OPERATION MANUAL
MODEL T802
PARAMAGNETIC OXYGEN ANALYZER
© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone: 800-324-5190
Phone: 858-657-9800
Fax: 858-657-9816
Email: [email protected]
Website: http://www.teledyne-api.com/
Copyright 2010-2013
Teledyne Advanced Pollution Instrumentation
07275B DCN6418
14 January 2013
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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, SO2, NOX and Ozone.
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 api-
NOTICE OF COPYRIGHT
© 2010-2013 Teledyne Advanced Pollution Instrumentation. All rights reserved.
TRADEMARKS
All trademarks, registered trademarks, brand names or product names appearing
in this document are the property of their respective owners and are used herein
for identification purposes only.
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SAFETY MESSAGES
Important safety messages are provided throughout this manual for the purpose
of avoiding personal injury or instrument damage. Please read these messages
carefully. Each safety message is associated with a safety alert symbol, and are
placed throughout this manual; the safety symbols are also located inside the
instrument. It is imperative that you pay close attention to these messages, the
descriptions of which are as follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message for
specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or the
instrument.
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
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 use and maintenance of this or any other
Teledyne API product, contact Teledyne API’s Technical Support Department:
Telephone: 800-324-5190
Email: [email protected]
or access the service options on our website at http://www.teledyne-api.com/
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CONSIGNES DE SÉCURITÉ
Des consignes de sécurité importantes sont fournies tout au long du présent
manuel dans le but d’éviter des blessures corporelles ou d’endommager les
instruments. Veuillez lire attentivement ces consignes. Chaque consigne de
sécurité est représentée par un pictogramme d’alerte de sécurité; ces
pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les
symboles correspondent aux consignes suivantes :
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL
/
MISE EN GARDE : Lire la consigne
complémentaire pour des renseignements spécifiques
MISE EN GARDE : Surface chaude
Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou
sans les outils appropriés pourrait entraîner des dommages aux pièces ou à
l’instrument.
Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent
être effectuées uniquement par du personnel de maintenance qualifié.
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central
de la mise à la terre sécuritaire de l’instrument.
MISE EN GARDE
Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce
manuel. Si vous utilisez cet instrument d’une autre manière que celle pour
laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible
et entraîner des conséquences dangereuses.
NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!
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WARRANTY
WARRANTY POLICY (02024F)
Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne
Instruments, Inc., provides that:
Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should
equipment failure occur, TAPI assures its customers that prompt service and support
will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, TAPI stands ready
to provide on-site or in-plant service at reasonable rates similar to those of other
manufacturers in the industry. All maintenance and the first level of field
troubleshooting are to be performed by the customer.
NON-TAPI MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by TAPI is warranted and will be repaired
to the extent and according to the current terms and conditions of the respective
equipment manufacturer’s warranty.
PRODUCT RETURN
All units or components returned to Teledyne API should be properly packed for
handling and returned freight prepaid to the nearest designated Service Center.
After the repair, the equipment will be returned, freight prepaid.
The complete Terms and Conditions of Sale can be reviewed at
http://www.teledyne-api.com/terms_and_conditions.asp
CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions
and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration
may void your warranty. For anti-ESD handling and packing instructions please refer to “Packing
Components for Return to Teledyne API’s Technical Support” in the Primer on Electro-Static
Discharge section of this manual, and for RMA procedures please refer to our Website at
http://www.teledyne-api.com under Customer Support > Return Authorization.
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ABOUT THIS MANUAL
This operation manual, PN 07275, is comprised of multiple documents in
PDF format, as listed below.
Part No.
07275
06530
07269
06535
06532
Rev
Name/Description
B
C
A
A
C
T802 Operation manual
Menu Trees and Software Documentation (inserted as Appendix A in this manual)
Spare Parts List (located in Appendix B of this manual)
Expendables Kit (located in Appendix B of this manual)
Repair Request Form (inserted as Appendix C in this manual)
Appendix D Documents:
0738001
07380
05803
06698
06882
06731
A
A
B
D
B
A
Interconnect List
Interconnect Diagram
SCH, PCA 05802, MOTHERBOARD, GEN-5
SCH, PCA 06697, INTRFC, LCD TCH SCRN
SCH, LVDS TRANSMITTER BOARD
SCH, AUXILLIARY-I/O BOARD
Note
We recommend that this manual be read in its entirety before any attempt is
made to operate the instrument.
ORGANIZATION
This manual is divided among three main parts and a collection of appendices at
the end:
Part I contains introductory information that includes an overview of the
analyzer, specifications, descriptions of the available options, installation and
connection instructions, and the initial calibration and functional checks.
Part II comprises the operating instructions, which include setup and calibration,
as well as remote operation, and ends with the specifics of calibrating for use in
monitoring within EPA protocol.
Part III provides detailed technical information starting with maintenance,
troubleshooting and service, frequently asked questions, principles of operation, a
primer on electrostatic discharge, and a glossary.
The appendices at the end of the manual provide support information such as
version-specific software documentation, lists of spare parts* and recommended
stocking levels, and schematics.
*Part numbers do not reflect real-time updates – contact Sales or Technical
Support).
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CONVENTIONS USED
In addition to the safety symbols as presented in the Important Safety Information
page, this manual provides special notices related to the safety and effective use
of the analyzer and other pertinent information.
Special Notices appear as follows:
COULD DAMAGE INSTRUMENT AND VOID WARRANTY
ATTENTION
This special notice provides information to avoid damage to your
instrument and possibly invalidate the warranty.
IMPORTANT
IMPACT ON READINGS OR DATA
Could either affect accuracy of instrument readings or cause loss of
data.
Note
Pertinent information associated with the proper care, operation or
maintenance of the analyzer or its parts.
REVISION HISTORY
T802 Operation and Maintenance Manual, PN07275
Date
Rev
B
DCN
6418
6005
Description
Administrative Updates and specs updates
Initial Release
2013 January 14
2011 February 18
A
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TABLE OF CONTENTS
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI).......................................................................... i
Safety Messages ...................................................................................................................................................iii
Warranty ................................................................................................................................................................ v
About This Manual................................................................................................................................................vii
Table of Contents ................................................................................................................................................. ix
1. INTRODUCTION, FEATURES AND OPTIONS..................................................................17
1.1. T802 Overview..............................................................................................................................................17
1.2. Features........................................................................................................................................................17
1.3. Options .........................................................................................................................................................18
2. SPECIFICATIONS, APPROVALS & COMPLIANCE................................................................21
2.1. Specifications................................................................................................................................................21
2.2. Approvals and Certifications.........................................................................................................................22
2.2.1. Safety ....................................................................................................................................................22
2.2.2. EMC.......................................................................................................................................................22
2.2.3. Other Type Certifications.......................................................................................................................22
3. GETTING STARTED...........................................................................................................23
3.1. Unpacking the T802 Analyzer ......................................................................................................................23
3.1.1. Ventilation Clearance ............................................................................................................................25
3.2. Instrument Layout.........................................................................................................................................25
3.2.1. Front Panel............................................................................................................................................25
3.3. Connections and Setup ................................................................................................................................32
3.3.1. Electrical Connections...........................................................................................................................32
3.3.2. Pneumatic Connections ........................................................................................................................46
3.4. Startup, Functional Checks, and Initial Calibration.......................................................................................52
3.4.1. Startup...................................................................................................................................................52
3.4.2. Functional Checks.................................................................................................................................54
3.4.3. Initial Calibration....................................................................................................................................55
4. BASIC OPERATION...........................................................................................................63
4.1. Overview of Operating Modes......................................................................................................................63
4.2. Sample Mode................................................................................................................................................65
4.3. Calibration Mode...........................................................................................................................................66
4.4. Setup Mode ..................................................................................................................................................67
4.4.1. Primary Setup Menu..............................................................................................................................67
4.4.2. Secondary Setup Menu (Setup>More)..................................................................................................68
5.1. SETUP CFG: Configuration Information..................................................................................................69
5.2. SETUP ACAL: [NOT USED]....................................................................................................................69
5.3. SETUP DAS: Internal Data Acquisition System ......................................................................................69
5.4. SETUP RNGE: Analog Output Reporting Range Configuration..............................................................70
5.4.1. Physical Range versus Analog Output Reporting Ranges....................................................................70
5.4.2. Analog Output Ranges for O2 Concentration ........................................................................................71
5.4.3. Reporting Range Modes .......................................................................................................................72
5.4.4. SETUP RNGE DIL: Using the Optional Dilution Ratio Feature.....................................................77
5.5. SETUP PASS: Password Feature ...........................................................................................................78
5.6. SETUP CLK: Setting the T802 Analyzer’s Internal Clock........................................................................81
5.6.1. Setting the Internal Clock’s Time and Day............................................................................................81
5.6.2. Adjusting the Internal Clock’s Speed.....................................................................................................82
5.7. SETUP MORE COMM: Communication Ports.....................................................................................83
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
5.7.1. ID (Machine Identification).....................................................................................................................83
5.7.2. INET (Ethernet) .....................................................................................................................................84
5.7.3. COM1[COM2] (Mode, Baude Rate and Test Port) ...............................................................................85
5.8. SETUP MORE VARS: Internal Variables (VARS)...............................................................................85
5.9. SETUP MORE DIAG: Diagnostics Functions....................................................................................88
5.9.1. Signal I/O...............................................................................................................................................90
5.9.2. Analog Output........................................................................................................................................91
5.9.3. Analog I/O Configuration.......................................................................................................................91
5.9.4. Turning an Analog Output Over-Range Feature ON/OFF ..................................................................103
5.9.5. Adding a Recorder Offset to an Analog Output...................................................................................104
5.9.6. Selecting a Test Channel Function for Output A4...............................................................................105
5.9.7. AIN Calibration ....................................................................................................................................107
5.9.8. Analog Inputs (XIN1…XIN8) Option Configuration .............................................................................108
5.10. SETUP MORE ALRM: Using the Gas Concentration Alarms (Option 61).......................................109
5.10.1. Setting the T802 Option 61 Concentration Alarm Limits...................................................................110
6. COMMUNICATIONS SETUP AND OPERATION.............................................................113
6.1. Data Terminal/Communication Equipment (DTE DCE) ...................................................................................113
6.2. Communication Modes, Baud Rate and Port Testing ................................................................................113
6.2.1. COM Port Communication Modes.......................................................................................................114
6.2.2. COM Port Baud Rate ..........................................................................................................................116
6.2.3. COM Port Testing................................................................................................................................117
6.3. Remote Access via the Ethernet ................................................................................................................118
6.3.1. Configuring the Ethernet Interface using DHCP .................................................................................118
6.3.2. Manually Configuring the Network IP Addresses................................................................................121
6.4. USB Port for Remote Access .....................................................................................................................124
6.5. Communications Protocols.........................................................................................................................126
6.5.1. MODBUS Setup ..................................................................................................................................126
6.5.2. Hessen ................................................................................................................................................128
7. DATA ACQUISITION SYSTEM (DAS) & APICOM.............................................................138
7.1. DAS Structure.............................................................................................................................................139
7.1.1. DAS Channels.....................................................................................................................................139
7.1.2. Default DAS Channels.........................................................................................................................140
7.1.3. SETUP DAS VIEW: Viewing DAS Channels and Individual Records.........................................143
7.1.4. SETUP DAS EDIT: Accessing the DAS Edit Mode ....................................................................144
7.2. Remote DAS Configuration ........................................................................................................................157
7.2.1. DAS Configuration via APICOM..........................................................................................................157
7.2.2. DAS Configuration via Terminal Emulation Programs ........................................................................159
8. REMOTE OPERATION.....................................................................................................160
8.1. Computer Mode..........................................................................................................................................160
8.1.1. Remote Control via APICOM ..............................................................................................................160
8.2. Interactive Mode .........................................................................................................................................161
8.2.1. Remote Control via a Terminal Emulation Program............................................................................161
8.3. Remote Access by Modem.........................................................................................................................164
8.4. COM Port Password Security.....................................................................................................................166
9. CALIBRATION PROCEDURES .......................................................................................169
9.1. Before Calibration.......................................................................................................................................170
9.1.1. Required Equipment, Supplies, and Expendables..............................................................................170
9.1.2. Calibration Gases................................................................................................................................170
9.1.3. Data Recording Devices......................................................................................................................171
9.2. Manual Calibration Checks and Calibration ...............................................................................................172
9.2.1. Setup for Basic Calibration Checks and Calibration ...........................................................................172
9.2.2. Performing a Basic Manual Calibration Check....................................................................................173
9.2.3. Performing a Basic Manual Calibration...............................................................................................174
9.3. Assessing Calibration Quality.....................................................................................................................176
9.4. Calibration of the T802’s Electronic Subsystems.......................................................................................176
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Table of Contents
9.4.1. Pressure Calibration............................................................................................................................176
9.4.2. Flow Calibration...................................................................................................................................178
9.5. Calibration of the Optional CO2 Sensor......................................................................................................179
9.5.1. CO2 Calibration Setup .........................................................................................................................179
9.5.2. Set CO2 Span Gas Concentration.......................................................................................................179
9.5.3. Activate CO2 Sensor Stability Function...............................................................................................180
9.5.4. CO2 Zero/Span Calibration:.................................................................................................................181
10.1. Maintenance Schedule.............................................................................................................................185
10.2. Predictive Diagnostics ..............................................................................................................................189
10.3. Maintenance Procedures..........................................................................................................................189
10.3.1. Replacing the Sample Particulate Filter............................................................................................189
10.3.2. Rebuilding the Sample Pump............................................................................................................190
10.3.3. Performing Leak Checks...................................................................................................................191
10.3.4. Performing a Sample Flow Check.....................................................................................................192
10.3.5. Cleaning the Optical Bench...............................................................................................................193
10.3.6. Cleaning Exterior Surfaces of the T802 ............................................................................................193
11. TROUBLESHOOTING AND SERVICE..........................................................................195
11.1. General Troubleshooting..........................................................................................................................195
11.1.1. Fault Diagnosis with WARNING Messages ......................................................................................196
11.1.2. Fault Diagnosis with TEST Functions ...............................................................................................199
11.1.3. DIAG SIGNAL I/O: Using the Diagnostic Signal I/O Function.....................................................200
11.2. Using the Internal Electronic Status LEDs ...............................................................................................202
11.2.1. CPU Status Indicator.........................................................................................................................202
11.2.2. Relay PCA Status Indicators.............................................................................................................202
11.3. Gas Flow Problems ..................................................................................................................................203
11.3.1. T802 Internal Gas Flow Diagrams.....................................................................................................204
11.3.2. Typical Sample Gas Flow Problems .................................................................................................205
11.4. Calibration Problems ................................................................................................................................207
11.4.1. Miscalibrated .....................................................................................................................................207
11.4.2. Non-Repeatable Zero and Span .......................................................................................................207
11.4.3. Inability to Span – No SPAN Button..................................................................................................208
11.4.4. Inability to Zero – No ZERO Button...................................................................................................208
11.5. Other Performance Problems...................................................................................................................208
11.5.1. Temperature Problems......................................................................................................................208
11.6. Subsystem Checkout................................................................................................................................209
11.6.1. AC Mains Configuration ....................................................................................................................209
11.6.2. DC Power Supply ..............................................................................................................................209
11.6.3. I2C Bus...............................................................................................................................................210
11.6.4. Touchscreen Interface.......................................................................................................................210
11.6.5. LCD Display Module..........................................................................................................................210
11.6.6. Relay Board.......................................................................................................................................211
11.6.7. Sensor Assembly...............................................................................................................................211
11.6.8. Pressure/Flow Sensor Assembly ......................................................................................................211
11.6.9. Motherboard ......................................................................................................................................212
11.6.10. CPU.................................................................................................................................................213
11.6.11. RS-232 Communications ................................................................................................................214
11.6.12. Optional CO2 Sensor.......................................................................................................................215
11.7. Repair Procedures....................................................................................................................................215
11.7.1. Repairing Sample Flow Control Assembly........................................................................................215
11.7.2. Disk-On-Module Replacement Procedure ........................................................................................216
11.8. FAQ’s........................................................................................................................................................217
11.9. Technical Assistance................................................................................................................................218
12. PRINCIPLES OF OPERATION ......................................................................................219
12.1. Paramagnetic Oxygen Measurement.......................................................................................................219
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
12.1.1. Magnetic Properties of O2 Gas..........................................................................................................219
12.1.2. Principle of Measurement..................................................................................................................219
12.2. NDIR Measurement of CO2 ......................................................................................................................221
12.2.1. Operation within the T802 Analyzer ..................................................................................................222
12.3. Pneumatic Operation................................................................................................................................222
12.3.1. Pneumatic Operation of the CO2 Sensor ..........................................................................................223
12.4. Flow Rate Control.....................................................................................................................................224
12.4.1. Critical Flow Orifice............................................................................................................................224
12.4.2. Particulate Filter.................................................................................................................................225
12.4.3. Pneumatic Sensors ...........................................................................................................................225
12.5. Electronic Operation.................................................................................................................................226
12.5.1. Overview............................................................................................................................................226
12.5.2. Electronic Operation of the CO2 Sensor............................................................................................227
12.5.3. Central Processing Unit (CPU)..........................................................................................................228
12.5.4. Relay Board.......................................................................................................................................229
12.5.5. Heater Control ...................................................................................................................................232
12.5.6. Motherboard ......................................................................................................................................232
12.5.7. Front Panel Touch Screen/Display Interface ....................................................................................235
12.5.8. Software Operation............................................................................................................................237
12.5.9. Adaptive Filter....................................................................................................................................237
12.5.10. Calibration - Slope and Offset .........................................................................................................238
12.5.11. Temperature and Pressure Compensation.....................................................................................238
12.5.12. Internal Data Acquisition System (DAS) .........................................................................................238
13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................239
13.1. How Static Charges are Created..............................................................................................................239
13.2. How Electro-Static Charges Cause Damage ...........................................................................................240
13.3. Common Myths About ESD Damage.......................................................................................................241
13.4. Basic Principles of Static Control..............................................................................................................242
13.4.1. General Rules....................................................................................................................................242
13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance..................................................244
LIST OF FIGURES
Figure 3-1:
Figure 3-2.
Figure 3-3.:
Figure 3-4:
Figure 3-5:
Figure 3-6:
Figure 3-7:
Figure 3-8:
Figure 3-9:
Figure 3-10:
Figure 3-11:
Figure 3-12:
Figure 3-13.
Figure 3-14:
Figure 3-15:
Figure 3-16:
Figure 3-17:
Figure 3-18:
Figure 3-19:
Front Panel Layout.........................................................................................................25
Display Screen and Touch Control................................................................................. 26
Display/Touch Control Screen Mapped to Menu Charts................................................ 28
Rear Panel Layout..........................................................................................................29
Internal Layout................................................................................................................ 31
Analog In Connector.......................................................................................................33
Analog Output Connector............................................................................................... 34
Current Loop Option Installed ........................................................................................ 35
Status Output Connector................................................................................................ 37
Control Input Connector ................................................................................................. 38
Concentration Alarm Relay ............................................................................................ 39
Default Pin Assignments, Rear Panel COM Port Connectors ....................................... 41
CPU Connector Pin-Outs for RS-232 Mode................................................................... 42
Jumper and Cables for Multidrop Mode......................................................................... 44
RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram........................................ 45
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ....................... 48
T802 Internal Gas Flow (Basic Configuration) ............................................................... 50
T802 – Internal Gas Flow with CO2 Sensor Option........................................................ 51
Viewing and Clearing T802 WARNING Messages ........................................................ 53
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Table of Contents
Figure 4-1:
Figure 4-2:
Figure 5-1:
Figure 5-2:
Figure 5-3:
Figure 5-4:
Figure 7-1:
Figure 7-2:
Figure 7-3:
Figure 7-4:
Figure 9-1:
Figure 9-2:
Figure 10-1:
Figure 11-1:
Figure 11-2:
Figure 11-3:
Figure 11-4:
Figure 11-5:
Figure 11-6:
Figure 11-7:
Figure 11-8:
Figure 12-1:
Figure 12-2:
Figure 12-3:
Figure 12-4:
Figure 12-5:
Figure 12-6:
Figure 12-7:
Figure 12-8:
Figure 12-9.
