2)
NOY OUT (2)
[cal gas out port]
CAL IN (3)
NOY IN (4)
NO OUT (4)
NO IN (5)
NOY OUT (5)
CAL OUT (6)
CAL IN (6)
Figure 2. Rear Panel Pneumatic Connections
Pneumatic tubes and rear panel labels include numbers to facilitate matching connections between
instruments.
07303E DCN7996 15
Model T200U NOy Option Manual Addendum
Caution
The internal Converter components will become
extremely hot and must be allowed to cool after
3.3 Initial Operation
If you are unfamiliar with the T200U NOy analyzer, we recommend that you read
the principles of operation in Section 4.1 of this operation manual before
proceeding.
1. After confirming proper supply voltage, turn on the power to the analyzer and
to the 501 NOy pump pack, and plug in the external Pump.
• The front panel displays should immediately light as the instruments start
up.
• The 501 NOy requires about 30 minutes for the external Converter to come
up to operating temperature.
• The T200U NOy requires about 30 minutes for the ozone generator to start
up. During that time the instrument will not respond to span gas.
• After 30 min, the display on the 501 NOy front panel should read 315
indicating that the external Converter is at operating temperature.
• Follow the instructions in the T200 Manual and the T200U Addendum to
confirm proper operation of the analyzer.
2. Proceed to Section 5 of this T200U NOy manual to perform a Zero/Span
check.
power-off before being touched.
o
C,
16 07303E DCN7996
Model T200U NOy Option Manual Addendum
4.0 PRINCIPLE OF OPERATION
The TAPI Model T200U NOy is designed to measure the concentration of NO,
, and other compounds that are too unstable to be measured when taken in
NO
2
through the normal ambient air sample inlet system. Please refer to the T200U
manual supplied with this system for a general discussion of the operation of a NOx
analyzer. The suite of compounds known collectively as NOy is composed of
roughly 30 compounds. The NOy measurement is generally done in conjunction
with a standard NOx measurement, with the difference between the two being the
concentration of the unstable compounds, sometimes referred to as NOz.
The analyzer measures two independent gas streams. One bypasses the external
Converter and measures NO in the sample. The other pulls the sample through the
external Converter and is displayed as NOy
the NOy measurement
is equivalent to the delivered NOx calibration gases.
The system is composed of four modules:
Under normal calibration conditions
.
• The T200U NOy analyzer, without a Moly converter
• A 501 NOy Bypass Pump containing:
• bypass pump
• flow control
• sample filtration
• moly temperature control
• pneumatic provisions for calibration
• Externally mounted molybdenum converter (external Converter)
• External Pump
The T200U NOy system allows the point of sampling to be located in close
proximity to the Converter. This configuration provides minimal time delay
between the sample inlet and the remotely mounted (~10 meters above ground)
external Converter. Minimizing the transit time between the sample inlet and
Converter enables the conversion of labile components of NOy. The equation for
the conversion is:
315oC
3 NOY + Mo ---> 3 NO + MoO
3
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18 07303E DCN7996
Model T200U NOy Option Manual Addendum
5.0 CALIBRATION AND CAL CHECKS
Unlike most NOx analyzers, the T200U NOy does not have a sample inlet port on
its rear panel. The sample inlet is located on the outside of the external Converter.
The steps in this section include:
• Entering the expected NO and NOy span gas concentrations in the analyzer.
• Running the zero calibration or check procedure
• Running the span calibration or check procedure
The analyzer always routes the zero/span gas through the external Converter. In
standard configuration, the calibration gas needs to be input at the CAL IN (3) port
of the 501 NOy bypass pump. In all cases, the calibration gas delivered must be
under a small amount of pressure (2-5 psig) to overcome the resistance of the
tubing.
NOTE
Do not vent the Zero or Span gas to the atmosphere prior to the
analyzer. The gases actually vent at the external Converter sample
port.
Calibration gas being provided to the 501 NOy bypass system also flows to the
analyzer. Flow requirements are 0.80 LPM for NO bypass, 0.80 LPM for NOy
bypass and 1 LPM for the analyzer. Calibration gas flow must be in sufficient
excess (~4 LPM) to prevent any ambient air from entering the sample inlet of the
external Converter during calibration.