Figure 12-10:
Figure 12-11:
Figure 12-12:
Figure 12-13:
Figure 12-14:
Figure 12-15:
Figure 13-1:
Figure 13-2:
Front Panel Touchscreen and Display........................................................................... 64
Viewing Test Functions .................................................................................................. 65
Analog Output Connector Pin Out.................................................................................. 71
Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 98
Default DAS Channel Setup.........................................................................................142
APICOM Remote Control Program Interface............................................................... 157
APICOM User Interface for Configuring the DAS ........................................................ 158
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ..................... 172
CO2 Sensor Calibration Set Up....................................................................................179
Sample Particulate Filter Assembly..............................................................................190
Viewing and Clearing Warning Messages ...................................................................198
Example of Signal I/O Function....................................................................................201
CPU Status Indicator....................................................................................................202
Relay PCA Status LEDS Used for Troubleshooting..................................................... 203
T802– Basic Internal Gas Flow ....................................................................................204
T802 – Internal Pneumatics with CO2 Sensor Option 67............................................. 205
Location of Diagnostic LEDs on CO2 Sensor PCA....................................................... 215
Critical Flow Restrictor Assembly / Disassembly ......................................................... 216
Paramagnetic O2 Sensor Design .................................................................................220
Paramagnetic O2 Sensor Block Diagram ..................................................................... 220
CO2 Sensor Theory of Operation .................................................................................221
T802 – Internal Pneumatic Flow – Basic Configuration ............................................... 223
T802 – Internal Pneumatic Flow with CO2 Sensor Option ........................................... 224
Flow Control Assembly & Critical Flow Orifice.............................................................225
T802 Electronic Block Diagram....................................................................................227
CPU Card .....................................................................................................................229
Relay PCA Layout (PN 04135).....................................................................................230
Relay PCA with AC Relay Retainer in Place................................................................231
Status LED Locations – Relay PCA .............................................................................232
Power Distribution Block Diagram................................................................................235
Front Panel and Display Interface Block Diagram ....................................................... 236
Basic Software Operation.............................................................................................237
Triboelectric Charging ..................................................................................................239
Basic Anti-ESD Workbench.......................................................................................... 242
LIST OF TABLES
Table 1-1.
Table 2-1:
Table 3-1:
Table 3-2.
Table 3-3.
Table 3-4.
Table 3-5:
Table 3-6:
Table 3-7:
Table 3-8:
Table 3-9:
Table 4-1:
Analyzer Options ............................................................................................................18
T802 Specifications........................................................................................................ 21
Ventilation Clearance ..................................................................................................... 25
Display Screen and Touch Control Description ............................................................. 27
Rear Panel Component Descriptions............................................................................. 30
Analog Input Pin Assignments .......................................................................................33
Analog Output Pin-Outs ................................................................................................. 34
Status Output Signals..................................................................................................... 37
Control Input Signals...................................................................................................... 38
NISTSRMs Available for Traceability of O2 Calibration Gases ....................................... 47
Front Panel Display during System Warm-Up ............................................................... 52
Analyzer Operating Modes............................................................................................. 64
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Table of Contents
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Table 4-2:
Table 6-4:
Table 6-5:
Table 5-2:
Table 5-3:
Table 5-4:
Table 5-5:
Table 5-6:
Table 5-7:
Table 5-8:
Table 5-9:
Table 6-1:
Table 6-2:
Table 6-3:
Table 6-4:
Table 6-5:
Table 6-6:
Table 7-1:
Table 7-2:
Table 7-3:
Table 8-2:
Table 9-1:
Table 9-2:
Table 10-1.
Table 10-2:
Table 10-3:
Table 11-1:
Table 11-2:
Table 11-3:
Table 11-4:
Table 11-5:
Table 11-6:
Table 11-7:
Table 11-8:
Table 12-1:
Table 13-1:
Table 13-2:
Test Functions Defined .................................................................................................. 66
Primary Setup Mode Features and Functions................................................................ 67
Secondary Setup Mode Features and Functions........................................................... 68
Variable Names (VARS)................................................................................................. 86
Diagnostic Mode (DIAG) Functions................................................................................ 88
DIAG - Analog I/O Functions..........................................................................................91
Analog Output Voltage Range Min/Max......................................................................... 93
Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 98
Current Loop Output Check .........................................................................................102
O2 Concentration Alarm Default Settings .....................................................................109
COM Port Communication Modes................................................................................114
Ethernet Status Indicators............................................................................................ 118
LAN/Internet Configuration Properties ......................................................................... 119
RS-232 Communication Parameters for Hessen Protocol........................................... 128
Teledyne API Hessen Protocol Response Modes .......................................................131
Default Hessen Status Flag Assignments....................................................................135
Front Panel LED Status Indicators for DAS .................................................................138
DAS Data Channel Properties......................................................................................140
DAS Data Parameter Functions...................................................................................147
Teledyne API Serial I/O Command Types ................................................................... 162
NISTSRM's Available for Traceability of O2 Calibration Gases..................................... 171
Calibration Data Quality Evaluation.............................................................................. 176
T802 Maintenance Schedule........................................................................................187
T802 Test Function Record..........................................................................................188
Predictive uses for Test Functions ...............................................................................189
Warning Messages - Indicated Failures.......................................................................198
Test Functions - Indicated Failures ..............................................................................200
Relay PCA Watchdog LED Failure Indications ............................................................202
Relay PCA Status LED Failure Indications ..................................................................203
DC Power Test Point and Wiring Color Codes ............................................................209
DC Power Supply Acceptable Levels...........................................................................210
Analog Output Test Function - Nominal Values Current Outputs ................................ 212
Status Outputs Check ..................................................................................................213
Relay PCA Status LEDs...............................................................................................231
Static Generation Voltages for Typical Activities..........................................................240
Sensitivity of Electronic Devices to Damage by ESD................................................... 240
LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION
A-1 - T802 Software Menu Trees
A-2 - T802 Setup Variables for Serial I/O
A-3 - T802 Warnings and Test Functions
A-4 - T802 Signal I/O Definitions
A-5 - T802 DAS Functions
A-6 - T802 Terminal Command Designators
A-7 - T802 MODBUS® Register Map
APPENDIX B - T802 SPARE PARTS LIST
APPENDIX C – T802 REPAIR QUESTIONNAIRE
APPENDIX D – T802 ELECTRONIC SCHEMATICS
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PART I
–
GENERAL INFORMATION AND SETUP
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Section 1 General Information
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
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1. INTRODUCTION, FEATURES AND OPTIONS
1.1. T802 OVERVIEW
The Model T802 (also referred to as T802) Paramagnetic Oxygen Analyzer is a
microprocessor-controlled analyzer that determines the concentration of
molecular oxygen (O2) in a sample gas drawn through the instrument. It uses a
paramagnetic sensor that relies on the relatively high reactivity of O2 molecules
to magnetic fields to generate a current that is proportional to the amount of O2
present in the sensor chamber.
The T802 analyzer’s multi-tasking software gives the ability to track and report a
large number of operational parameters in real time. These readings are
compared to diagnostic limits kept in the analyzer’s memory where, should any
fall outside of those limits, the analyzer issues automatic warnings.
Built-in data acquisition capability using the analyzer's internal memory, allows
the logging of multiple parameters including averaged or instantaneous
concentration values, calibration data, and operating parameters such as pressure
and flow rate. Stored data are easily retrieved through the serial port or optional
Ethernet port via our APICOM software or from the front panel, allowing
operators to perform predictive diagnostics and enhanced data analysis by
tracking parameter trends. Multiple averaging periods of one minute to 365 days
are available for over a period of one year.
1.2. FEATURES
Some exceptional features of your T802 Paramagnetic Oxygen Analyzer are:
Non-depleting, paramagnetic sensor for O2 specific measurement:
Virtually no cross-sensitivities
Rapid response times
No consumable parts
Consistent performance over time
No susceptibility to CO2 poisoning (unlike electromechanical O2 sensors)
Microprocessor controlled for versatility
LCD Graphical User Interface with capacitive touch screen
Multi-tasking software for viewing of test variables during operation
Continuous self checking with alarms
Bi-directional USB, RS-232, and 10BaseT/100BaseT Ethernet ports for
remote operation (optional RS-485)
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
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Introduction, Features and Options
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
HAZARD
Strong Oxidizer
OXYGEN IS A STRONG OXIDIZER.
This is a general purpose instrument designed for usage in nonhazardous areas. Ensure
that all safety precautions related combustible gases are followed.
Before working with the casing open, be sure to turn off power to the analyzer, and
perform air or N2 gas purging of not only the analyzer inside, but also the sample gas line.
In addition, carefully prevent oil and grease from adhering to any tubing. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.
1.3. OPTIONS
Table 1-1 presents the options available with the T802 analyzer. For assistance
with ordering, please contact the Sales department of Teledyne API at:
PHONE (toll free,
North America)
800-324-5190
FAX:
858-657-9816
PHONE (Direct):
E-MAIL:
858-657-9800
www.teledyne-api.com
WEB SITE
Table 1-1. Analyzer Options
Option
Number
Option
Description/Notes
Reference
Pumps meet all typical AC power supply standards while exhibiting same pneumatic
performance.
Pumps
10A
10B
10C
10D
10E
14
External Pump 100V - 120V @ 60 Hz
External Pump 220V - 240V @ 50 Hz
External Pump 220V - 240V @ 60 Hz
External Pump 100V – 120V @ 50 Hz
External Pump 100V @ 60 Hz
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Internal Pump
13
High Voltage Internal Pump 240V @ 50Hz
Rack Mount
Kits
Options for mounting the analyzer in standard 19” racks
20A
20B
21
Rack mount brackets with 26 in. chassis slides
Rack mount brackets with 24 in. chassis slides
N/A
N/A
Rack mount brackets only (compatible with carrying strap, Option 29) N/A
23
Rack mount for external pump pack (no slides)
N/A
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Introduction, Features and Options
Option
Number
Option
Description/Notes
Reference
Carrying Strap/Handle
Side-mounted strap for hand-carrying analyzer
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.
29
N/A
CAUTION - GENERAL SAFETY HAZARD
THE T802 WEIGHS ABOUT 28 POUNDS (12.7 KG). TAKE CARE TO
AVOID PERSONAL INJURY WHEN LIFTING/CARRYING THE
ANALYZER.
ALSO, DISCONNECT ALL CABLES AND TUBING FROM THE
ANALYZER BEFORE MOVING IT.
Used for connecting external voltage signals from other instrumentation (such as
meteorological instruments).
Analog Inputs w/USB port
Also can be used for logging these signals in the analyzer’s internal
DAS. (See Option 64A for USB port only).
Sections 3.3.1.2
and 5.9.8
64B
Current Loop Analog
Outputs
Adds isolated voltage-to-current conversion circuitry to the analyzer’s analog
outputs.
Can be configured for 0-20 mA or 4-20 mA.
41
May be ordered separately for any of the analog outputs.
Can be installed at the factory or retrofitted in the field.
Section 3.3.1.4
Parts Kits
Spare parts and expendables
Expendables Kit for analyzer with a pump, includes a recommended
set of expendables for one year of operation.
42A
Appendix B
Appendix B
Expendables Kit for analyzer without a pump, includes a
recommended set of expendables for one year of operation.
42D
Communication Cables
For remote serial, network and Internet communication with the analyzer.
Type
Description
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.
60A
RS-232
Shielded, straight-through DB-9F to DB-9F cable of about
1.8 m length.
60B
60C
60D
RS-232
Ethernet
USB
Sections 3.3.1.8
and 6
Patch cable, 2 meters long, used for Internet and LAN
communications.
Cable for direct connection between instrument (rear
panel USB port) and personal computer.
Concentration Alarm Relay Issues warning when gas concentration exceeds limits set by user.
Four (4) “dry contact” relays on the rear panel of the instrument. This
61
RS-232 Multidrop
62
relay option is different from and in addition to the “Contact Closures”
that come standard on all TAPI instruments.
Section 3.3.1.7
Enables communications between host computer and up to eight analyzers.
Multidrop card seated on the analyzer’s CPU card.
Each instrument in the multidrop network requires this card and a
communications cable (Option 60B).
Section 3.3.1.8
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Introduction, Features and Options
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Option
Option
Description/Notes
Reference
Number
USB COM Port
64A
inputs). Disabled when using Multidrop or RS-485 communication.
Second Gas Sensor
67A
Carbon Dioxide (CO2) Sensor 0-20%
Special Features
Built in features, software activated
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.
N/A
N/A
N/A
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.
N/A
N/A
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 3.4.3.2
and 5.4.4
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2. SPECIFICATIONS, APPROVALS & COMPLIANCE
2.1. SPECIFICATIONS
Table 2-1: T802 Specifications
PARAMETER
O2 Sensor
Ranges
SPECIFICATION
Min: 0-1% Full scale
Max: 0-100% Full scale (user selectable)
< 0.02% (RMS)
< 0.05% of reading (RMS)
< 0.04%
Zero Noise1
Span Noise1
Lower Detectable Limit2
Zero Drift3
< ±0.02%/24 hours; < ±0.05%/7 days
< ±0.1%/7 days
Span Drift
< ±0.1%
Accuracy
< ±0.1%
Linearity
< ±0.01%/degree C
Temperature Coefficient
CO2 Sensor Option
Ranges
Min: 0-1% Full scale
Max: 0-20% Full scale (user selectable; dual ranges and auto ranging supported)
< 0.02% (RMS)
< 0.1% of reading (RMS)
< 0.04%
< ±0.02%/24 hours; < ±0.05%/7 days
< ±0.1%/7 days
Zero Noise1
Span Noise1
Lower Detectable Limit2
Zero Drift
Span Drift
< ±(1.5% of range +2% of reading)
< ±0.01%/degree C
Accuracy
Temperature Coefficient
<60 seconds to 95%
Rise and Fall Time
120ml ±20ml/min
0-95% RH
Flow Rate
Humidity Range
25-31 in HG
Pressure Range
AC Power
100V – 120V 60 Hz (77W); 220V – 240 V 50 Hz (80W)
All Outputs: 0.1 V, 1 V, 5 V or 10 V
Analog Output Ranges
Three outputs convertible to 4-20 mA isolated current loop.
All Ranges with 5% under/over-range
Recorder Offset
± 10%
Analog Output Resolution
1 part in 4096 of selected full-scale voltage
1 Ethernet: 10/100Base-T
2 RS-232 (300 – 115,200 baud)
2 USB device ports
Standard I/O
8 opto-isolated digital status outputs
6 opto-isolated digital control inputs
4 analog outputs
1 USB com port
1 RS485
Optional I/O
8 analog inputs (0-10V, 12-bit)
4 digital alarm outputs
Multidrop RS232
3 4-20mA current outputs
Alarm outputs
2 opto-isolated alarms outputs with user settable alarm limits
1 As defined by the USEPA.
2 Defined as twice the Zero Noise level by the USEPA.
3 Note: Zero Drift is typically < 0.1% O2 during the first 24 hours of operation.
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Specifications, Approvals & Compliance Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
2.2. APPROVALS AND CERTIFICATIONS
The Teledyne API Model T802 Paramagnet Oxygen Analyzer was tested and
certified for Safety and Electromagnetic Compatibility (EMC). This section
presents the compliance statements for those requirements and directives.
2.2.1. SAFETY
IEC 61010-1:2001, Safety requirements for electrical equipment for
measurement, control, and laboratory use.
CE: 2006/95/EC, Low-Voltage Directive
North American:
cNEMKO (Canada): CAN/CSA-C22.2 No. 61010-1-04
NEMKO-CCL (US): UL No. 61010-1 (2nd Edition)
2.2.2. EMC
EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial Immunity
EN 55011 (CISPR 11), Group 1, Class A Emissions
FCC 47 CFR Part 15B, Class A Emissions
CE: 2004/108/EC, Electromagnetic Compatibility Directive
2.2.3. OTHER TYPE CERTIFICATIONS
For additional certifications, please contact Technical Support:
Toll-free Phone: 800-324-5190
Phone: 858-657-9800
Fax: 858-657-9816
Email: [email protected]
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3. GETTING STARTED
This section addresses the procedures for unpacking the instrument and
inspecting for damage, presents clearance specifications for proper ventilation,
introduces the instrument layout, then presents the procedures for getting started:
making electrical and pneumatic connections, and conducting an initial
calibration check.
3.1. UNPACKING THE T802 ANALYZER
CAUTION
GENERAL SAFETY HAZARD
To avoid personal injury, always use two persons to lift and carry the T802.
CAUTION – AVOID WARRANTY INVALIDATION
Printed circuit assemblies (PCAs) are sensitive to electro-static
discharges too small to be felt by the human nervous system. Damage
resulting from failure to use ESD protection when working with electronic
assemblies will void the instrument warranty.
See A Primer on Electro-Static Discharge in this manual for more information on
preventing ESD damage.
CAUTION!
Do not operate this instrument until removing dust plugs from SAMPLE and
EXHAUST ports on the rear panel!
Note
Teledyne API recommends that you store shipping containers/materials
for future use if/when the instrument should be returned to the factory
for repair and/or calibration service. See Warranty section in this manual
and shipping procedures on our Website at http://www.teledyne-api.com
under Customer Support > Return Authorization.
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Section II Operating Instructions
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Verify that there is no apparent external shipping damage. If damage has
occurred, please advise the shipper first, then Teledyne API.
Included with your analyzer is a printed record of the final performance
characterization performed on your instrument at the factory.
This record, Final Test and Validation Data Sheet, PN 068350000, is an
important quality assurance and calibration record for this instrument. It should
be placed in the quality records file for this instrument.
1. Carefully remove the top cover of the analyzer and check for internal shipping
damage as follows:
a) Remove the locking screw located in the top, center of the Front panel;
b) Remove the two flat head, Phillips screws on the sides of the instrument
(one per side towards the rear);
c) Slide the cover backwards until it clears the analyzer’s front bezel;
d) Lift the cover straight up.
2. Inspect the interior of the instrument to make sure all circuit boards and other
components are in good shape and properly seated.
3. Check that the connectors of the various internal wiring harnesses and
pneumatic hoses are firmly and properly seated.
4. Verify that all of the optional hardware ordered with the unit has been installed.
These are listed on the paperwork accompanying the analyzer.
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3.1.1. VENTILATION CLEARANCE
Whether the analyzer is set up on a bench or installed into an instrument rack, be
sure to leave sufficient ventilation clearance.
Table 3-1:
AREA
Ventilation Clearance
MINIMUM REQUIRED CLEARANCE
4 in.
Back of the instrument
Sides of the instrument
1 in.
1 in.
Above and below the instrument
manual for more information.
3.2. INSTRUMENT LAYOUT
Instrument layout shows front panel and display, rear panel connectors, and
internal chassis layout.
3.2.1. FRONT PANEL
Figure 3-1 shows the analyzer’s front panel layout, followed by a close-up of the
on the front panel are provided for the connection of peripheral devices:
plug-in mouse (not included) to be used as an alternative to the touchscreen
interface
thumb drive (not included) to download updates to instruction software
(contact TAPI Technical Support for information).
Figure 3-1:
Front Panel Layout
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Section II Operating Instructions
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
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
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
the screen.
COULD DAMAGE INSTRUMENT AND VOID WARRANTY
ATTENTION
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
LEDs indicating the states of Sample, Calibration and Fault, as follows:
Name
Color
State
Off
Definition
Unit is not operating in sample mode, DAS is disabled.
On
Sample Mode active; Front Panel Display being updated; DAS data
being stored.
SAMPLE Green
Unit is operating in sample mode, front panel display being updated,
DAS hold-off mode is ON, DAS disabled
Blinking
Off
Auto Cal disabled
CAL
Yellow
Red
On
Auto Cal enabled
Blinking
Unit is in calibration mode
Off
Blinking
No warnings exist
Warnings exist
FAULT
Displays the actual concentration of the sample gas currently being measured by the analyzer in the
currently selected units of measure
Conc
Mode
Displays the name of the analyzer’s current operating mode
Displays a variety of informational messages such as warning messages, operational data, test function
values and response messages during interactive tasks.
Param
Control Buttons
Displays dynamic, context sensitive labels on each button, which is blank when inactive until applicable.
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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Section II Operating Instructions
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Table 3-3. Rear Panel Component Descriptions
Component
Function
Pulls ambient air into chassis through side vents and exhausts through rear.
Connector for three-prong cord to apply AC power to the analyzer.
CAUTION! The cord’s power specifications (specs) MUST comply with the power
specs on the analyzer’s rear panel Model number/Volt/Freq information label
cooling fan
AC power
connector
Identifies the analyzer model number and provides power specs
Inlet connection to be used for any one of the following:
Model/specs label
Sample gas
Span gas
Calibration gas
Zero air
SAMPLE
Connect an exhaust gas line of not more than 10 meters long here that leads outside
the shelter or immediate area surrounding the instrument.
EXHAUST
Not used.
SPAN 1
SPAN2/VENT
ZERO AIR
RX TX
Not used.
Not used.
LEDs indicate receive (RX) and transmit (TX) activity on the when blinking.
Serial communications port for RS-232 or RS-485.
Serial communications port for RS-232 only.
COM 2
RS-232
Switch to select either data terminal equipment or data communication equipment
during RS-232 communication.
DCE DTE
For outputs to devices such as Programmable Logic Controllers (PLCs).
For voltage or current loop outputs to a strip chart recorder and/or a data logger.
For remotely activating the zero and span calibration modes.
STATUS
ANALOG OUT
CONTROL IN
ALARM
Option for concentration alarms and system warnings.
Connector for network or Internet remote communication, using Ethernet cable
ETHERNET
Option for external voltage signals from other instrumentation and for logging these
signals
ANALOG IN
USB
Option for direct connection to personal computer, using USB com cable.
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Section II Operating Instructions
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
3.3. CONNECTIONS AND SETUP
connections for setup and preparing for instrument operation.
3.3.1. ELECTRICAL CONNECTIONS
Note
To maintain compliance with EMC standards, it is required that the
cable length be no greater than 3 meters for all I/O connections,
which include Analog In, Analog Out, Status Out, Control In,
Ethernet/LAN, USB, RS-232, and RS-485.
This section presents the electrical connections for AC power and
communications.
3.3.1.1. CONNECTING POWER
WARNING - ELECTRICAL SHOCK HAZARD
High Voltages are present inside the analyzers case.
Turn OFF analyzer power before disconnecting or connecting PCAs, wiring
harnesses or electrical subassemblies.
Power connection must have functioning ground connection.
Do not defeat the ground wire on power plug.
Do not operate with cover off.
Attach the power cord to the analyzer and plug it into a power outlet capable of
carrying at least 10 A current at your AC voltage and that it is equipped with a
functioning earth ground.
CAUTION
GENERAL SAFETY HAZARD
The T802 analyzer can be configured for both 100-130 V and 210-240 V at either
47 or 63 Hz.
To avoid damage to your analyzer, make sure that the AC power voltage
matches the voltage indicated on the Analyzer’s serial number label tag (See
Figure 3-4) before plugging the T802 into line power.
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3.3.1.2. ANALOG INPUTS (OPTION 64) CONNECTIONS
The Analog In connector is used for connecting external voltage signals from
other instrumentation (such as meteorological instruments) and for logging these
signals in the analyzer’s internal DAS. The input voltage range for each analog
input is 0-10 VDC, and the input impedance is nominally 20kΩ in parallel with
0.1µF.
Figure 3-6:
Analog In Connector
Pin assignments for the Analog In connector are presented in Table 3-4.
Table 3-4. Analog Input Pin Assignments
DAS
PIN
DESCRIPTION
PARAMETER1
AIN 1
1
Analog input # 1
Analog input # 2
Analog input # 3
Analog input # 4
Analog input # 5
Analog input # 6
Analog input # 7
Analog input # 8
Analog input Ground
2
AIN 2
3
AIN 3
4
AIN 4
5
6
AIN 5
AIN 6
7
AIN 7
8
AIN 8
GND
N/A
3.3.1.3. ANALOG OUTPUT CONNECTIONS
The T802 is equipped with several analog output channels accessible through the
ANALOG OUT connector on the rear panel of the instrument. The standard
configuration for these outputs is VDC. An optional current loop output is
available for each (Section 3.3.1.4).
When the instrument is in its default configuration, channels A1 and A2 output a
signal that is proportional to the O2 concentration of the sample gas. Either can
be used for connecting the analog output signal to a chart recorder or for
interfacing with a data logger.
If the optional CO2 sensor is installed, A3 outputs a signal proportional to the
CO2 concentration of the sample gas.
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Section II Operating Instructions
Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
one of the parameters accessible through the <TST TST> buttons of the unit’s
Sample display.
To access these signals attach a strip chart recorder and/or data-logger to the
appropriate analog output connections on the rear panel of the analyzer.
ANALOG OUT
A1
A2
A3
A4
+
-
+
-
+
-
+
-
Figure 3-7:
Analog Output Connector
Table 3-5:
Analog Output Pin-Outs
PIN
1
ANALOG OUTPUT
VOLTAGE SIGNAL
CURRENT SIGNAL
I Out +
V Out
Ground
V Out
A1
2
I Out -
3
I Out +
A2
4
Ground
V Out
I Out -
5
A3
I Out +
(Only used if CO2
sensor is installed)
6
Ground
I Out -
7
8
V Out
NA
NA
A4
Ground
3.3.1.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP
This option adds isolated, voltage-to-current conversion circuitry to the
analyzer’s analog outputs. If your analyzer had this option installed at the
factory, there are no further connections to be made. Otherwise, it can be installed
as a retrofit for each of the analog outputs of the analyzer . This option converts
the DC voltage analog output to a current signal with 0-20 mA output current.
The outputs can be scaled to any set of limits within that 0-20 mA range.
However, most current loop applications call for either 2-20 mA or 4-20 mA
range. All current loop outputs have a +5% over-range. Ranges with the lower
limit set to more than 1 mA (e.g., 2-20 or 4-20 mA) also have a -5% under-range.
Figure 3-8 provides installation instructions and illustrates a sample combination
of one current output and two voltage outputs configuration. The section
following this provides instructions for converting current loop analog outputs to
standard 0-to-5 VDC outputs. Information on calibrating or adjusting these
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Figure 3-8:
Current Loop Option Installed
CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD
VOLTAGE OUTPUTS
CAUTION
Servicing or handling of circuit components requires electrostatic discharge
(ESD) protection, i.e. ESD grounding straps, mats and containers. Failure to
use ESD protection when working with electronic assemblies will void the
damage.
To convert an output configured for current loop operation to the standard 0 to 5
VDC output operation:
1. Turn off power to the analyzer.
2. If a recording device was connected to the output being modified, disconnect
it.
3. Remove the top cover as follows:
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a) Remove the set screw located at the top center of the rear panel
b) Remove the screws fastening the top cover to the unit (two per side).
c) Slide cover back.
d) Lift the cover straight up.
4. Remove the screw holding the current loop option to the motherboard.
5. Disconnect the current loop option PCA from the appropriate connector on
the motherboard (see Figure 3-8).
a) Each connector, J19, J21 and J23, requires two shunts: Place one shunt
on the two left-most pins.
an example).
6. Reattach the top case to the analyzer.
7. The analyzer is now ready to have a voltage-sensing, recording device
attached to that output.
3.3.1.5. CONNECTING THE STATUS OUTPUTS
The status outputs report analyzer conditions via optically isolated NPN
transistors, which sink up to 50 mA of DC current. These outputs can be used to
interface with devices that accept logic-level digital inputs, such as programmable
logic controllers (PLCs). Each status bit is an open collector output that can
withstand up to 40 VDC. All of the emitters of these transistors are tied together
and connected at Pin D.
Note
Most PLCs have internal provisions for limiting the current that the input will
draw from an external device. When connecting to a unit that does not have
this feature, an external dropping resistor must be used to limit the current
through the transistor output to less than 50 mA.
At 50 mA, the transistor will drop approximately 1.2V from its collector to
emitter.
The status outputs are accessed via a 12-pin connector on the analyzer’s rear
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STATUS
1
2
3
4
5
6
7
8
D
+
Figure 3-9:
Status Output Connector
Table 3-6: Status Output Signals
Rear Panel
Status Definition
Label
Condition
SYSTEM OK
ON if no faults are present.
1
OFF any time the HOLD OFF feature is active, such as during calibration or when
any faults exist invalidating the O2 measurement.
CONC VALID
2
ON if concentration measurement is valid.
CAL MODE
SPAN CAL
ON whenever the instrument is being calibrated. The Mode field
ON whenever the instrument’s SPAN point is being calibrated.
ON if unit is in high range of either the DUAL or AUTO range modes.
3
4
5
RANGE2 CAL
If this analyzer is equipped with an optional CO2 sensor, this Output is ON when that
sensor is in calibration mode. Otherwise this output us unused.
CO2 CAL
6
SPARE
7 & 8
D
EMITTER BUS
DC POWER
The emitters of the transistors on Pins 1-8 are bussed together.
+ 5 VDC, 300 mA source (combined rating with Control Output, if used).
+
Digital Ground
The ground level from the analyzer’s internal DC power supplies
3.3.1.6. CONNECTING THE CONTROL INPUTS
If you wish to use the analyzer to remotely activate the zero and span calibration
modes, several digital control inputs are provided through a 10-pin connector
labeled CONTROL IN on the analyzer’s rear panel.
There are two methods for energizing the control inputs. The internal +5V
available from the pin labeled “+” is the most convenient method (Figure 3-10,
left). However, if full isolation is required, an external 5 VDC power supply
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CONTROL IN
CONTROL IN
A
B
C
D
E
F
U
+
A
B
C
D
E
F
U
+
5 VDC
Power Supply
+
-
External Power Connections
Local Power Connections
Figure 3-10:
Control Input Connector
Table 3-7: Control Input Signals
Input # Status Definition
ON Condition
The analyzer is placed in Calibration mode. The mode field of the display
will read O2 CAL R or O2 CAL ZR
A
B
C
CAL MODE
The analyzer is placed in span calibration mode as part of performing a low
span (midpoint) calibration. The mode field of the display will read O2 CAL
SR. If not active, it will be in ZERO MODE.
REMOTE SPAN CAL
The analyzer is placed in span calibration mode as part of performing a High
Span calibration.
RANGE2 CAL
CO2 CAL
ONLY available if the optional CO2 is installed. Initiates calibration of the
CO2 sensor CO2 CAL R or CO2 CAL ZR
D
E & F
SPARE
The ground level from the analyzer’s internal DC power supplies (same as
chassis ground)
Digital Ground
U
+
External Power input
Input pin for +5 VDC required to activate Pins A – F.
Internally generated 5V DC power. To activate inputs A – F, place a jumper
between this pin and the “U” pin. The maximum amperage through this port
is 300 mA (combined with the analog output supply, if used).
5 VDC output
3.3.1.7. CONCENTRATION ALARM RELAY (OPTION 61)
The Teledyne API T-Series analyzers have an option for four (4) “dry contact”
relays on the rear panel of the instrument. This relay option is different from and
in addition to the “Contact Closures” that come standard on all TAPI instruments.
3-11). They are a Common (C), a Normally Open (NO), and a Normally Closed
(NC) pin.
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Figure 3-11:
Concentration Alarm Relay
Alarm 1 “System OK 2”
Alarm 2“Conc 1”
Alarm 3“Conc 2”
Alarm 4“Range Bit”
“ALARM 1” RELAY
Alarm 1 which is “System OK 2” (system OK 1, is the status bit) is in the
energized state when the instrument is “OK” & there are no warnings. If there is
a warning active or if the instrument is put into the “DIAG” mode, Alarm 1 will
change states. This alarm has “reverse logic” meaning that if you put a meter
across the Common & Normally Closed pins on the connector you will find that
it is OPEN when the instrument is OK. This is so that if the instrument should
turn off or lose power, it will change states & you can record this with a data
logger or other recording device.
“ALARM 2” RELAY & “ALARM 3” RELAY
The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration
Alarm 1” set point in the software & the “Alarm 3 Relay” on the rear panel is
associated with the “Concentration Alarm 2” set point in the software.
Alarm 2 Relay
Alarm 3 Relay
Alarm 2 Relay
Alarm 3 Relay
O2 Alarm 1 = xxx %
O2 Alarm 2 = xxx %
CO2 Alarm 1 = xxx % (If CO2 option is present)
CO2 Alarm 2 = xxx % (If CO2 option is present)
The Alarm 2 Relay will be turned on any time the concentration set-point is
exceeded & will return to its normal state when the concentration value goes back
below the concentration set-point.
Even though the relay on the rear panel is a NON-Latching alarm & resets when
the concentration goes back below the alarm set point, the warning on the front
panel of the instrument will remain latched until it is cleared. You can clear the
warning on the front panel by either pushing the CLR button on the front panel or
through the serial port.
The software for this instrument is flexible enough to allow you to configure the
alarms so that you can have 2 alarm levels for each gas.
O2 Alarm 1 = 20 %
O2 Alarm 2 = 100 %
CO2 Alarm 1 = 20 %
CO2 Alarm 2 = 100 %
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In this example, O2 Alarm 1 & CO2 Alarm 1 will both be associated with the
“Alarm 2” relay on the rear panel. This allows you to have multiple alarm levels
for individual gases.
A more likely configuration for this would be to put one gas on the “Alarm 1”
relay & the other gas on the “Alarm 2” relay.
O2 Alarm 1 = 20 %
O2 Alarm 2 = Disabled
CO2 Alarm 1 = Disabled
CO2 Alarm 2 = 80 %
“ALARM 4” RELAY
This relay is connected to the “range bit”. If the instrument is configured for “Auto
Range” & the instrument goes up into the high range, it will turn this relay on.
3.3.1.8. CONNECTING THE COMMUNICATION INTERFACES
The T-Series analyzers are equipped with connectors for remote communications
interfaces: Ethernet, USB, RS-232, optional RS-232 Multidrop, and optional RS-
options, 60A through 60D), each type of communication method must be
configured using the SETUP>COMM menu (Section 5.7).
ETHERNET CONNECTION
For network or Internet communication with the analyzer, connect an Ethernet
cable from the analyzer’s rear panel Ethernet interface connector to an Ethernet
port.
USB OPTION CONNECTION
For direct communication between the analyzer and a personal computer (PC),
connect a USB cable between the analyzer and desktop or laptop USB ports. (If
this option is installed, the COM2 port can only be used for RS232 multidrop
communication). USB driver download is required.
RS-232 CONNECTION
For RS-232 communications with data terminal equipment (DTE) or with data
either a DB9-female-to-DB25-male cable, Option 60A, or a DB9-female-to-DB9-
female cable, Option 60B) from the analyzer’s rear panel RS-232 port to the
appropriate.
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IMPORTANT
IMPACT ON READINGS OR DATA
Cables that appear to be compatible because of matching
connectors may incorporate internal wiring that makes the link
inoperable. Check cables acquired from sources other than
Teledyne API for pin assignments before using.
Received from the factory, the analyzer is set up to emulate a DCE or modem,
with Pin 3 of the DB-9 connector designated for receiving data and Pin 2
designated for sending data..
COM1: RS-232 (fixed) DB-9 male connector
Baud rate: 115200 bits per second (baud)
Data Bits: 8 data bits with 1 stop bit
Parity: None
COM2: RS-232 (configurable to RS 485), DB-9 female connector
Baud rate:19200 bits per second (baud)
Data Bits: 8 data bits with 1 stop bit
Parity: None
Figure 3-12:
Default Pin Assignments, Rear Panel COM Port Connectors
The signals from these two connectors are routed from the motherboard via a
wiring harness to two 10-pin connectors on the CPU card, J11 and J12 (Figure
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Figure 3-13.
CPU Connector Pin-Outs for RS-232 Mode
To assist in properly connecting the serial ports to either a computer or a modem,
there are activity indicators just above the RS-232 port. Once a cable is
connected between the analyzer and a computer or modem, both the red and
green LEDs should be on.
If the lights are not lit, use the small switch on the rear panel to switch it
between DTE and DCE modes
If both LEDs are still not illuminated, make sure the cable is properly
constructed.
RS-232 MULTIDROP OPTION CONNECTION
When the RS-232 Multidrop option is installed, connection adjustments and
configuration through the menu system are required. This section provides
instructions for the internal connection adjustments, then for external
connections, and ends with instructions for menu-driven configuration.
Note
Because the RS-232 Multidrop option uses both the RS232 and
COM2 DB9 connectors on the analyzer’s rear panel to connect the
chain of instruments, COM2 port is no longer available for separate
RS-232 or RS-485 operation.
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COULD DAMAGE INSTRUMENT AND VOID WARRANTY
ATTENTION
Printed Circuit Assemblies (PCAs) are sensitive to electro-static
discharges too small to be felt by the human nervous system. Failure to
use ESD protection when working with electronic assemblies will void
preventing ESD damage.
In each instrument with the Multidrop option there is a shunt jumpering two pins
on the serial Multidrop and LVDS printed circuit assembly (PCA), as shown in
Figure 3-14. This shunt must be removed from all instruments except that
designated as last in the multidrop chain, which must remain terminated. This
requires powering off and opening each instrument and making the following
adjustments:
1. With NO power to the instrument, remove its top cover and lay the rear
panel open for access to the Multidrop/LVDS PCA, which is seated on the
CPU.
2. On the Multidrop/LVDS PCA’s JP2 connector, remove the shunt that jumpers
instrument in the chain where the shunt should remain at Pins 21 22).
3. Check that the following cable connections are made in all instruments
J3 on the Multidrop/LVDS PCA to the CPU’s COM1 connector
(Note that the CPU’s COM2 connector is not used in Multidrop)
J4 on the Multidrop/LVDS PCA to J12 on the motherboard
J1 on the Multidrop/LVDS PCS to the front panel LCD
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Figure 3-14:
Jumper and Cables for Multidrop Mode
(Note: If you are adding an instrument to the end of a previously configured chain,
remove the shunt between Pins 21 22 of JP2 on the Multidrop/LVDS PCA in
the instrument that was previously the last instrument in the chain.)