The maximum 50-ft length of tubing between the 501 NOy and the remote
Converter has been proven to generate too much backpressure for some brands of
calibrators. Teledyne calibrators are designed to overcome this potential issue.
We strongly recommend that span calibration be done with NO span gas. Span
checks can be done with one of: NO only, NO
only, or a mixture of NO and NO2
2
(GPT).
Zero air used for all calibration procedures, including GPT, should have <1 ppt NO
and NO
a dew point of -5
, less than 1 ppt of major interferents such as SO2, NH3, hydrocarbons and
2
o
C or less. The calibration gasses should be from a reliable
supplier, since the quality of the tank concentration values ultimately determines
the accuracy of the analyzer.
NOTE
The T200U NOy does NOT have equivalency approval.
07303E DCN7996 19
Model T200U NOy Option Manual Addendum
Press EXIT
Returns instrument to SAMPLE mode.
5.1 Calibration or Cal Check Procedure
Calibration of the analyzer can be checked or adjusted using gas introduced through
the CAL IN (3) port on the 501 NOy rear panel. The calibration gas is routed to a
tee fitting (see CAL IN in Figure 4), near the sample inlet on the external Converter
assembly.
Since the zero gas concentration is defined as 0 ppb, it is not necessary to enter the
expected zero value. Table 2 details the zero calibration procedure.
Table 2 Manual Zero Calibration Procedure
Step Action Comment
1. Press CAL The analyzer enters the calibrate mode.
2. Wait For Stability
Type STB < 0.1 PPB
3. Press ZERO If performing only Zero Cal Check, do not press ENTR,
4. Press ENTR Pressing ENTR actually changes the calculation equations.
5. Press EXIT The analyzer returns to sampling. Immediately after
Wait for reading to stabilize at zero value.
press EXIT to avoid actually zeroing the instrument.
calibration, data are not added to the DAS averages.
Table 3 Enter Expected Span Gas Concentrations Procedure For NO & NOy
Step Action Comment
1. Press
CAL>CONC>NOy
2. Press ENTR ENTR stores the expected NOy span value.
3. Press
CAL>CONC>NO
This menu sequence causes the analyzer to prompt for the
expected NOy concentration.
Enter the NOy span concentration value by pressing the
applicable touchscreen buttons to set the expected value.
Now enter the expected NO span concentration as in step
one.
4. Press ENTR Pressing ENTR stores the NO span value and returns the
5.
If desired, compensation for converter efficiency (CE) can be included in the NOy
concentration calculation. Prior to calibration, the converter efficiency should
either be set to 1.0 or determined per the procedure in the T200 manual.
20 07303E DCN7996
prompt to the CONC menu.
Model T200U NOy Option Manual Addendum
Table 4 Span Calibration Procedure
Step Action Comment
1. Press CAL The analyzer enters the calibrate mode.
2. Wait For Stability
Type STB < 2 PPB
3. Press SPAN If performing only Span Cal Check, do not press ENTR,
4. Press ENTR Pressing ENTR actually changes the calculation equations
5. Press EXIT The analyzer returns to sampling. Immediately after
Wait for reading to stabilize at span value.
press EXIT to avoid actually spanning the instrument.
and causes the instrument to read the NO and NOy span
concentrations.
calibration, data are not added to the DAS averages.
07303E DCN7996 21
Model T200U NOy Option Manual Addendum
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22 07303E DCN7996
Model T200U NOy Option Manual Addendum
6.0 MAINTENANCE
6.1 Maintenance Schedule
The schedule for preventative maintenance is presented in Table 5 below.