4. Close the instrument.
cables to interconnect the host RS232 port to the first analyzer’s RS232 port;
then from the first analyzer’s COM2 port to the second analyzer’s RS232
port; from the second analyzer’s COM2 port to the third analyzer’s RS232
port, etc., connecting in this fashion up to eight analyzers, subject to the
distance limitations of the RS-232 standard.
6. On the rear panel of each analyzer, adjust the DCE DTE switch so that the
green and the red LEDs (RX and TX) of the COM1 connector (labeled
RS232) are both lit. (Ensure you are using the correct RS-232 cables
internally wired specifically for RS-232 communication; see Table 1-1,
“Communication Cables” and the preceding subsection, “RS-232
Connection”).
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Female DB9
Male DB9
Host
RS-232 port
Analyzer
Analyzer
Analyzer
Last Analyzer
COM2
COM2
COM2
COM2
RS-232
RS-232
RS-232
RS-232
Ensure jumper is
installed between
JP2 pins 21
last instrument of
multidrop chain.
22 in
Figure 3-15:
RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram
7. BEFORE communicating from the host, power on the instruments and check
a. In the SETUP Mode menu go to SETUP>MORE>COMM>ID. The default
ID is typically the model number or “0”.
b. to change the identification number, press the button below the digit to be
changed.
c. Press/select ENTER to accept the new ID for that instrument.
8. Next, in the SETUP>MORE>COMM>COM1 menu (do not use the COM2
menu for multidrop), edit the COM1 MODE parameter as follows:
press/select EDIT and set only QUIET MODE, COMPUTER MODE, and
MULTIDROP MODE to ON. Do not change any other settings.
9. Press/select ENTER to accept the changed settings, and ensure that COM1
MODE now shows 35.
10. Press/select SET> to go to the COM1 BAUD RATE menu and ensure it
reads the same for all instruments (edit as needed so that all instruments are
set at the same baud rate).
Teledyne API recommends setting up the first link, between the Host and the
first analyzer, and testing it before setting up the rest of the chain.
Note
Note
The (communication) Host instrument can address only one instrument at a
time, each by its unique ID (see step 7 above).
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RS-485 CONNECTION
As delivered from the factory, COM2 is configured for RS-232 communications.
This port can be reconfigured for operation as a non-isolated, half-duplex RS-485
port. Using COM2 for RS-485 communication will disable the USB port. To
reconfigure this port for RS-485 communication, please contact the factory.
3.3.2. PNEUMATIC CONNECTIONS
This section presents information about gases and pneumatic connections.
CAUTION
GENERAL SAFETY HAZARD
While O2 is itself not toxic, the sample gas measured by, and in some cases the
calibration gases used with the T802 can contain other components that are
hazardous (e.g. NO, NO2, SO2, CO, etc).
Obtain a Material Safety Data Sheet (MSDS) for each such gas. Read and
rigorously follow the safety guidelines described there.
Do not vent sample gases containing hazardous components into enclosed areas.
3.3.2.1. CALIBRATION GASES
ZERO GAS
Zero gas is similar in chemical composition to the earth’s atmosphere but
scrubbed of all components that might affect the analyzers readings. Teledyne
API recommends using pure N2 when calibrating the zero point of your O2
sensor.
CAUTION
GENERAL SAFETY HAZARD
Rapid release of pure N2 gas into an enclosed space can displace oxygen, and
therefore represents an asphyxiation hazard. This may happen with few
warning symptoms.
Do not vent calibration gases into enclosed areas.
3.3.2.2. SPAN GAS
Span gas is specifically mixed to match the chemical composition of the type of
gas being measured at near full scale of the desired measurement range. In this
case, O2 measurements made with the T802 analyzer, Teledyne API recommends
using 21% O2 in N2 when calibrating the span point of your O2 sensor.
Cylinders of calibrated O2 gas traceable to NIST-Standard Reference Material
specifications (also referred to as SRMs or EPA protocol calibration gases) are
commercially available (see Table 3-8).
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Table 3-8: NISTSRMs Available for Traceability of O2 Calibration Gases
NIST-SRM
2657a
Type
Nominal Concentration
O2 in N2
2%
10%
21%
0.5%
1%
2658a
O2 in N2
2659a
O2 in N2
2619a1
2620a1
2622a1
2624a1
2744b1
27451
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
2%
3%
7%
16%
1 Used to calibrate optional CO2 sensor.
3.3.2.3. INTERFERENTS
It should be noted that other gases also react to magnetic influences and will be
detected by the T802’s paramagnetic sensor. Usually this influence is extremely
minor and can be disregarded; however, several gases, such as Nitrogen dioxide
(NO2) and Nitric oxide (NO), have strong enough paramagnetic properties to be
of concern.
If the Sample Gas to be measured contains high levels of these gases, the gases
used for both the zero point calibration and the span calibration should contain
the same components in the same proportion in order to cancel any interference
effects. Performing calibrations with O2 mixed in N2 in such applications, could
induce significant errors into the O2 measurements.
3.3.2.4. BASIC PNEUMATIC CONNECTIONS
inlets/outlets referred to in this section.
analyzer.
IMPORTANT
IMPACT ON READINGS OR DATA
Sample and calibration gases should only come into contact with
Stainless Steel, PTFE (Teflon) tubing, glass or electroless nickel.
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COULD DAMAGE INSTRUMENT AND VOID WARRANTY
ATTENTION
Remove dust plugs from rear panel exhaust and supply line fittings
before powering on/operating instrument. These plugs should be
kept for reuse in the event of future storage or shipping to prevent
debris from entering the pneumatics.
CAUTION
GENERAL SAFETY HAZARD
The exhaust from the analyzer’s internal or customer supplied external
pump MUST be vented outside the immediate area or shelter surrounding
the instrument.
Figure 3-16:
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas
3.3.2.5. SAMPLE GAS SOURCE
Attach a sample inlet line to the SAMPLE inlet port. The SAMPLE input line
should not be more than two (2) meters long.
Maximum pressure of any gas at the SAMPLE inlet should not exceed 1.5 in-
Hg above ambient pressure and ideally should equal ambient atmospheric
pressure.
In applications where the sample gas is received from a pressurized
manifold, a vent must be placed on the sample gas before it enters the
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3.3.2.6. CALIBRATION GAS SOURCES
The source of calibration gas is also attached to the SAMPLE inlet, but only
when a calibration operation is actually being performed.
Zero air and span gas flows should be supplied in excess of the 120 cm3/min
demand of the analyzer.
Note
3.3.2.7. INPUT GAS VENTING
for two reasons: in order to ensure that the gases input do not exceed the
maximum inlet pressure of the analyzer, and to prevent back diffusion and
pressure effects. These vents should be:
At least 0.2m long
No more than 2m long and
Vented outside the shelter or immediate area surrounding the instrument
3.3.2.8. EXHAUST OUTLET
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust
line should be:
PTEF tubing; minimum O.D ¼”
A maximum of 10 meters long
Vented outside the T802 analyzer’s enclosure, preferably outside the shelter
or at least into a well-ventilated area.
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Figure 3-18:
T802 – Internal Gas Flow with CO2 Sensor Option
Leak Check:
IMPORTANT
Run a leak check once the appropriate pneumatic connections
have been made; check all pneumatic fittings for leaks using the
procedures defined in Section 10.3.3.
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3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL
CALIBRATION
IMPORTANT
IMPACT ON READINGS OR DATA
The analyzer’s cover must be installed to ensure that the
temperatures of the internal components are properly controlled.
If you are unfamiliar with the theory of operation, we recommend that you read
menu trees described in Appendix A.1.
3.4.1. STARTUP
After the electrical and pneumatic connections are made, an initial functional
check is in order. Turn on the instrument. The pump and exhaust fan should start
immediately. The display will show a splash screen and other information during
the initialization process while the CPU loads the operating systems, the
firmware, and the configuration data.
The analyzer should automatically switch to Sample Mode after completing the
boot-up sequence and start monitoring O2 gas. However, there is a warm-up
period of about 60 minutes before reliable gas measurements can be taken.
During the warm-up period, the front panel display may behave as described in
Table 3-9: Front Panel Display during System Warm-Up
FIELD
COLOR
BEHAVIOR
SIGNIFICANCE
Conc
(Concentration)
N/A
Displays current,
compensated H2S
concentration
This is normal operation, but deemed inaccurate during the
warm-up period.
Mode
N/A
N/A
Displays blinking
“SAMPLE”
Instrument is in sample mode but is still in the process of
warming up.
Displays menus,
parameters, and
messages.
Param
(Parameters)
Use any warning messages as a means of diagnosing problems.
STATUS LEDS
Sample
Green
On
Unit is operating in sample mode; front panel display is being
updated.
Cal
Yellow
Red
Off
The instrument’s calibration is not enabled.
Fault
Blinking
The analyzer is warming up and hence out of specification for a
fault-free reading. various warning messages appear in the
Param field.
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3.4.1.1. WARNING MESSAGES
Because internal temperatures and other conditions may be outside the specified
limits during the analyzer’s warm-up period, the software will suppress most
warning conditions for 30 minutes after power up. If warning messages persist
after the 60-minute warm up period, investigate their cause using the
To view and clear warning messages, press:
SAMPLE
TEST
SYSTEM RESET
CAL
Suppresses the
warning messages
MSG CLR SETUP
MSG CLR SETUP
MSG CLR SETUP
SAMPLE
TEST
SYSTEM RESET
CAL
MSG returns the active
warnings to the message
field.
NOTE:
If a warning message persists after
several attempts to clear it, the message
may indicate a real problem and not an
artifact of the warm-up period
SAMPLE
SYSTEM RESET
CAL
Press CLR to clear the current
TEST
message.
If more than one warning is
active, the next message will take
its place.
SYSTEM
SYSTEM RESET
TEST
CLR SETUP
Once the last warning has
been cleared, the RANGE
function will be displayed in
the analyzer’s main
STANDBY
TEST
RANGE=100.00 %
O2=XXX.XX
MESSAGE FIELD.
CAL
MSG
SETUP
Figure 3-19:
Viewing and Clearing T802 WARNING Messages
Table 3-10 lists brief descriptions of the warning messages that may occur during
startup.
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Table 3-10:
Warning Messages
MESSAGE
MEANING
ANALOG CAL WARNING
BOX TEMP WARN
The instrument’s A/D circuitry or one of its analog outputs is not calibrated.
The temperature inside the chassis is outside the specified limits.
CANNOT DYN SPAN 3
Remote span calibration failed while the dynamic span feature was set to turned on
CANNOT DYN ZERO 4
CO2 ALRM1 WARNING1, 2
CO2 ALRM2 WARNING1, 2
CO2 CELL TEMP WARN1
CONFIG INITIALIZED
DATA INITIALIZED
Remote zero calibration failed while the dynamic zero feature was set to turned on
Concentration alarm 1 is enabled and the measured CO2 level is ≥ the set point.
Concentration alarm 2 is enabled and the measured CO2 level is ≥ the set point.
CO2 sensor cell temperature outside of warning limits.
Configuration storage was reset to factory configuration or erased.
DAS data storage was erased.
O2 ALRM1 WARNING2
O2 ALRM2 WARNING2
O2 CELL TEMP WARN
REAR BOARD NOT DET
RELAY BOARD WARN
SAMPLE FLOW WARN
SAMPLE PRESS WARN
SYSTEM RESET5
Concentration alarm 1 is enabled and the measured O2 level is ≥ the set point.
Concentration alarm 2 is enabled and the measured O2 level is ≥ the set point.
O2 sensor cell temperature outside of warning limits.
The CPU is unable to communicate with the motherboard.
The firmware is unable to communicate with the relay board.
The flow rate of the sample gas is outside the specified limits.
Sample gas pressure outside of operational parameters.
The analyzer was rebooted or the CPU was reset.
1 Only enabled when the optional CO2 Sensor is installed.
2 Alarm warnings only present when optional concentration alarm relay package is installed.
3 Clears the next time successful span calibration is performed.
4 Clears the next time successful zero calibration is performed.
5 Does not clear after power up.
3.4.2. FUNCTIONAL CHECKS
After the analyzer’s components have warmed up for at least 60 minutes, verify
that the software properly supports any hardware options that were installed. For
information on navigating through the analyzer’s software menus, see the menu
trees described in Appendix A.1.
Check to make sure that the analyzer is functioning within allowable operating
parameters. Appendix C includes a list of test functions viewable from the
analyzer’s front panel as well as their expected values. These functions are also
useful tools for diagnosing performance problems with your analyzer (see Section
The enclosed Final Test and Validation Data Sheet (PN 068350000) lists these
values before the instrument left the factory. Remember until the unit has
completed its warm up these parameters may not have stabilized.
If your local area network (LAN) is running a dynamic host configuration
protocol (DHCP) software package, the Ethernet will automatically configure its
interface with your LAN. However, it is a good idea to check these settings to
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make sure that the DHCP has successfully downloaded the appropriate network
settings from your network server (see Section 6.3.1).
If your network is not running DHCP see your network administrator or
configure the Ethernet interface manually (see Section 6.3.2).
3.4.3. INITIAL CALIBRATION
To perform the following calibration you must have sources for zero air and span
gas available for input into the SAMPLE port on the back of the analyzer. See
The initial calibration should be carried out using the same reporting range set up
as used during the analyzer’s factory calibration. This will allow you to compare
your calibration results to the factory calibration as listed on the Final Test and
Validation Data Sheet.
If both available DAS parameters for a specific gas type are being reported via
the instrument’s analog outputs e.g. CONC1 and CONC2 when the DUAL
range mode is activated, separate calibrations should be carried out for each
parameter.
Use the RNG1 button when calibrating for CONC1 (equivalent to LOW
RANGE).
Use the RNG2 button when calibrating for CONC2 (equivalent to HIGH
RANGE).
The calibration procedures assume:
that the zero point and span gases have been adjusted for known
interferents (Section 3.3.2.3)
that the calibration gas will be supplied through the SAMPLE gas inlet on
that the pneumatic setup matches that described in Section 3.3.2.4.
Perform the following outline of procedures for each sensor:
is possible to perform the following procedure with any range setting we
recommend that you perform this initial checkout using the following reporting
range settings:
Mode Setting: SNGL
Analog Output Reporting Range: 20.95% (default displays 100.00%)
2. If the Dilution Ratio Option is enabled on your T802, perform the Dilution
Ratio set up as presented in Section 3.4.3.2.
3. Set the expected Span Gas Concentration for O2 as presented in Section
3.4.3.3. This should be 80% of concentration range for which the analyzer’s
analog output range is set.
The basic analyzer is now ready for operation. However, if your T802 is equipped
with the optional CO2 sensor, this sensor should be calibrated during installation
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for instructions.
Note
Once you have completed the above set-up procedures, please fill out the
Quality Questionnaire that was shipped with your unit and return it to
Teledyne API. This information is vital to our efforts in continuously
improving our service and our products. THANK YOU.
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3.4.3.2. DILUTION RATIO (OPTION) SET UP
If the dilution ratio option is enabled on your T802 and your application involves diluting the sample gas
before it enters the analyzer, set the dilution ratio as follows:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
< TST TST > CAL
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
MODE SET
RANGE CONTROL MENU
DIL
EXIT
Toggle these buttons to
set the dilution factor.
SETUP X.X
O2 DIL FACTOR:1.0 Gain
This is the number by
which the analyzer will
multiply the O2
0
0
0
0
1
.0 ENTR EXIT
concentration of the gas
passing through the
reaction cell.
EXAMPLE
SETUP X.X
O2 DIL FACTOR 10.0 Gain
.0 ENTR EXIT
0
0
0
1
0
EXIT ignores the
SETUP X.X
CO2 DIL FACTOR:1.0 Gain
.0 ENTR EXIT
Only appears if the
optional CO2 sensor
is installed.
new setting.
0
0
0
0
1
ENTR accepts the
new setting.
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3.4.3.3. SET O2 SPAN GAS CONCENTRATION
Set the expected O2 span gas concentration. This should be 80% of concentration range for which the
analyzer’s analog output range is set.
SAMPLE
RANGE=100.00 %
O2=XXX.XX
<TST TST> CAL CALZ CALS
SETUP
SAMPLE
O2 CO2
GAS TO CAL:O2
Only appears if either
the optional CO2 sensor
is installed.
ENTR EXIT
SAMPLE
RANGE TO CAL:RNG1
Only appears if the
analyzer is set for
DUAL range mode
RNG1 RNG2
ENTR EXIT
O2 M-P CAL
RANGE=100.00 %
O2=XXX.XX
EXIT
<TST TST> ZERO SPAN CONC
O2 M-P CAL
O2 SPAN CONC:20.95 %
.9
EXIT ignores the new
setting and returns to
the previous display.
The O2 span concentration value is
automatically default to
0
2
0
5
ENTR EXIT
20.95 %.
If this is not the the concentration of
the span gas being used, toggle
these buttons to set the correct
concentration of the O2 calibration
gas.
ENTR accepts the new
setting and returns to
the
CONCENTRATION
MENU.
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3.4.3.4. ZERO/SPAN CALIBRATION
To perform the zero/span calibration procedure, press:
The CO2 sensor assembly itself does not have any serviceable parts and is
enclosed in an insulated canister.
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SECTION II
–
OPERATING INSTRUCTIONS
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4. BASIC OPERATION
The T802 analyzer is a computer-controlled analyzer with a dynamic menu
interface that allows all major operations to be controlled from the front panel
touchscreen through these user-friendly menus. (A complete set of menu trees is
located in Appendix A of this manual)
This section includes Step-by-Step instructions for using the display/touchscreen
to set up and operate the analyzer's basic O2 measurement features and functional
modes.
4.1. OVERVIEW OF OPERATING MODES
The T802 software has a variety of operating modes. Most commonly, the
analyzer will be operating in Sample Mode. In this mode a continuous read-out
of the gas concentration is displayed on the front panel. SAMPLE mode is used
to:
perform calibrations
run test functions
read and clear warning messages
output analog data (when enabled)
The next most commonly used operating mode is SETUP mode, which is used
to:
perform certain configuration operations, such as programming the DAS
system or the configurable analog output channels
set up the analyzer’s serial communication channels (RS-232, RS-485,
Ethernet)
perform various diagnostic tests during troubleshooting
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Figure 4-1:
Front Panel Touchscreen and Display
The mode field of the front panel display indicates to the user which operating
mode the unit is currently running.
In addition to SAMPLE and SETUP, other modes the analyzer can be operated
in are:
Table 4-1: Analyzer Operating Modes
MODE
EXPLANATION
SAMPLE
Sampling normally, flashing text indicates adaptive filter is on.
SAMPLE A
Indicates that unit is in Sample Mode while AUTOCAL feature is active.
This is the basic calibration mode of the instrument and is activated by pressing the CAL key.
O2 M-P CAL
SETUP mode is being used to configure the analyzer. The gas measurement will continue during this
process. The revision of the T802 firmware being run will appear after the word “SETUP”
SETUP [X.X]
CAL O2 Z[type] 2 & 3
CAL O2 S[type] 2 & 3
CAL CO2 Z[type] 2 & 3
CAL CO2 S[type] 2 & 3
DIAG Mode
Unit is performing O2 ZERO calibration procedure.
Unit is performing O2 SPAN calibration procedure
Unit is performing CO2 ZERO calibration procedure (when the optional CO2 sensor is installed).
Unit is performing CO2 SPAN calibration procedure (when the optional CO2 sensor is installed).
One of the analyzer’s diagnostic modes is active (Section 5.9).
[type:]
2M: initiated manually by the user via the front panel touchscreen.
3R: initiated remotely through the COM ports or digital control inputs.
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Basic Operation
4.2. SAMPLE MODE
This is the analyzer’s standard operating mode. In this mode the instrument is
analyzing the gas in the sample chamber, calculating O2 concentration and
reporting this information to the user via the front panel display, the analog
outputs and, if set up properly, the RS-232/485/Ethernet ports.
A variety of TEST functions are available for viewing at the front panel
whenever the analyzer is at the MAIN MENU. These functions provide
information about the various functional parameters related to the analyzers
operation and its measurement of gas concentrations. This information is
particularly useful when troubleshooting a performance problem (see Section
To view these TEST functions, press,
Figure 4-2:
Viewing Test Functions
Note
Note
A value of “Warnings” displayed for any of the TEST functions indicates an
out-of-range reading or the analyzer’s inability to calculate it.
All pressure measurements are represented in terms of absolute pressure.
Absolute, atmospheric pressure is 29.92 in-Hg-A at sea level. It decreases
about 1 in-Hg per 300 m gain in altitude. A variety of factors such as air
conditioning and passing storms can cause changes in the absolute
atmospheric pressure.
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Table 4-2: Test Functions Defined
PARAMETER
DISPLAY TITLE
UNITS
%
MEANING
RANGE
RANGE1
RANGE2
The full scale limit at which the reporting range of the analyzer is
currently set. THIS IS NOT the Physical Range of the instrument.
Range
CO2 Range1
CO2 RANGE
The range setting for the optional CO2 Sensor
%
Standard deviation of O2 concentration readings. Data points are
recorded every ten seconds using the last 25 data points. This
function can be reset to show O2 or CO2 stability in instruments with
those sensor options installed.
STABIL
%
Stability
The absolute pressure of the Sample gas as measured by a
pressure sensor located inside the sample chamber.
PRES
In-Hg-A
cm3/min
-
Sample Pressure
Sample Flow
Sample mass flow rate as measured by the flow rate sensor in the
sample gas stream.
SAMPLE FL
O2 SLOPE
O2 Sensor
Slope
O2 slope, computed during zero/span calibration.
O2 OFFSET
BOX TEMP
-
O2 offset, computed during zero/span calibration.
The temperature inside the analyzer chassis.
O2 Sensor Offset
Box Temperature
C
O2 Cell
Temperature
O2 CELL TEMP
The current temperature of the O2 sensor measurement cell.
The current temperature of the CO2 sensor measurement cell.
CO2 slope, computed during zero/span calibration.
C
C
-
CO2 CELL
TEMP
CO2 Cell
Temperature1
CO2 Sensor
Slope1
CO2 SLOPE
CO2 OFFSET
TIME
CO2 Sensor
Offset 1
-
CO2 offset, computed during zero/span calibration.
The current time. This is used to create a time stamp on DAS
readings, and by the AUTOCAL feature to trigger calibration events.
-
Current Time
1 Only appears when the optional CO2 sensor is installed.
4.3. CALIBRATION MODE
The T802 will switch into calibration mode when the user touches the CAL
button. In this mode the user can, in conjunction with introducing zero or span
gases of known concentrations into the analyzer, cause it to adjust and recalculate
the slope (gain) and offset of the its measurement range. This mode is also used
to check the current calibration status of the instrument.
For more information about setting up and performing standard calibration
operations or checks, see Section 9, Calibration Procedures.
Note
It is recommended that span calibration be performed at 80% of full scale of
the analyzer’s currently selected reporting range.
EXAMPLES:
If the reporting range is set for 0 to 50%, an appropriate span point would
be 40%.
If the of the reporting range is set for 0 to 100%, an appropriate span point
would be 80%.
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Basic Operation
4.4. SETUP MODE
The SETUP mode contains a variety of choices that are used to configure the
analyzer’s hardware and software features, perform diagnostic procedures, gather
information on the instrument’s performance and configure or access data from
the internal data acquisition system (DAS). SETUP mode has a Primary and a
Secondary setup menu.
Note
Any changes made to a variable during one of the SETUP procedures are not
acknowledged by the instrument until the ENTR button is pressed. If the EXIT
button is pressed before the ENTR button, the analyzer will beep to notify the
user that the newly entered value has been lost.
Setup Mode can be protected by password security through the SETUP>PASS
adjustments.
4.4.1. PRIMARY SETUP MENU
For a visual representation of the software menu trees, refer to Appendix A-1.
The areas accessible under the SETUP mode are shown below:
Table 6-4: Primary Setup Mode Features and Functions
MENU
ITEM
MANUAL
SECTION
MODE OR FEATURE
DESCRIPTION
Analyzer Configuration
Lists key hardware and software configuration information
CFG
Auto Cal Feature
(Special configuration; consult factory).
ACAL
Internal Data Acquisition
Analog Output Reporting
Range Configuration
Calibration Password
Security
Used to set up the DAS system and view recorded data
Used to configure the output signals generated by the
instruments Analog outputs.
DAS
RNGE
Turns the calibration password feature ON/OFF
Used to Set or adjust the instrument’s internal clock
PASS
CLK
Internal Clock Configuration
This button accesses the instrument’s secondary setup
menu
See
Table 6-5
Advanced SETUP features
MORE
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4.4.2. SECONDARY SETUP MENU (SETUP>MORE)
Table 6-5: Secondary Setup Mode Features and Functions
MENU
MANUAL
SECTION
MODE OR FEATURE
DESCRIPTION
ITEM
Used to set up and operate the analyzer’s various external I/O
channels including RS-232, RS-485, modem communication
and/or Ethernet access.
External Communication
Channel Configuration
COM
Used to view various variables related to the instruments current
operational status
System Status Variables
VARS
Changes made to any variable will not be recorded in the
instrument’s memory until the ENTR key is pressed.
Pressing the EXIT key ignores the new setting.
Used to access a variety of functions that configure, test or
diagnose problems with a variety of the analyzer’s basic
systems.
System Diagnostic Features
and
DIAG
Analog Output Configuration
Most notably, the menus to configure the output signals
generated by the instruments Analog outputs, are located here.
Used to turn the instrument’s two alarms on and off as well as
set the trigger limits for each.
Alarm Limit Configuration1
1
ALRM
Alarm warnings only present when optional concentration alarm relay package is installed.
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5. SETUP MENU
The SETUP menu is used to set instrument parameters for performing
configuration, calibration, reporting and diagnostics operations.
5.1. SETUP CFG: CONFIGURATION INFORMATION
Pressing the CFG key displays the instrument’s configuration information. This
display lists the analyzer model, serial number, firmware revision, software
library revision, CPU type and other information.
Special instrument or software features or installed options may also be listed
here.
Use this information to identify the software and hardware installed in your
T802 analyzer when contacting Technical Support.
To access the configuration table, press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
Press NEXT or PREV to scroll through the
following list of Configuration information:
SETUP X.X
PREV NEXT
SUPPORT: TELEDYNE-API.COM
EXIT
Press EXIT at
any time to
MODEL TYPE, NUMBER AND NAME
PART NUMBER
SERIAL NUMBER
return to the
SETUP menu
SOFTWARE REVISION
LIBRARY REVISION
OS REVISION
5.2. SETUP ACAL: [NOT USED]
ACAL on the primary SETUP menu is a special configuration. Contact factory.
5.3. SETUP DAS: INTERNAL DATA ACQUISITION SYSTEM
configuration and operation details.
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5.4. SETUP RNGE: ANALOG OUTPUT REPORTING RANGE
CONFIGURATION
5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING
RANGES
Functionally, the T802 analyzers have one hardware PHYSICAL RANGE that is
capable of determining O2 concentrations from 0.00 % to 100.00 %.
This architecture improves reliability and accuracy by avoiding the need for
extra, switchable, gain-amplification circuitry. Once properly calibrated, the
analyzer’s front panel will accurately report concentrations along the entire span
of its physical range.
Because many applications use only a small part of the analyzer’s full physical
range, data resolution problems can occur for most analog recording devices. For
example, in a typical application where a T802 is being used to measure
atmospheric O2 concentration, the full scale of expected values is only 21% of the
instrument’s full measurement range. Unmodified, the corresponding output
signal would also be recorded across only 21% of the range of the recording
device.
The T802 analyzers solve this problem by allowing the user to select a scaled
reporting range for the analog outputs that only includes that portion of the
physical range relevant to the specific application.
Only this REPORTING RANGE of the analog outputs is scaled, the physical
range of the analyzer and the readings displayed on the front panel remain
unaltered.
Note
Both the DAS values stored in the CPU’s memory and the concentration
values reported on the front panel are unaffected by the settings chosen for
the reporting range(s) of the instrument.
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5.4.2. ANALOG OUTPUT RANGES FOR O2 CONCENTRATION
The analyzer has several active analog output signals accessible through a
connector on the rear panel (see Figure 3-4).
ANALOG OUT
CO2 CONC RANGE1
Only active if the Optional CO2
O2 concentration
outputs
Sensor is installed
Test Channel
A1
A2
A3
A4
+
-
+
-
+
-
+
-
LOW range when DUAL
HIGH range when DUAL
mode is selected
mode is selected
Figure 5-1:
Analog Output Connector Pin Out
All three outputs can be configured either at the factory or by the user for full
scale outputs of 0.1 VDC, 1VDC, 5VDC or 10VDC.
Additionally A1 and A2 may be equipped with optional 0-20 mA current loop
drivers and configured for any current output within that range (e.g. 0-20, 2-20,
4-20, etc.). The user may also adjust the signal level and scaling of the actual
output voltage or current to match the input requirements of the recorder or data
logger (See Section 5.9.5).
The A1 and A2 channels output a signal that is proportional to the O2
concentration of the sample gas. Several modes are available which allow them
to operate independently or be slaved together (See Section 5.4.3).
EXAMPLE:
A1 OUTPUT: Output Signal = 0-5 VDC representing 0-100 % concentration
values
A2 OUTPUT: Output Signal = 0 – 10 VDC representing 0-22 % concentration
values.
Output A3 is only active if the CO2 sensor option is installed. In this case a
signal representing the currently measured CO2 concentration is output on this
channel.
output several of the test functions accessible via the <TST TST> menu buttons.
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5.4.3. REPORTING RANGE MODES
The T802 provides three analog output range modes to choose from.
Single range (SNGL) mode sets a single maximum range for the analog
output. If single range is selected both outputs are slaved together and will
represent the same measurement span (e.g. 0-20 %), however their
electronic signal levels may be configured for different ranges (e.g. 0-10
VDC vs. 0.1 VDC).
Dual range (DUAL) allows the A1 and A2 outputs to be configured with
different measurement spans as well as separate electronic signal levels.
Auto range (AUTO) mode gives the analyzer the ability to output data via a
low range and high range. When this mode is selected the analyzer will
automatically switch between the two ranges dynamically as the
concentration value fluctuates.
Range status is also output via the external digital I/O status outputs (See Section
To select the Analog Output Range Type press:
Upper span limit setting for the individual range modes are shared. Resetting the
span limit in one mode also resets the span limit for the corresponding range in
the other modes as follows:
SNGL
Range
DUAL
Range1
Range2
AUTO
Low Range
High Range
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5.4.3.1. RNGE MODE SNGL: CONFIGURING THE T802 ANALYZER FOR SINGLE
RANGE MODE
Single Range Mode (SNGL) is the default reporting range mode for the analyzer.
When the single range mode is selected (SNGL), all analog O2 concentration
outputs (A1 and A2) are slaved together and set to the same reporting range
limits (e.g. 0- 22.00 %). The span limit of this reporting range can be set to any
value within the physical range of the analyzer.
Although both outputs share the same concentration reporting range, the
electronic signal ranges of the analog outputs may still be configured for different
values (e.g. 0-5 VDC, 0-10 VDC, etc; see Section 5.9.3.1)
To select SNGL range mode and to set the upper limit of the range, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.4.3.2. RNGE MODE DUAL: CONFIGURING THE T802 ANALYZER FOR DUAL
RANGE MODE
Selecting the DUAL range mode allows the A1 and A2 outputs to be configured
with different reporting ranges. The analyzer software calls these two ranges
RNG1 (low) and RNG2 (high).
The O2L RANGE 1 setting corresponds with the analog output labeled A1 on
the rear panel of the instrument.
The O2H RANGE 2 setting corresponds with the A2 output.
In DUAL range mode the RANGE test function displayed on the front panel will
be replaced by two separate functions:
O2 RN1: The range setting for the A1 output.
O2 rn2: The range setting for the A2 output.
To select the DUAL range mode press following keystroke sequence
.
When the instrument’s range mode is set to Dual the concentration field in the
upper right hand corner of the display alternates between displaying the low
range value and the high range value. The concentration that would be displayed,
is identified as follows: ”O2L” = LOW (or A1) and ”O2H” = HIGH (or A2).
Note
In DUAL range mode O2L and O2H have separate slopes and offsets for
computing O2 concentrations. The two ranges must be independently
calibrated.
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Note
If the optional CO2 sensor is installed, the concentration field of the T802’s
display
will
report
a
value
labeled,
”CO2
RANGE:”.
Only one test function is available (CO2 RNG) which reflects the range
setting for C2L and only this value is reported via the analyzer’s Analog
Outputs (Output A3).
To set the upper range limit for each independent reporting range, press:
.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.4.3.3. RNGE MODE AUTO: CONFIGURING THE T802 ANALYZER FOR AUTO
RANGE MODE
In AUTO range mode, the analyzer automatically switches the reporting range
between two user-defined ranges (low and high).
The unit will switch from low range to high range when the O2 concentration
exceeds 98% of the low range span.
The unit will return from high range back to low range once the O2
concentration falls below 75% of the low range span.
In AUTO Range mode the instrument reports the same data in the same range on
both the A1 and A2 outputs and automatically switches both outputs between
ranges as described above.
Also the RANGE test function displayed on the front panel will be replaced by
two separate functions:
O2 RNG1: The LOW range setting for all analog outputs.
O2 RNG2: The HIGH range setting for all analog outputs.
The high/low range status is also reported through the external, digital status bits
(See Section 3.3.1.5).
To set individual ranges press the following keystroke sequence.
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(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
5.4.4. SETUP RNGE DIL: USING THE OPTIONAL DILUTION RATIO
FEATURE
This feature is a optional software utility that allows the user to compensate for
any dilution of the sample gas that may occur before it enters the sample inlet.
Typically this occurs in continuous emission monitoring (CEM) applications
where the sampling method used to remove the gas from the stack, dilutes the
sample.
To set up and use the dilution ratio option:
1. In the DIAG menu, use the 929 password and navigate to Factory Options
and enable the Dilution Ratio feature. (Press ENTER to save setting, and
then return to SETUP menu).
2. Select the reporting range mode and set the reporting range upper limit (see
Section 5.4.3).
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3. Ensure that the upper span limit entered for the reporting range is the
maximum expected concentration of the non-diluted gas.
4. Set the dilution factor as a gain (e.g., a value of 20 means 20 parts diluent
and 1 part of sample gas):
5. Calibrate the analyzer.
Make sure that the calibration span gas is either supplied through the
same dilution system as the sample gas or has an appropriately lower
actual concentration.
EXAMPLE: If the reporting range limit is set for 100 % and the dilution
ratio of the sample gas is 20, either:
a span gas with the concentration of 100 % can be used if the span gas
passes through the same dilution steps as the sample gas, or;
a 5 % span gas must be used if the span gas IS NOT routed through the
dilution system.
5.5. SETUP PASS: PASSWORD FEATURE
The menu system provides password protection of the calibration and setup
functions to prevent unauthorized adjustments. When the passwords have been
enabled in the PASS menu item, the system will prompt the user for a password
anytime a password-protected function (e.g., SETUP) is selected. This allows
normal operation of the instrument, but requires the password (101) to access to
the menus under SETUP. When PASSWORD is disabled (SETUP>PASS>OFF),
any operator can enter the Primary Setup (SETUP) and Secondary Setup
(SETUP>MORE) menus. Whether PASSWORD is enabled or disabled, a
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password (default 818) is required to enter the VARS or DIAG menus in the
SETUP>MORE menu.
Table 5-1:
Password Levels
PASSWORD
LEVEL
MENU ACCESS ALLOWED
Null (000)
Operation
All functions of the main menu (top level, or Primary, menu)
Access to Primary and Secondary SETUP Menus when PASSWORD is
enabled
Configuration/Maintenance
101
818
Configuration/Maintenance Access to Secondary SETUP Submenus VARS and DIAG whether
PASSWORD is enabled or disabled.
IMPORTANT
IMPACT ON READINGS OR DATA
There are more VARS available when using the password, 929, for
configuration. Use caution when pressing any buttons while in this
setup. Any changes made may alter the performance of the
instrument or cause the instrument to not function properly. To
discard an accidental change to a setup parameter, press EXIT.
To enable or disable passwords, press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG DAS RNGE PASS CLK MORE
EXIT
SYSTEM
PASSWORD ENABLE: OFF
Toggle this
OFF
ENTR EXIT
button to
enable, disable
password
SETUP X.X
PASSWORD ENABLE: ON
ENTR EXIT
feasture
EXIT discards the new
ON
setting
ENTR accepts the
new setting
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Example: If all passwords are enabled, the following keypad sequence would be
required to enter the SETUP menu:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SYSTEM
0
ENTER SETUP PASS:0
Press individual
buttons to set
number
0
0
0
ENTR EXIT
SYSTEM
1
ENTER SETUP PASS:0
1
EXAMPLE: This
password enables the
SETUP mode
ENTR EXIT
Analyzer enters selected menu
Note
When PASSWORD ENABLE is set to OFF, the instrument still prompts for a
password when entering the VARS and DIAG menus, but it displays the
default password (818). Press ENTR to continue.
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5.6. SETUP CLK: SETTING THE T802 ANALYZER’S
INTERNAL CLOCK
The analyzer has an internal clock for setting the time and day; it’s speed can be
adjusted to compensate for faster or slower CPU clocks. Press SETUP>CLK to
access the clock.
5.6.1. SETTING THE INTERNAL CLOCK’S TIME AND DAY
The T802 has a time of day clock that supports the time of day TEST function,
the time stamps for the DAS feature and most COM port messages.
To set the clock’s time and day, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.6.2. ADJUSTING THE INTERNAL CLOCK’S SPEED
In order to compensate for CPU clocks that run faster or slower, you can adjust a
variable called CLOCK_ADJ to speed up or slow down the clock by a fixed
amount every day. The CLOCK_ADJUST variable is accessed via the VARS
submenu: To change the value of this variable, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.7. SETUP MORE COMM: COMMUNICATION PORTS
setup instructions and operation information. To arrive at the communications
menu, press SETUP>MORE>COMM.
5.7.1. ID (MACHINE IDENTIFICATION)
Each type of Teledyne API’s analyzer is configured with a default ID code. The
default ID code for the T802 analyzers is typically 802, but could also be “0”.
The ID number is only important if more than one analyzer is connected to the
same communications channel such as when several analyzers are:
on the same Ethernet LAN (Section 6.5.1)
in an RS-232 multidrop chain (Section 3.3.1.8)
when applying MODBUS protocol (Section 6.5.1).
when applying HESSEN protocol (Section 6.5.2)
If two analyzers of the same model type are used on one channel, the ID codes of
one or both of the instruments needs to be changed.
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To edit the instrument’s ID code, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
The ID can also be used for to identify any one of several analyzers attached to
the same network but situated in different physical locations, e.g., by location
number, company asset number, etc.)..