Qualified Maintenance Personnel Required
Table 5 Preventative Maintenance Calendar
Item Maintenance Interval
Zero/Span Calibration Annually or after maintenance or repairs
Zero/Span Checks Daily
Particulate Filter Weekly / as needed
Ozone Flow Check every year and replace o-ring and orifice in reaction
cell
Ozone Dryer Filter-DFU Replace every year
Reaction Cell Window Clean annually or as necessary (refer to T200 Manual)
Sample Flow Check every 2 months
Converter Check efficiency every 2 months
Pneumatic Lines Check every 3 months
Factory Calibration Calibrate each year or after repairs
Leak Check Check every 6 months
Replace bypass flow orifices Every year / as needed
Rebuild 501 NOy bypass
pump
Every year (check part number on pump label)
07303E DCN7996 23
Model T200U NOy Option Manual Addendum
NOTE
and clean with cloth prior to assembly
6.2 Replacing the Sample Particulate Filters
The particulate filter should be inspected often for signs of plugging or
contamination. It is also common for dirt particles to cause instrument drift, and
affect accuracy.
To check and change the filter:
1. Fold down the 501 NOy front panel.
2. Locate both filters on the left and right side of the 501 NOy front panel. See
Figure 3 for an exploded view of the filter assembly.
3. Visually inspect the filter through the glass window.
4. If the filter appears dirty, unscrew the hold-down ring, remove the Teflon o-ring
and then the filter.
5. Replace the filter, being careful that the element is fully seated in the bottom
of the holder. Replace the Teflon o-ring (refer to Figure 3 for orientation of oring with cutouts), then screw on the hold-down ring and hand tighten. Do not
overtighten; this can cause the glass window to crack!
Handle the filter assembly wetted surfaces (glass window, Teflon holder) as little as possible
24 07303E DCN7996
Model T200U NOy Option Manual Addendum
Figure 3. Replacing the Particulate Filter
6.3 Checking Analyzer Flow Rate
The External Pump is capable of maintaining the analyzer reaction cell pressure at
less than 5.0 In-Hg-A. If a higher pressure is noted, the Pump may need servicing.
Check the Pump and pneumatic system for leaks or rebuild the Pump.
CAUTION!
Never operate the analyzer without the ozone destruct component properly
seated and connected within the pneumatic path. The ozone destruct, which is
heated, is integrated into a metal enclosure, at the exhaust of the reaction cell,
inside the instrument.
The sample flow as measured at ports NO IN (1) and NOy IN (2) at the rear of the
analyzer should be 1000 ± 100 cc/min.
See Figure 1 for component locations.
07303E DCN7996 25
Model T200U NOy Option Manual Addendum
6.4 Replacing the Converter
The heater, thermocouple, and converter interior assembly is designed to be
replaced as a single unit. Check Figure 4 for the assembly location.
The converter operates at 315°C. Severe burns can result if not enough time
is allowed for the assembly to cool. Do not handle assembly until it is at room
temperature.
1. Turn off the power to the 501 NOy at its front panel ON/OFF switch.
2. Unplug the 501 NOy Assembly from the AC main.
3. Allow the external Converter to cool.
4. Disconnect the gas fittings, the power connector, and the thermocouple to the
converter (Figure 4).
5. Remove the interior-assembly box from the chassis by loosening the 4 captive
screws that secure the assembly to the chassis.
6. Remove bottom bracket and re-attach it to the replacement box with interior
assembly.
CAUTION!
7. Install the box with interior assembly back into the analyzer, tightening the 4
captive screws.
8. Re-attach the electrical and pneumatic fittings. Leak check the assembly when
completed.
9. Plug the 501 NOy into the AC main and power back on. (The insulation can
emit a burnt odor for the first 24 hours; this is normal).
10. Allow the Converter to burn-in for 24 hours.
11. After the 24-hour burn-in, re-calibrate the instrument.
26 07303E DCN7996
Figure 4. NOy Converter Interior Assembly Location
6.5 Inspecting Pneumatic Lines
Particulate matter in the pneumatic lines will affect both flow rate and response
time. It is important that the pneumatic system be periodically inspected and
thoroughly cleaned if necessary. Clean by disassembling and passing methanol
through three times. Dry with clean zero air.
Also, inspect all pneumatic lines for cracks and abrasion on a regular basis.
Replace as necessary.
Model T200U NOy Option Manual Addendum
07303E DCN7996 27
Model T200U NOy Option Manual Addendum
28 07303E DCN7996
Figure 5. Pneumatics
6.6 Checking for Leaks
If a leak checker is not available, it is possible to leak check the instrument using
the sample pump plus a shut-off valve.
1. Turn off power to the analyzer and the 501 NOy, and unplug the external
Pump.
2. Cap the sample inlet of the external Converter, the BYPASS OUT port of the
501 NOy and the ozone generator air inlet (located inside the analyzer, Figure
6).
Model T200U NOy Option Manual Addendum
Figure 6. Location of O3 Generator Air Inlet
3. Insert a shut-off valve between the external Pump and the EXHAUST port at
the rear of the analyzer.
4. Turn on both the analyzer power and the external Pump only. Monitor the
Reaction cell pressure on the front panel. Close the shutoff valve and monitor
the cell pressure. The pressure should not increase more than 1"Hg (.5psi) in
5 minutes. If there is a leak, locate
described below.
07303E DCN7996 29
it by using a pressure leak checker
Model T200U NOy Option Manual Addendum
Using a leak checker:
1. Turn off power to the analyzer and 501 NOy, and unplug the external Pump.
2. Disconnect the external Pump from the analyzer’s rear panel. Cap the sample
inlet of the external Converter, the BYPASS OUT port of the 501 NOy, the
ozone generator air inlet (located inside the analyzer, Figure 6), and connect
the leak checker to the instrument exhaust port.
CAUTION!
Pressure must be less than 15 PSI.
3. Pressurize the system and check for leaks by watching overall pressure. The
pressure should not drop more than 1"Hg (.5psi) in 5 minutes.
If the instrument fails the pressure test, each fitting needs to be leak checked to find
the location. Use a soap solution, such as snoop leak checker, for this purpose.
NOTE
Be careful that the system is always pressurized so as not to draw soap solution into the
plumbing system. Make sure you dry off any accumulated bubble solution. Start by checking
the external fittings first.
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Model T200U NOy Option Manual Addendum
CAUTION!
The operations outlined in this section must be performed by qualified
7.0 TROUBLESHOOTING AND ADJUSTMENTS
maintenance personnel only!
This section of the manual contains information on diagnosing and repairing
instrument performance problems.
As a guide to troubleshooting, think of the T200U NOy as two systems: pneumatics
and electronics.
• Pneumatics - Over 50% of all instrument problems are traced to pneumatic
leaks. Suspect a leak first.
• Electronics – External Converter temp control unit or DC power supply for
the converter temperature readout.
Another trouble-shooting tip has to do with incorrect span gas concentration:
• This could come either from the calibrator itself or from incorrectly entering
the expected span gas concentration in the instrument.
• If the instrument does not respond to span gas, check troubleshooting
section in the T200 manual.
The above should get you started in diagnosing and repairing the most common
faults. If these reasons have been eliminated and there are still problems with the
unit, the next thing to do is a Factory Calibration covered in the T200 manual. If
difficulties persist, contact our service department.
7.1 Operation Verification – Diagnostic Techniques
This section provides guidance on diagnosing some possible problems.
7.1.1 Pneumatic System
Refer to Figure 5 for a diagram of this system’s pneumatics, to be used in
conjunction with diagnostics and troubleshooting.
7.1.2 Leak Check
Refer to Section 6.6 for the leak check procedure.
7.1.3 501 NOy Bypass Pump Diagnostic Procedures
The 501 NOy bypass pump is capable of maintaining a total bypass flow rate of
~2.2 lpm. If flow checks indicate a fall off in bypass flow, the pump may need
servicing. Check the pump, inlet fittings, and analyzer for leaks first. If other
causes have been eliminated, rebuild the pump.
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Model T200U NOy Option Manual Addendum
7.1.4 Electrical Fault Isolation
AC mains power is supplied to the:
• bypass pump
• input power to the converter temperature controller
• output power to converter box
Referring to Figure 8, check the AC mains supply voltage to each of these
components.
The converter temperature is monitored and adjusted as needed by the controller
located on the 501 NOy front panel. The controller cycles power to the external
converter, thereby maintaining the temperature at 315 OC, using the solid state
relay.