5.7.2. INET (ETHERNET)
Use SETUP>COMM>INET to configure Ethernet communications, whether
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5.7.3. COM1[COM2] (MODE, BAUDE RATE AND TEST PORT)
Use the SETUP>COMM>COM1[COM2] menus to:
configure communication modes (Section 6.2.1)
view/set the baud rate (Section 6.2.2)
test the connections of the com ports (Section 6.2.3).
Configuring COM1 or COM2 requires setting the DCE DTE switch on the rear
5.8. SETUP MORE VARS: INTERNAL VARIABLES
(VARS)
The T802 has several-user adjustable software variables, which define certain
operational parameters. Usually, these variables are automatically set by the
instrument’s firmware, but can be manually redefined through the VARS menu.
The following table lists all variables that are available within the 818 password
protected level. See Appendix A2 for a detailed listing of all of the T802
variables that are accessible through the remote interface.
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Table 5-2: Variable Names (VARS)
VARS
ALLOWED
SETTINGS
NO.
VARIABLE
DESCRIPTION
Default
settings
Changes the internal Data Acquisition System (DAS) HOLD
OFF timer:
May be set for
intervals
between
0.5 – 20 min
No data are stored in the DAS channels during situations
when the software considers the data to be questionable
such as during warm up or just after the instrument returns
from one of its calibration modes to SAMPLE Mode.
DAS_HOLD_OFF
STABIL_GAS1
15 min.
0
Selects which gas measurement is displayed when the
STABIL test function is selected.
O2; CO2
O2
1
2
NOTE: It is strongly recommended that this variable
NOT be changed.
TPC_ENABLE
DYN_ZERO
Special configuration;
consult factory
ON, OFF
ON
ON enables, OFF disables temperature and pressure
compensation
[Automatically adjusts offset and slope of the O2 response
when performing a zero point calibration during an AutoCal.]
[ON, OFF]
[ON, OFF]
[OFF]
[OFF]
AUTO
0 sec
3
4
5
6
DYN_SPAN
Special configuration;
consult factory
[Automatically adjusts offset and slope of the O2 response
when performing a zero point calibration during an AutoCal.]
Allows the user to set the number of significant digits to the
AUTO, 1, 2,
3, 4
CONC_PRECISION right of the decimal point display of concentration and
stability values.
Adjusts the speed of the analyzer’s clock. Choose the +
sign if the clock is too slow, choose the - sign if the clock is
too fast.
-60 to +60
s/day
CLOCK_ADJ
Pressing the OFF button to display SERVICE_CLEAR:ON,
followed by pressing ENTR resets the service interval timer
and returns this Var back to its default setting, ready for the
next reset.
SERVICE_CLEAR
7
8
ON, OFF
OFF
Displays time in hours since last service (restarted by the
SERVICE_CLEAR Variable).
TIME_SINCE_SVC
SVC_INTERVAL
0-50,000
0
0
Sets the interval in hours between service reminders.
0-100,000
9
1
This VAR only appears if the optional CO2 sensor is installed.
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To access and navigate the VARS menu, use the following key sequence.
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
MSG
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
In all cases:
EXIT discards the new
setting
COMM VARS DIAG
EXIT
ENTR accepts the
SETUP X.X
ENTER PASSWORD:818
new setting
8
1
8
ENTR EXIT
Toggle these
buttons to enter
the correct
SETUP X.X
0) DAS_HOLD_OFF=15.0 Minutes
PASSWORD
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
DAS_HOLD_OFF=15.0 Minutes
1
5
.0
ENTR EXIT
Toggle these keys to set
the iDAS HOLDOFF time
period in minutes
SETUP X.X
1) STABIL_GAS=O2
(MAX = 20 minutes).
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
STABIL_GAS=NO
TPC_ENABLE:ON
O2
CO2
ENTR EXIT
ENTR EXIT
Use these buttons to select
which gas will be reported
by the STABIL test function
SETUP X.X
2) TPC_ENABLE=ON
(CO2 is only available if
the optional CO2 sensor is
installed)
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
ON
SETUP X.X
3) DYN_ZERO=OFF
Toggle to turn on or turn
OFF temperature pressure
compensation.
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
4) DYN_SPAN=OFF
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
5) CONC_PRECISION=AUTO
PREV NEXT JUMP
EDIT PRNT EXIT
SETUP X.X
CONC_PRECISION=AUTO
ENTR EXIT
AUTO
1
2
3
4
Use these buttons to select
the precision of the O2
concentration display
SETUP X.X
6) CLOCK_ADJUST=0 Sec/Day
PREV NEXT JUMP
EDIT ENTR EXIT
SETUP X.X
CLOCK_ADJUST=0 Sec/Day
ENTR EXIT
+
0
0
Enter sign and number of
seconds per day the clock
gains (-) or loses(+)
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5.9. SETUP MORE DIAG: DIAGNOSTICS FUNCTIONS
A
series of diagnostic tools is grouped together under the
SETUPMOREDIAG menu. These tools can be used in a variety of
troubleshooting and diagnostic procedures and are referred to in many places of
the maintenance and trouble-shooting sections of this manual.
The various operating modes available under the DIAG menu are:
Table 5-3: Diagnostic Mode (DIAG) Functions
Front Panel Mode
Indicator
MANUAL
SECTION
DIAG SUBMENU
SUBMENU FUNCTION
Allows observation of all digital and analog signals in
the instrument. Allows certain digital signals such as
heaters to be toggled ON and OFF. These
parameters are dependent on firmware revision, (see
Appendix A).
SIGNAL I/O
DIAG I/O
When entered, the analyzer performs an analog
ANALOG OUTPUT output step test. This can be used to calibrate a
DIAG AOUT
chart recorder or to test the analog output accuracy.
This submenu allows the user to configure the
analyzer’s analog output channels, including
choosing what parameter will be output on each
ANALOG I/O
channel. Instructions that appear here allow
DIAG AIO
CONFIGURATION adjustment and calibration of the voltage signals
associated with each output as well as calibration of
the analog to digital converter circuitry on the
motherboard.
PRESSURE
This function is used to calibrate the Sample
Pressure sensor.
DIAG PCAL
DIAG FCAL
DIAG TCHN
CALIBRATION1
FLOW
This function is used to calibrate the sample gas
flow.
CALIBRATION1
TEST CHAN
OUTPUT
Selects one of the available test channel signals to
output over the A4 analog output channel.
1
These settings are retained after exiting DIAG mode.
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To access the DIAG functions press the following menu sequence:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
MSG SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG DAS ACAL RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
ENTR EXIT
EXIT
SETUP X.X
ENTER PASSWORD:818
8
1
8
DIAG
SIGNAL I/O
PREV NEXT
ENTR
ENTR
DIAG
PREV NEXT
ANALOG OUTPUT
EXIT
EXIT returns to the
SECONDARY SETUP
MENU
DIAG
PREV NEXT
ANALOG I/O CONFIGURATION
ENTR
EXIT
ENTR Activates the
selected DIAG
submenu
DIAG
PREV NEXT
PRESSURE CALIBRATION
ENTR
EXIT
EXIT
DIAG
PREV NEXT
FLOW CALIBRATION
ENTR
DIAG
PREV
TEST CHANNEL OUTPUT
ENTR
EXIT
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.9.1. SIGNAL I/O
The signal I/O diagnostic mode allows a user to review and change the digital and
analog input/output functions of the analyzer. It can also be used for
list of the parameters available for review under this menu.
IMPACT ON READINGS OR DATA
IMPORTANT
Any changes of signal I/O settings will remain in effect only until the
signal I/O menu is exited. Exceptions are the ozone generator
override and the flow sensor calibration, which remain as entered
when exiting.
Access the Signal I/O test mode from the DIAG Menu and press ENTR to access
its parameters:
DIAG
SIGNAL I / O
Press NEXT & PREV to
move between signal
types.
PREV NEXT JUMP
ENTR EXIT
Press JUMP to go
directly to a specific
signal
DIAG I / O
0) EXT_ZERO_CAL=OFF
PREV NEXT JUMP
PRNT EXIT
See Appendix A-4 for
a complete list of
available SIGNALS
EXAMPLE
DIAG I / O
JUMP TO: 12
EXAMPLE:
1
2
ENTR EXIT
Enter 12 to Jump to
12) ST_SYSTEM_OK=ON
DIAG I / O
12) ST_SYSTEM_OK = ON
Exit to return
to the
DIAG menu
PREV NEXT JUMP
ON PRNT EXIT
Pressing the PRNT button will send a formatted
printout to the serial port and can be captured
with a computer or other output device.
Toggle ON/(OFF) button to
change status.
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5.9.2. ANALOG OUTPUT
The T802 analyzer comes equipped with four analog outputs.
The first two outputs (A1 & A2) carry analog signals that represent the
The third output (A3) is only active if the analyzer is equipped with the
optional CO2.
The fourth output (A4) outputs a signal that can be set to represent the
5.9.3. ANALOG I/O CONFIGURATION
The following lists the analog I/O functions that are available in the T802
analyzer.
Table 5-4: DIAG - Analog I/O Functions
SUB MENU
FUNCTION
Initiates a calibration of the A1, A2, A3 and A4 analog output channels that determines
the slope and offset inherent in the circuitry of each output.
AOUT
CALIBRATED
These values are stored in the memory and applied to the output signals by the CPU
automatically.
Sets the basic electronic configuration of the A1 output (O2 Concentration).
There are four options:
RANGE1: Selects the signal type (voltage or current loop) and level of the output
REC OFS: Allows them input of a DC offset to let the user manually adjust the
CONC_OUT_1
CONC_OUT_2
output level
AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature
CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this
one channel only.
Same as for CONC_OUT_1 but for analog channel A2 but only if Auto or Dual
range is selected (Oxygen high range, RNG2)
Same as for CONC_OUT_1 but for analog channel A3 but only if the optional CO2
CONC_OUT_3
TEST OUTPUT
sensor is installed.
Same as for CONC_OUT_1 but for analog channel A4 (TEST CHANNEL)
AIN
CALIBRATED
Initiates a calibration of the A-to-D Converter circuit located on the Motherboard.
XIN1
.
.
.
For each of 8 external analog inputs channels, shows the gain, offset,
engineering units, and whether the channel is to show up as a Test function.
XIN8
1
Any changes made to RANGE or REC_OFS require recalibration of this output.
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To access the ANALOG I/O CONFIGURATION sub menu, press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
MSG
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
SETUP X.X
ENTER PASSWORD:818
8
1
8
ENTR EXIT
Toggle these
buttons to enter
the correct
DIAG
SIGNAL I/O
PASSWORD
NEXT
ENTR
EXIT
Continue pressing NEXT until ...
AIO Configuration Submenu
DIAG
ANALOG I/O CONFIGURATION
ENTR
PREV NEXT
EXIT
EXIT
EXIT
EXIT
EXIT
DIAG AIO
AOUTS CALIBRATED: NO
SET> CAL
DIAG AIO
CONC_OUT_1: 5V, OVR, CAL
Adjusts the signal output
for Analog Output A1
<SET SET> EDIT
DIAG AIO
CONC_OUT_2: 5V, OVR, CAL
Adjusts the signal output
for Analog Output A2
<SET SET> EDIT
DIAG AIO
CONC_OUT_3: 5V, OVR, CAL
Adjusts the signal output
<SET SET> EDIT
for Analog Output A3
(CO2 Sensor Only)
DIAG AIO
TEST_OUTPUT: 5V,OVR, CAL
Scrolls to the parameter to be
output on the TEST channel and
adjusts its signal output
<SET SET> EDIT
EXIT
DIAG AIO
<SET
AIN CALIBRATED: YES
CAL
EXIT
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.9.3.1. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION
In its standard configuration the analog outputs are set to output a 0 – 5 VDC
signals. Several other output ranges are available. Each range is usable from -
5% to + 5% of the rated span.
Table 5-5: Analog Output Voltage Range Min/Max
RANGE NAME
RANGE SPAN
0-100 mVDC
0-1 VDC
MINIMUM OUTPUT
-5 mVDC
MAXIMUM OUTPUT
105 mVDC
0.1V
1V
-0.05 VDC
1.05 VDC
5V
0-5 VDC
-0.25 VDC
5.25 VDC
10V
0-10 VDC
-0.5 VDC
10.5 VDC
The default offset for all VDC ranges is 0-5 VDC.
CURR
0-20 mA
0 mA
20 mA
While these are the physical limits of the current loop modules, typical applications use 2-20 or 4-20 mA for the lower and
upper limits. Please specify desired range when ordering this option.
The default offset for all current ranges is 0 mA.
To change the output type and range, select the ANALOG I/O
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5.9.3.2. CALIBRATION OF THE ANALOG OUTPUTS
Analog output calibration should to be carried out on first startup of the analyzer
(performed in the factory as part of the configuration process) or whenever
recalibration is required. The analog outputs can be calibrated automatically,
either as a group or individually, or adjusted manually.
In its default mode, the instrument is configured for automatic calibration of all
channels, which is useful for clearing any analog calibration warnings associated
with channels that will not be used or connected to any input or recording device,
e.g., data logger.
Manual calibration should be used for the 0.1V range or in cases where the
outputs must be closely matched to the characteristics of the recording device.
Manual calibration requires the AUTOCAL feature to be disabled.
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5.9.3.4. AUTOMATIC GROUP CALIBRATION OF THE ANALOG OUTPUTS
IMPORTANT
IMPACT ON READINGS OR DATA
Manual calibration should be used for any analog output set for a
0.1V output range or in cases where the outputs must be closely
matched to the characteristics of the recording device.
Before performing this procedure, ensure that the AUTO CAL for
To
calibrate
the
outputs
as
a
group
with
the
AOUTS
CALIBRATION command, select the ANALOG I/O CONFIGURATION
submenu (see Section 5.9.3) then press:
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5.9.3.5. AUTOMATIC INDIVIDUAL CALIBRATION OF THE ANALOG OUTPUTS
To use the AUTO CAL feature to initiate an automatic calibration for an
individual analog output, select the ANALOG I/O CONFIGURATION
submenu (see Section 5.9.3) then press:
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5.9.3.6. MANUAL CALIBRATION OF THE ANALOG OUTPUTS CONFIGURED FOR
VOLTAGE RANGES
For highest accuracy, the voltages of the analog outputs can be manually
calibrated.
Note
The menu for manually adjusting the analog output signal level will only
appear if the AUTO-CAL feature is turned off for the channel being adjusted
Calibration is performed with a voltmeter connected across the output terminals
and by changing the actual output signal level using the front panel keys in 100,
analog output connector.
V
+DC Gnd
Figure 5-2:
Setup for Checking / Calibrating DCV Analog Output Signal Levels
Table 5-6:
Voltage Tolerances for the TEST CHANNEL Calibration
MINIMUM
FULL
SCALE
ZERO
SPAN
SPAN
ADJUSTMENT
TOLERANCE VOLTAGE
TOLERANCE
(1 count)
0.1 VDC
1 VDC
±0.0005V
±0.001V
±0.002V
±0.004V
90 mV
900 mV
4500 mV
4500 mV
±0.001V
±0.001V
±0.003V
±0.006V
0.02 mV
0.24 mV
1.22 mV
2.44 mV
5 VDC
10 VDC
To adjust the signal levels of an analog output channel manually, select the
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5.9.3.7. MANUAL ADJUSTMENT OF CURRENT LOOP OPTION OUTPUT SPAN AND
OFFSET
A current loop option may be purchased for the A1, A2 and A3 analog outputs of
the analyzer. This option places circuitry in series with the output of the A-to-D
converter on the motherboard that changes the normal DC voltage output to a 0-
The outputs can be ordered scaled to any set of limits within that 0-20 mA
range, however most current loop applications call for either 0-20 mA or 4-20
mA range spans.
All current loop outputs have a + 5% over range. Ranges whose lower limit is
set above 1 mA also have a –5 under range.
To switch an analog output from voltage to current loop, follow the instructions
menu).
Adjustment of the signal zero and span levels of the current loop output is done
by raising or lowering the voltage output of the D-to-A converter circuitry on the
analyzer’s motherboard. This raises or lowers the signal level produced by the
current loop option circuitry.
The software allows this adjustment to be made in 100, 10 or 1 count increments.
Since the exact amount by which the current signal is changed per D-to-A count
varies from output-to-output and instrument–to–instrument, you will need to
measure the change in the signal levels with a separate, current meter placed in
the analog output connector.
Figure 5-3:
Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter
CAUTION - GENERAL SAFETY HAZARD
Do not exceed 60 V peak voltage between current loop outputs and instrument ground.
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To adjust the zero and span signal levels of the current outputs, select the
An alternative method for measuring the output of the Current Loop converter is
to connect a 250 ohm 1% resistor across the current loop output in lieu of the
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output connector). This allows the use of a voltmeter connected across the
resistor to measure converter output as VDC or mVDC.
V
+DC Gnd
Figure 5-4:
Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels
In this case, follow the procedure above but adjust the output for the following
values:
Table 5-7:
% FS
Current Loop Output Check
Voltage across
Voltage across
Resistor for 2-20 mA
Resistor for 4-20 mA
0
500 mVDC
1000 mVDC
5000 mVDC
100
5000 mVDC
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5.9.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE
ON/OFF
In its default configuration, a ± 5% over-range is available on each of the T802’s
analog outputs. This over-range can be disabled if your recording device is
sensitive to excess voltage or current.
To turn the over-range feature on or off, select the ANALOG I/O
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5.9.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT
Some analog signal recorders require that the zero signal be significantly different
from the baseline of the recorder in order to record slightly negative readings
from noise around the zero point. This can be achieved in the T802 by defining a
zero offset, a small voltage (e.g., 10% of span).
To add a zero offset to a specific analog output channel, select the ANALOG I/O
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5.9.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4
The test functions available to be reported are:
Table 5-8: Test Channels Functions available on the T802’s Analog Output
TEST CHANNEL
NONE
DESCRIPTION
ZERO
FULL SCALE
Test Channel is turned off
The absolute pressure of the Sample gas as
measured by a pressure sensor located inside
the sample chamber.
SAMPLE PRESSURE
0 "Hg
40 "Hg
Sample mass flow rate as measured by the
flow rate sensor in the sample gas stream.
SAMPLE FLOW
O2 CELL TEMP
0 cm3/m
1000 cm3/m
The temperature of the gas inside the O2
sensor sample chamber.
0C
70C
The temperature of the gas inside the optional
CO2 sensor sample chamber.
CO2 CELL TEMP
CHASSIS TEMP
0C
70C
The temperature inside the analyzer chassis.
0C
70C
Once a function is selected, the instrument not only begins to output a signal on
the analog output, but also adds TEST to the list of test functions viewable via
the front panel display.
To activate the TEST Channel and select a function (in this example SAMPLE
PRESSURE), press:
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SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
SETUP X.X
ENTER PASSWORD:818
8
1
8
ENTR EXIT
Toggle these
buttons to enter
the correct
DIAG
SIGNAL I/O
PASSWORD
PREV NEXT
ENTR EXIT
Continue pressing NEXT until ...
DIAG
TEST CHAN OUTPUT
PREV NEXT
ENTR
EXIT
DIAG
TEST CHAN:NONE
PREV NEXT
ENTR EXIT
Toggle these buttons
to choose a mass flow
controller TEST
DIAG
TEST CHANNEL:SAMPLE PRESSURE
ENTR EXIT
channel parameter
EXIT discards the new
PREV NEXT
setting
ENTR accepts the
new setting
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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5.9.7. AIN CALIBRATION
This is the sub-menu to conduct a calibration of the T802 analyzer’s analog
inputs. This calibration should only be necessary after major repair such as a
replacement of CPU, motherboard or power supplies.