7.2 Setting the Converter Temperature
A front panel-mounted programmable controller maintains the temperature of the
remote external Converter. By pressing the PV/SV button in the lower left corner
of the controller, you can see the Present Value (actual temperature) or the Set
Value (temperature set point). The temperature and PID (proportional, integral and
derivative) control parameters have been set at the factory and no further
adjustment should be necessary. Should you need to adjust the temperature, follow
these steps:
1. Select SV with the PV/SV button.
2. Press the "up-arrow" under the digit you want to change (the digit will flash),
3. Press the "up-arrow" under the digit or the "down-arrow" at the left to scroll the
digit to the desired value.
4. Repeat for the other two digits.
5. Press the ENTER button.
6. Select PV with the PV/SV button to observe the actual temperature.
7.2.1 Temperature Controller Setup
The temperature controller has been programmed at the factory and should not need
to be altered under normal usage. Indications that would require re-programming
are:
• Failure / replacement of controller.
• Replacement of thermocouple element.
• Controller’s loss of PID parameters leading to instability of the temp setpoint.
In the event that the control parameters are changed or in the event that a new
controller is installed, it must be reprogrammed to suit the thermal characteristics
of the instrument. The controller includes an Autotuning feature, which can be used
to properly set the PID factors.
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Model T200U NOy Option Manual Addendum
SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
DATA
SEL
HYS HYSTERESIS
SET TO 0.3
SEL
0 = OPEN 1 = LOCKED
2 = SV ONLY OPEN
To start the Autotune procedure:
1. Press SEL until A7 (AT) is displayed
2. Press Data until value = 1 (enable Autotune)
• While Autotuning, the decimal point LED will blink.
• NOTE: During the procedure, it is normal for the temp to overshoot up to
100°C.
• When the decimal point LED turns off, Autotune is complete. No further
adjustment should be necessary.
Table 6 Temperature Controller Programming Guide
PRESS DISPLAY ACTION
P PROP BAND UP/DOWN SET TO 5.0 (ENTER)
i INTEGRAL SET TO 50
d DERIVATIVE TIME SET TO 15
AL LOW ALARM SETP SET TO 300
AH HIGH ALARM SETP SET TO 330
7C CYCLE TIME SET TO 2 (FOR FAST SYSTEM)
LOC LOCK
NOTE: DO NOT SET THE TEMPERATURE (SV) HIGHER THAN 320oC.
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Model T200U NOy Option Manual Addendum
P-SU
P-AH
A7
SECONDARY MENU (The fixed characteristics of the system).
PRESS DISPLAY ACTION
SEL hold until
*Thermocouple
SEL hold until
*Thermocouple
SEL hold until
p-n1
Type K:
p-n2
Type J:
p-n2
SET TO 0 – REVERSE ACTION
SET TO 3 = TYPE K THERMOCOUPLE
SET TO 2 = TYPE J THERMOCOUPLE
SEL p-dF DIGITAL FILTER SET TO 5
SEL P-SL LOWER LIMIT SET TO -40 (-40ºC)
SEL
SEL
UPPER LIMIT SET TO 350 (350ºC)
ALARM
SET TO 0
SEL P-An HYTERESIS SET TO 5
SEL P-dP PROG DECIMAL SET TO 0
SEL PVOF PROCESS OFFSET LEAVE AT 0
SEL SVOF SET POINT OFFS LEAVE AT 0
SEL
SEL
SEL hold until
P-F
P-n1
RETURNS TO MAIN MENU
SET TO 0 (0 = oC, 1 = oF)
ALREADY CONFIGURED
SEL
SEL hold until
SEL SCROLL TO
PV/SV
SET DISPLAY TO 315 °C
P PROP BAND ALREADY CONFIGURED
SET TO 1 (AUTOTUNE )
* See Figure 7 to determine whether the thermocouple is Type K or Type J.
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Model T200U NOy Option Manual Addendum
Figure 7. Thermocouples, J-Type and K-Type
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Model T200U NOy Option Manual Addendum
36 07303E DCN7996
Figure 8. Electrical Diagram
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