To perform an analog input calibration, select the ANALOG I/O
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5.9.8. ANALOG INPUTS (XIN1…XIN8) OPTION CONFIGURATION
To configure the analyzer’s optional analog inputs, define for each channel:
gain (number of units represented by 1 volt)
offset (volts)
engineering units to be represented in volts (each press of the touchscreen
button scrolls the list of alphanumeric characters from A-Z and 0-9)
whether to display the channel in the Test functions
To adjust settings for the Analog Inputs option parameters press:
DIAG
ANALOG I / O CONFIGURATION
PREV
NEXT
ENTR
EXIT
EXIT
DIAG AIO
AOUTS CALIBRATED: NO
Press SET> to scroll to the first
channel. Continue pressing SET>
to view each of 8 channels.
< SET SET> CAL
DIAG AIO
XIN1:1.00,0.00,V,OFF
Press EDIT at any channel
< SET SET> EDIT
EXIT
to to change Gain, Offset,
Units and whether to display
the channel in the Test
functions (OFF/ON).
DIAG AIO
XIN1 GAIN:1.00V/V
SET> EDIT
EXIT
DIAG AIO
XIN1 OFFSET:0.00V
DIAG AIO
XIN1 GAIN:1.00V/V
< SET SET> EDIT
EXIT
+
0
0
1
.0
0
ENTR EXIT
DIAG AIO
XIN1 UNITS:V
Press to change
Gain value
< SET SET> EDIT
EXIT
EXIT
DIAG AIO
< SET
XIN1 DISPLAY:OFF
EDIT
Pressing ENTR records the new setting
and returns to the previous menu.
Pressing EXIT ignores the new setting and
returns to the previous menu.
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5.10. SETUP MORE ALRM: USING THE GAS
CONCENTRATION ALARMS (OPTION 61)
The T802 includes two O2 concentration alarms. Each alarm has a user settable
limit, and is associated with an opto-isolated TTL relay accessible via the status
concentration measured by the instrument rises above that limit, the alarm‘s
status output relay is closed.
The default settings for ALM1 and ALM2 are:
Table 5-9: O2 Concentration Alarm Default Settings
ALARM
STATUS
Disabled
Disabled
Disabled
Disabled
LIMIT SET POINT1
10.00 %
O2 ALARM1
O2 ALARM2
CO2 ALARM11
CO2 ALARM21
30.0 %
5.000 %1
10.00 %1
1
Only available if the optional CO2 sensor is installed.
Note
To prevent the concentration alarms from activating during span calibration
operations make sure to press CAL button prior to introducing span gas into
the analyzer..
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5.10.1. SETTING THE T802 OPTION 61 CONCENTRATION ALARM
LIMITS
To enable either of the O2 concentration alarms and set the Limit points, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6. COMMUNICATIONS SETUP AND OPERATION
This instrument’s rear panel connections include an Ethernet port, a USB port
(option) and two serial communication (COM) ports labeled RS232, which is the
COM1 port, and COM2 (see Figure 3-2). Both COM ports operate similarly and
give the user the ability to communicate with, issue commands to, and receive
data from the analyzer through an external computer system or terminal.
Connection instructions were provided in Section 3.3.1.8.
This section provides pertinent information regarding communication equipment,
describes the instrument’s communications modes, presents configuration
instructions for the communications ports, and provides instructions for their use,
including communications protocol. Data acquisition is presented in Section 7.
By default, both COM ports operate on the RS-232 protocol.
6.1. DATA TERMINAL/COMMUNICATION EQUIPMENT (DTE DCE)
RS-232 was developed for allowing communications between data terminal
equipment (DTE) and data communication equipment (DCE). Basic data
terminals always fall into the DTE category whereas modems are always
considered DCE devices.
Electronically, the difference between the DCE and DTE is the pin assignment of
the Data Receive and Data Transmit functions.
DTE devices receive data on Pin 2 and transmit data on Pin 3.
DCE devices receive data on Pin 3 and transmit data on Pin 2.
A switch located below the serial ports on the rear panel allows the user to switch
between DTE (for use with data terminals) or DCE (for use with modems). Since
computers can be either DTE or DCE, check your computer to determine which
mode to use.
6.2. COMMUNICATION MODES, BAUD RATE AND PORT
TESTING
Use the SETUP>MORE>COMM menu to configure COM1 (labeled RS232 on
instrument rear panel) and/or COM2 (labeled COM2 on instrument rear panel)
for communication modes, baud rate and/or port testing for correct connection. If
using a USB option communication connection, setup requires USB driver
download and configuring a few settings for (Section 6.4).
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6.2.1. COM PORT COMMUNICATION MODES
Each of the analyzer’s serial ports can be configured to operate in a number of
the mode ID numbers and displays this combined number on the front panel
display. For example, if Quiet mode (01), computer mode (02) and Multi-Drop-
Enabled mode (32) are selected, the analyzer would display a combined MODE
ID of 35.
Table 6-1: COM Port Communication Modes
DESCRIPTION
MODE1
QUIET
ID
1
Quiet mode suppresses any feedback from the analyzer (such as warning messages) to
the remote device and is typically used when the port is communicating with a computer
program where such intermittent messages might cause communication problems.
Such feedback is still available but a command must be issued to receive them.
Computer mode inhibits echoing of typed characters and is used when the port is
communicating with a computer operated control program.
COMPUTER
2
16
HESSEN
PROTOCOL
The Hessen communications protocol is used in some European countries. TELEDYNE
API PN 02252 contains more information on this protocol.
When turned on this mode switches the COM port settings from
E, 8, 1
E, 7, 1
8192
2048
1024
4
●
NO PARITY; 8 data bits; 1 stop bit to EVEN PARITY; 8 data bits; 1 stop bit.
When turned on this mode switches the COM port settings from
●
NO PARITY; 8 DATA BITS; 1 stop bit to EVEN PARITY; 7 DATA BITS; 1 stop bit.
Configures the COM2 Port for RS-485 communication. RS-485 mode has precedence
over multidrop mode if both are enabled.
RS-485
When enabled, the serial port requires a password before it will respond (see Section
SECURITY
MULTIDROP
PROTOCOL
Multidrop protocol allows a multi-instrument configuration on a single communications
channel. Multidrop requires the use of instrument IDs.
32
ENABLE
MODEM
Enables to send a modem initialization string at power-up. Asserts certain lines in the
RS-232 port to enable the modem to communicate.
64
ERROR
Fixes certain types of parity errors at certain Hessen protocol installations.
CHECKING2
128
256
XON/XOFF
Disables XON/XOFF data flow control also known as software handshaking.
HANDSHAKE2
Enables CTS/RTS style hardwired transmission handshaking. This style of data
transmission handshaking is commonly used with modems or terminal emulation
protocols as well as by Teledyne Instrument’s APICOM software.
HARDWARE
HANDSHAKE
8
HARDWARE
FIFO
Disables the HARDWARE FIFO (First In – First Out), When FIFO is enabled it improves
data transfer rate for that COM port.
512
COMMAND
PROMPT
Enables a command prompt when in terminal mode.
4096
1 Modes are listed in the order in which they appear in the
SETUP MORE COM COM[1 OR 2] MODE menu
2 The default setting for this feature is ON. Do not disable unless instructed to by Teledyne API Technical Support
personnel.
Note
Communication Modes for each COM port must be configured
independently.
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Press the following button sequence to select communication modes for one of
the COM Ports, such as the following example where HESSEN is enabled:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.2.2. COM PORT BAUD RATE
To select the baud rate of either of the COM Ports, go to
SETUP>MORE>COMM and select either COM1 or COM2 as follows:
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6.2.3. COM PORT TESTING
The serial ports can be tested for correct connection and output in the COM
menu. This test sends a string of 256 ‘w’ characters to the selected COM port.
While the test is running, the red LED on the rear panel of the analyzer should
flicker.
To initiate the test press the following menu sequence.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.3. REMOTE ACCESS VIA THE ETHERNET
For network or Internet communication, the analyzer can be connected to any
standard 10BaseT or 100BaseT Ethernet network via low-cost network hubs,
switches or routers. The interface operates as a standard TCP/IP device on port
3000. This allows a remote computer to connect through the Internet to the
analyzer using APICOM, terminal emulators or other programs.
The Ethernet cable connector on the rear panel has two LEDs indicating the
Ethernet’s current operating status.
Table 6-2:
Ethernet Status Indicators
LED
FUNCTION
amber (link)
On when connection to the LAN is valid.
Flickers during any activity on the LAN.
green (activity
The analyzer is shipped with DHCP enabled by default. This allows the
instrument to be connected to a network or router with a DHCP server. The
instrument will automatically be assigned an IP address by the DHCP server. This
configuration is useful for quickly getting an instrument up and running on a
network. However, for permanent Ethernet connections, a static IP address should
address.
6.3.1. CONFIGURING THE ETHERNET INTERFACE USING DHCP
The Ethernet for your T802 uses Dynamic Host Configuration Protocol (DHCP)
to configure its interface with your LAN automatically. This requires that your
network servers also be running DHCP. The analyzer will do this the first time
you turn the instrument on after it has been physically connected to your network.
Note
Check the INET settings the first time you power up your analyzer after it has
been physically connected to the LAN/Internet to make sure that the DHCP
has successfully downloaded the appropriate information from you network
the analyzer’s front panel display.
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Table 6-3: LAN/Internet Configuration Properties
PROPERTY
DEFAULT STATE
DESCRIPTION
This displays whether the DHCP is turned ON or OFF.
Press EDIT and toggle ON for automatic configuration
after first consulting network administrator.
ON
DHCP
INSTRUMENT
IP ADDRESS
This string of four packets of 1 to 3 numbers each (e.g.
192.168.76.55.) is the address of the analyzer itself.
Can only be edited when DHCP is set to OFF.
0.0.0.0
0.0.0.0
GATEWAY IP
ADDRESS
A string of numbers very similar to the Instrument IP
address (e.g. 192.168.76.1.) that is the address of the
computer used by your LAN to access the Internet.
Can only be edited when DHCP is set to OFF.
Also a string of four packets of 1 to 3 numbers each (e.g.
255.255.252.0) that identifies the LAN to which the device
is connected.
All addressable devices and computers on a LAN must
have the same subnet mask. Any transmissions sent to
devices with different subnets are assumed to be outside
of the LAN and are routed through the gateway computer
onto the Internet.
SUBNET MASK
This number defines the terminal control port by which the
instrument is addressed by terminal emulation software,
such as Internet or Teledyne API’s APICOM.
3000
T802
TCP PORT1
The name by which your analyzer will appear when
addressed from other computers on the LAN or via the
HOST NAME
1 Do not change the setting for this property unless instructed to by Teledyne API’s Technical Support
personnel.
Note
If the gateway IP, instrument IP and the subnet mask are all zeroes (e.g.
“0.0.0.0”), the DCHP was not successful in which case you may have to
configure the analyzer’s Ethernet properties manually. See your network
administrator.
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(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.3.2. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES
There are several circumstances when you may need to configure the interface
settings of the analyzer’s Ethernet card manually:
your LAN is not running a DHCP software package
the DHCP software is unable to initialize the analyzer’s interface
you wish to create a static IP (recommended)
1. Connect a cable from the analyzer’s Ethernet port to a Local Area Network
(LAN) or Internet port.
2. Access Ethernet configuration through: SETUP>MORE>COMM>INET.
3. Follow the setup sequence as shown in the illustrations that follow, and edit
the Instrument and Gateway IP addresses and Subnet Mask to the desired
settings. (From the computer, enter the same information through an
application such as HyperTerminal).
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
SETUP X.X
COMMUNICATIONS MENU
< TST TST > CAL
ID
INET COM1 COM2
EXIT
EXIT
SAMPLE
ENTER SETUP PASS : 818
SETUP X.X
DHCP: ON
8
1
8
ENTR EXIT
<SET SET> EDIT
SETUP X.X
DHCP: ON
SETUP X.X
PRIMARY SETUP MENU
ON
ENTR EXIT
ENTR EXIT
CFG DAS RNGE PASS CLK MORE
EXIT
EXIT
SETUP X.X
DHCP: OFF
SETUP X.X SECONDARY SETUP MENU
OFF
COMM VARS DIAG
(continues in next illustration)
ENTR accept
new settings
EXIT ignores
new settings
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Internet Configuration Touchscreen Functions
(Continued from preceding illustration)
BUTTON
[0]
FUNCTION
Press this key to cycle through the range of
numerals and available characters (“0 – 9” & “ . ”)
<CH CH>
DEL
Moves the cursor one character left or right.
Deletes a character at the cursor location.
SETUP X.X
DHCP: OFF
Accepts the new setting and returns to the previous
menu.
ENTR
EXIT
SET> EDIT
EXIT
EXIT
Ignores the new setting and returns to the previous
menu.
Buttons appear only as applicable.
SETUP X.X INST IP: 000.000.000.000
<SET SET> EDIT
Cursor
location is
indicated by
brackets
SETUP X.X INST IP: [0] 00.000.000
<CH CH>
DEL [0]
ENTR EXIT
SETUP X.X GATEWAY IP: 000.000.000.000
<SET SET> EDIT
EXIT
SETUP X.X GATEWAY IP: [0] 00.000.000
<CH CH> DEL [?] ENTR EXIT
SETUP X.X SUBNET MASK:255.255.255.0
<SET SET> EDIT
EXIT
EXIT
SETUP X.X SUBNET MASK:[2]55.255.255.0
<CH CH> DEL [?] ENTR EXIT
SETUP X.X TCP PORT 3000
<SET
EDIT
The PORT number needs to remain at 3000.
Do not change this setting unless instructed to by
Teledyne API’s Customer Service personnel.
Pressing EXIT from
any of the above
display menus
causes the Ethernet
card to reinitialize its
internal interface
firmware
SETUP X.X
INITIALIZING INET 0%
…
INITIALIZING INET 100%
SETUP X.X
INITIALIZATI0N SUCCEEDED
SETUP X.X
INITIALIZATION FAILED
Contact your IT
Network Administrator
SETUP X.X
COMMUNICATIONS MENU
ID
INET COM1 COM2
EXIT
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6.3.2.1. CHANGING THE ANALYZER’S HOSTNAME
The HOSTNAME is the name by which the analyzer appears on your network.
The default name for all Teledyne API T802 analyzers is T802.
To change this name (particularly if you have more than one T802 analyzer on
your network), press:
BUTTON
<CH
FUNCTION
Moves the cursor one character to the left.
CH>
Moves the cursor one character to the right.
Inserts a character before the cursor location.
Deletes a character at the cursor location.
INS
DEL
Press to cycle through the range of numerals
and characters available for insertion. 0-9, A-
Z, space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } <
>\ | ; : , . / ?
[?]
Accepts the new setting and returns to the
previous menu.
ENTR
EXIT
Ignores the new setting and returns to the
previous menu.
Buttons appear only as applicable.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.4. USB PORT FOR REMOTE ACCESS
The analyzer can be operated through a personal computer by downloading the
TAPI USB driver and directly connecting their respective USB ports.
1. Install the Teledyne T-Series USB driver on your computer, downloadable
from the Teledyne API website under Help Center>Software Downloads
(www.teledyne-api.com/software).
2. Run the installer file: “TAPIVCPInstaller.exe”
3. Connect the USB cable between the USB ports on your personal computer
and your analyzer. The USB cable should be a Type A – Type B cable,
commonly used as a USB printer cable.
4. Determine the Windows XP Com Port number that was automatically
assigned to the USB connection. (Start → Control Panel → System →
Hardware → Device Manager). This is the com port that should be set in the
communications software, such as APICOM or Hyperterminal.
Refer to the Quick Start (Direct Cable Connection) section of the Teledyne
APICOM Manual, PN 07463.
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5. In the instrument’s SETUP>MORE>COMM>COM2 menu, make the following
settings:
Baud Rate: 115200
COM2 Mode Settings:
Quiet Mode
ON
ON
SECURITY MODE
MULTIDROP MODE
ENABLE MODEM
ERROR CHECKING
XON/XOFF HANDSHAKE
HARDWARE HANDSHAKE OFF
OFF
OFF
OFF
ON
Computer Mode
MODBUS RTU
MODBUS ASCII
E,8,1 MODE
E,7,1 MODE
RS-485 MODE
OFF
OFF
OFF
OFF
OFF
OFF
HARDWARE FIFO
ON
COMMAND PROMPT
OFF
6. Next, configure your communications software, such as APICOM. Use the
COM port determined in Step 4 and the baud rate set in Step 5. The figures
below show how these parameters would be configured in the Instrument
Properties window in APICOM when configuring a new instrument. See the
APICOM manual (PN 07463) for more details.
USB configuration requires that the baud rates of the instrument
and the PC match; check the PC baud rate and change if needed.
Note
Using the USB port disallows use of the rear panel COM2 port
except for multidrop communication.
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6.5. COMMUNICATIONS PROTOCOLS
This section presents MODBUS and HESSEN information.
6.5.1. MODBUS SETUP
The following set of instructions assumes that the user is familiar with MODBUS
communications, and provides minimal information to get started. For additional
instruction, please refer to the Teledyne API MODBUS manual, PN 06276. Also
refer to www.modbus.org for MODBUS communication protocols.
Minimum Requirements
Instrument firmware with MODBUS capabilities installed.
MODBUS-compatible software (TAPI uses MODBUS Poll for testing; see
www.modbustools.com)
Personal computer
Communications cable (Ethernet or USB or RS232)
Possibly a null modem adapter or cable
Actions
Set Com Mode parameters
Comm
Ethernet:
Using the front panel menu, go to SETUP – MORE – COMM – INET; scroll through
the INET submenu until you reach TCP PORT 2 (the standard setting is 502), then
continue to TCP PORT 2 MODBUS TCP/IP; press EDIT and toggle the menu
button to change the setting to ON, then press ENTR. (Change Machine ID if
needed: see “Slave ID”).
USB/RS232: Using the front panel menu, go to SETUP – MORE – COMM – COM2 – EDIT; scroll
through the COM2 EDIT submenu until the display shows COM2 MODBUS RTU:
OFF (press OFF to change the setting to ON. Scroll NEXT to COM2 MODBUS
ASCII and ensure it is set to OFF. Press ENTR to keep the new settings. (If RTU is
not available with your communications equipment, set the COM2 MODBUS ASCII
setting to ON and ensure that COM2 MODBUS RTU is set to OFF. Press ENTR to
keep the new settings).
Slave ID
If your analyzer is connected to a network with at least one other analyzer of the same model, a
unique Slave ID must be assigned to each. Using the front panel menu, go to SETUP – MORE –
COMM – ID. The MACHINE ID default is the same as the model number. Toggle the menu buttons
to change the ID.
Reboot analyzer
For the settings to take effect, power down the analyzer, wait 5 seconds, and power up the
analyzer.
Make appropriate cable
connections
Connect your analyzer either:
via its Ethernet or USB port to a PC (this may require a USB-to-RS232 adapter for your PC; if so,
also install the software driver from the CD supplied with the adapter, and reboot the computer if
required), or
via its COM2 port to a null modem (this may require a null modem adapter or cable).
Specify MODBUS software
settings
1. Click Setup / [Read / Write Definition] /.
a. In the Read/Write Definition window (see example that follows) select a Function (what you
(examples used here are for
MODBUS Poll software)
wish to read from the analyzer).
b. Input Quantity (based on your firmware’s register map).
c. In the View section of the Read/Write Definition window select a Display (typically Float
Inverse).
d. Click OK.
2. Next, click Connection/Connect.
a. In the Connection Setup window (see example that follows), select the options based on
your computer.
b. Press OK.
Read the MODBUS Poll
Register
Use the Register Map to find the test parameter names for the values displayed (see example that
follows If desired, assign an alias for each.
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6.5.2. HESSEN
The Hessen protocol is a multidrop protocol, in which several remote instruments
are connected via a common communications channel to a host computer. The
remote instruments are regarded as slaves of the host computer. The remote
instruments are unaware that they are connected to a multidrop bus and never
initiate Hessen protocol messages. They only respond to commands from the
host computer and only when they receive a command containing their own
unique ID number.
The Hessen protocol is designed to accomplish two things: to obtain the status of
remote instruments, including the concentrations of all the gases measured; and to
place remote instruments into zero or span calibration or measure mode. API’s
implementation supports both of these principal features.
The Hessen protocol is not well defined, therefore while API’s application is
completely compatible with the protocol itself, it may be different from
implementations by other companies.
Note
The following sections describe the basics for setting up your instrument to
operate over a Hessen Protocol network. For more detailed information as
well as a list of host computer commands and examples of command and
response message syntax, download the Manual Addendum for Hessen
Protocol from the Teledyne API web site: http://www.teledyne-
api.com/manuals/.
6.5.2.1. HESSEN COM PORT CONFIGURATION
Hessen protocol requires the communication parameters of the T802’s COM
ports to be set differently than the standard configuration as shown in the table
below.
Table 6-4:
RS-232 Communication Parameters for Hessen Protocol
PARAMETER
STANDARD
HESSEN
1200
7
Baud Rate
Data Bits
Stop Bits
Parity
300 – 115200
8
1
2
None
Full
Even
Half
Duplex
To change the baud rate of the T802’s COM ports, See Section 6.2.2.
To change the rest of the COM port parameters listed in the table above, see
Note
Make sure that the communication parameters of the host computer are also
properly set.
In addition, rather than issuing commands to the instrument in rapid
succession, bear in mind that the instrument software has a 200 ms latency
period before it responds to commands issued by the host computer.
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6.5.2.2. ACTIVATING HESSEN PROTOCOL
Once the COM port has been properly configured, the next step in configuring
the T802 to operate over a Hessen protocol network is to activate the Hessen
mode for COM ports and configure the communication parameters for the port(s)
appropriately. Press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.5.2.3. SELECTING A HESSEN PROTOCOL TYPE
Currently there are two versions of Hessen Protocol in use. The original
implementation, referred to as TYPE 1, and a more recently released version,
TYPE 2 that has more flexibility when operating with instruments that can
measure more than one type of gas.
For more specific information about the difference between TYPE 1and TYPE 2
download the Manual Addendum for Hessen Protocol from the Teledyne API
web site: http://www.teledyne-api.com/manuals/.
To select a Hessen Protocol Type press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
Note
While Hessen Protocol Mode can be activated independently for COM1 and
COM2, The TYPE selection affects both ports.
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6.5.2.4. SETTING THE HESSEN PROTOCOL RESPONSE MODE
The Teledyne API implementation of Hessen Protocol allows the user to choose
one of several different modes of response for the analyzer.
Table 6-5: Teledyne API Hessen Protocol Response Modes
MODE ID
MODE DESCRIPTION
This is the Default Setting. Reponses from the instrument are encoded as the traditional
command format. Style and format of responses depend on exact coding of the initiating
command.
CMD
Responses from the instrument are always delimited with <STX> (at the beginning of the
response, <ETX> (at the end of the response followed by a 2 digit Block Check Code
(checksum), regardless of the command encoding.
BCC
Responses from the instrument are always delimited with <CR> at the beginning and the end
of the string, regardless of the command encoding.
TEXT
To Select a Hessen response mode, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.5.2.5. GAS LIST ENTRY FORMAT AND DEFINITIONS
The T802 analyzer keeps a list of available gas types. Each entry in this list is of
the following format.
[GAS TYPE],[RANGE],[GAS ID],[REPORTED]
WHERE:
GAS TYPE = The type of gas being reported (e.g. O2, CO2).
RANGE
=
The concentration range for this entry in the gas list. This feature
permits the user to select which concentration range will be used
for this gas list entry. The T802 analyzer has two ranges:
0 -The HESSEN protocol to use whatever range is currently
active.
1 -The HESSEN protocol will always use RANGE1 for this gas list
entry
2 -The HESSEN protocol will always use RANGE2 for this gas list
entry
3 -Not applicable to the T802 analyzer.
GAS ID
=
An identification number assigned to a specific gas. In the case of
the T802 analyzer in its base configuration, there is only one gas
O2 , and its default GAS ID is 110. This ID number should not be
modified.
REPORT = States whether this list entry is to be reported or not reported when
ever this gas type or instrument is polled by the HESSEN network.
If the list entry is not to be reported this field will be blank.
The T802 analyzer is a single gas instrument that measures O2.
Thus the default gas list entry would be:
O2, 0, 110, REPORTED
No default gas list entry exists for CO2. If the optional CO2 senor is installed, the
following gas list entry should be added: CO2, 0, 111, REPORTED
These default settings cause the instrument to report the concentration value of
the currently active range. If you wish to have just concentration values stored
for a specific range, this list entry should be edited or additional entries should be
EXAMPLE:
Changing the above O2 gas list entry to read O2, 2, 110, REPORTED while
RANGE2 (HIGH) range was active would cause only the last O2 reading to be
recorded.
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6.5.2.6. EDITING OR ADDING HESSEN GAS LIST ENTRIES
To add or edit an entry to the Hessen Gas List, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.5.2.7. DELETING HESSEN GAS LIST ENTRIES
To delete an entry from the Hessen Gas list, press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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6.5.2.8. SETTING HESSEN PROTOCOL STATUS FLAGS
Teledyne API’s implementation of Hessen protocols includes a set of status bits
that the instrument includes in responses to inform the host computer of its
condition. Each bit can be assigned to one operational and warning message flag.
The default settings for these bit/flags are:
Table 6-6: Default Hessen Status Flag Assignments
DEFAULT BIT
STATUS FLAG NAME
ASSIGNMENT
WARNING FLAGS1
SAMPLE FLOW WARNING
0001
0080
INVALID CONC
(The instrument’s front panel display will show the
concentration as “Warnings”)
OPERATIONAL FLAGS1
In MANUAL Calibration Mode
In O2 ZERO Calibration Mode3
In CO2 ZERO Calibration Mode3
In O2 SPAN Calibration Mode3
In CO2 SPAN Calibration Mode3
0200
0400
0400
0800
0800
UNITS OF MEASURE FLAGS4
UGM
MGM
PPB
PPM
0000
2000
4000
6000
0001, 0002, 0004,
0008, 0010 0020, 0040,
0100, 1000, 8000
SPARE/UNUSED BITS
UNASSIGNED FLAGS (0000)
O2 CONC ALARM 22
BOX TEMP WARNING
O2 CELL TEMP WARN
CO2 CELL TEMP WARN
SAMPLE PRESS WARN
RELAY BOARD WARN
CANNOT DYN SPAN
CANNOT DYN ZERO
ANALOG CAL WARNING
CAL MP O2
CAL MP CO2
REAR BOARD NOT DET
SYSTEM RESET
CO2 CONC ALARM 12
O2 CONC ALARM 12
CO2 CONC ALARM 22
1
These status flags are standard for all instruments and should probably not be
modified.
2
3
Only applicable if the analyzer is equipped with an alarm option.
It is possible to assign more than one flag to the same Hessen status bit. This
allows the grouping of similar flags, such as all temperature warnings, under the
same status bit. Be careful not to assign conflicting flags to the same bit as each
status bit will be triggered if any of the assigned flags is active.
4
While these units are assigned flags, they are not applicable in the T802 which
reports in % when measuring O2 and when reporting CO2.
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To assign or reset the status flag bit assignments, press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
EXIT
SETUP X.X
COMMUNICATIONS MENU
SETUP X.X
HESSEN STATUS FLAGS
ID HESN COM1 COM2
<SET SET> EDIT
EXIT
SETUP X.X
HESSEN VARIATION:TYPE1
SETUP X.X
BOX TEMP WARNING:0000
SET> EDIT
EXIT
PREV NEXT
EDIT PRNT EXIT
Continue pressing SET> until ...
Continue pressing NEXT until desired
flag message is displayed
SETUP X.X O2 CELL TEMP WARN:0000
PREV NEXT
EDIT PRNT EXIT
SETUP X.X
O2 CELL TEMP WARNING:[0]000
EXIT discards the
<CH CH> INS DEL
[0]
ENTR EXIT
<CH and CH>
move the cursor
brackets “[ ]”
left and right along
the bit string.
new setting
ENTR accepts the
new setting
Press [?] repeatedly to cycle through
DEL deletes the
the available character set: 0-9
character currently
inside the cursor
brackets.
NOTE: Values of A-F can also be set
INS Inserts a the
character at the
but are meaningless.
current location of the
cursor brackets.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
6.5.2.9. INSTRUMENT ID
Each instrument on a Hessen Protocol network must have a unique ID code. If
more than one T802 analyzer is on the Hessen network, you will have to change
this code for all but one of the T802 analyzer’s on the Hessen network (see
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7. DATA ACQUISITION SYSTEM (DAS) & APICOM
The T802 analyzer contains a flexible and powerful, internal data acquisition
system (DAS) that enables the analyzer to store concentration and calibration data
as well as a host of diagnostic parameters. The DAS is capable of capturing
several months worth of data depending on how it is configured. The data are
stored in non-volatile memory and are retained even when the instrument is
powered off. Data are stored in plain text format for easy retrieval and use in
common data analysis programs (such as spreadsheet-type programs).
The DAS is designed to be flexible; users have full control over the type, length
and reporting time of the data. The DAS permits users to access stored data
through the instrument’s front panel or its communication ports.
The principle use of the DAS is logging data for trend analysis and predictive
diagnostics, which can assist in identifying possible problems before they affect
the functionality of the analyzer. The secondary use is for data analysis,
documentation and archival in electronic format.
To support the DAS functionality, Teledyne API offers APICOM, a program that
provides a visual interface for remote or local setup, configuration and data
retrieval of the DAS. The APICOM manual (included with the program),
contains a more detailed description of the DAS structure and configuration,
which is briefly described here.
The T802 includes a basic DAS configuration, which is enabled by default. New
data channels are also enabled by default, but each channel may be turned off for
later or occasional use.
The DAS can be disabled only by disabling or deleting its individual data
channels.
Note
The green SAMPLE LED on the instrument front panel, which indicates the
analyzer status, also indicates certain aspects of the DAS status:
Table 7-1: Front Panel LED Status Indicators for DAS
LED STATE
DAS STATUS
System is in calibration mode. Data logging can be enabled or disabled for this mode.
Calibration data are typically stored at the end of calibration periods, concentration data are
typically not sampled, diagnostic data should be collected.
steady off
Instrument is in hold-off mode, a short period after the system exits calibrations. DAS
channels can be enabled or disabled for this period. Concentration data are typically disabled
whereas diagnostic should be collected.
blinking
Sampling normally.
steady on
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IMPORTANT
IMPACT ON READINGS OR DATA
DAS operation is suspended whenever its configuration is edited using
the analyzer’s front panel and therefore data may be lost. To prevent
such data loss, it is recommended to use the APICOM graphical user
interface for DAS changes. Please be aware that all stored data will be
erased if the analyzer’s disk-on-module or CPU board is replaced or if the
configuration data stored there is reset..
7.1. DAS STRUCTURE
The DAS is designed around the feature of a “record”. A record is a single data
point. The type of data recorded in a record is defined by two properties:
PARAMETER type that defines the kind of data to be stored (e.g. the
average of gas concentrations measured with three digits of precision). See
Section 7.1.4.3.
A TRIGGER event that defines when the record is made (e.g. timer; every
The specific PARAMETER and TRIGGER events that describe an individual
record are defined in a construct called a DATA CHANNEL. Each data channel
relates one or more parameters with a specific trigger event and various other
operational characteristics related to the records being made (e.g. the channel’s
name, number of records to be made, time period between records, whether or not
the record is exported via the analyzer’s RS-232 port, etc.).
7.1.1. DAS CHANNELS
The key to the flexibility of the DAS is its ability to store a large number of
combinations of triggering events and data parameters in the form of data
channels. Users may create up to 50 data channels and each channel can contain
one or more parameters. For each channel, the following are selected:
One triggering event is selected
Up to 50 data parameters, which can be the shared between channels.
Several other properties that define the structure of the channel and allow the
user to make operational decisions regarding the channel.
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Table 7-2: DAS Data Channel Properties
DEFAULT
SETTING
PROPERTY
DESCRIPTION
SETTING RANGE
Up to 6 letters or digits 1
NAME
The name of the data channel.
“NONE”
Any available event
(see Appendix A-5).
TRIGGERING
EVENT
The event that triggers the data channel to measure
and store the datum
ATIMER
NUMBER AND
LIST OF
PARAMETERS
Any available parameter
(see Appendix A-5).
A User-configurable list of data types to be
recorded in any given channel.
1
(PMTDET)
000:00:01 to
366:23:59
(Days:Hours:Minutes)
1 to 30,000 (max), limited
by available storage
space. 2
The amount of time between each channel data
point.
000:01:00
(1 hour)
REPORT PERIOD
The number of reports that will be stored in the data
file. Once the limit is exceeded, the oldest data is
over-written.
NUMBER OF
RECORDS
100
Enables the analyzer to automatically report
channel values to the RS-232 ports.
RS-232 REPORT
OFF
ON
OFF or ON
OFF or ON
OFF or ON
CHANNEL
ENABLED
Enables or disables the channel. Allows a channel
to be temporarily turned off without deleting it.
Disables sampling of data parameters while
CAL HOLD OFF
OFF
instrument is in calibration mode. 3
1 More with APICOM, but only the first six are displayed on the front panel).
2
For information regarding the maximum number of channels, parameters, and records and how to calculate the file size for each data
channel, refer to the DAS manual downloadable from the TAPI website at http://www.teledyne-api.com/manuals/ under Special
Manuals.
3
When enabled records are not recorded until the DAS HOLDOFF period is passed after calibration mode. DAS HOLDOFF SET in the
7.1.2. DEFAULT DAS CHANNELS
CONC: Samples O2 concentration at one minute intervals and stores an average
every hour with a time and date stamp. Readings during calibration and
calibration HOLD OFF are not included in the data. By default, the last 800
hourly averages are stored.
PNUMTC: Collects sample flow and sample pressure data at five-minute
intervals and stores an average once a day with a time and date stamp. This data
is useful for monitoring the condition of the pump and critical flow orifice
(sample flow) and the sample filter (clogging indicated by a drop in sample
pressure) over time to predict when maintenance will be required. The last 360
daily averages (about 1 year) are stored.
CALDAT: Data channel logs new slope and offset of O2 measurements each
time a zero or span calibration is performed and the result changes the value of
the slope (triggering event: SLPCHG). The O2 stability (to evaluate if the
calibration value was stable) as well as the converter efficiency (for trend
reference) are also stored.
This data channel will store data from the last 200 calibrations and can be
used to document analyzer calibration; it also is useful for detecting trends in
slope and offset (instrument response) when performing predictive
diagnostics as part of a regular maintenance schedule.
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The CALDAT channel collects data based on events (e.g. a calibration
operation) rather than a timed interval and therefore does not represent any
specific length of time. As with all data channels, a date and time stamp is
recorded for every logged data point.
DETAILED: Samples six different parameters related to the operating status of
the analyzer’s optical sensors. For each parameter:
A value is logged once every minute;
An average of the last 60 readings is calculated once every minute (60
seconds).
The last 480 averages are stored (20 days).
This channel is useful for diagnosing problems that cause the instruments
measurements to drift slowly over time
FAST: Almost identical to DETAIL except that for each parameter:
Samples are taken once per minute and reported once per minute, in effect
causing the instrument to record an instantaneous reading of each parameter
every minute.
The last 360 readings for each parameter are recorded/reported.
This channel is useful for diagnosing transients; spikes and noise problems.
These default Data Channels can be used as they are, or they can be customized
from the front panel to fit a specific application. They can also be deleted to
make room for custom user-programmed Data Channels.
Appendix A-5 lists the firmware-specific DAS configuration in plain-text format.
This text file either can be loaded into APICOM and then modified and uploaded
to the instrument, or can be copied and pasted into a terminal program to be sent
to the analyzer.
IMPORTANT
IMPACT ON READINGS OR DATA
Sending a DAS configuration to the analyzer through its COM ports
will replace the existing configuration and will delete all stored data.
Back up any existing data and the DAS configuration before
uploading new settings.
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7.1.3. SETUP DAS VIEW: VIEWING DAS CHANNELS AND
INDIVIDUAL RECORDS
DAS data and settings can be viewed on the front panel through the following
keystroke sequence.
SAMPLE
RANGE=100.00%
MSG
O2=XXX.XX
SETUP
DAS VIEW – Menu Button Functions
TST STCAL
Button
FUNCTION
Moves the VIEW backward 10 records
Moves the VIEW backward 1 record or channel
Moves the VIEW forward 1 record or channel
Moves the VIEW forward 10 records
PV10
PREV
NEXT
NX10
<PRM
PRM>
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
DATA ACQUISITION
Selects the previous parameter on the list
Selects the next parameter on the list
VIEW EDIT
EXIT
EXIT
Buttons only appear when when applicable.
SETUP X.X
CONC: DATA AVAILABLE
NEXT VIEW
SETUP X.X
101:21:00 CONC1=20.99 %
PV10 PREV NX10 NEXT <PRM PRM>
EXIT
SETUP X.X
101:22:00 CONC1=20.97 %
SETUP X.X
102:04:55 STABIL=00.02
PV10 PREV NX10 NEXT <PRM PRM>
EXIT
PV10 PREV NX10 NEXT <PRM PRM>
EXIT
Continue pressing NEXT to view remaining
DAS channels
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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7.1.4. SETUP DAS EDIT: ACCESSING THE DAS EDIT MODE
DAS configuration is most conveniently done through the APICOM remote
control program. The following list of key strokes shows how to edit using the
front panel.
<TST TST> CAL
MSG
SETUP X.X
CFG ACAL
RNGE PASS CLK MORE EXIT
Selects the previous data channel in the list
Selects the next data channel in the list
SETUP X.X
VIEW
EXIT
EXIT
Inserts a new data channel into the list BEFORE the
selected channel
Deletes the currently selected data channel
Enters EDIT mode
SETUP X.X
8
1
8
Exports the configuration of all data channels to the
RS-232 interface
SETUP X.X
NEXT
INS DEL
PRNT
Enters EDIT mode for the selected channel
When editing the data channels, the top line of the display indicates some of the
configuration parameters.
For example, the display line:
0) CONC: ATIMER, 2, 4032, RS232
Translates to the following configuration:
0
Channel No.
CONC
Channel Name
ATIMER Trigger Event
2
Parameters – number of parameters included in this channel
Event – number of data points this channel is set up to store
4032
RS-232 Port via which values automatically reported
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7.1.4.1. EDITING DAS DATA CHANNEL NAMES
To edit the name of a DAS data channel, follow the instruction shown in Section
Starting at the EDIT CHANNEL MENU
SETUP X.X
NEXT
0) CONC: ATIMER 2, 4032, RS232
INS DEL EDIT PRNT EXIT
SETUP X.X
NAME: CONC
SET> EDIT
EXIT
SETUP X.X
NAME: CONC
C
O
N
C
—
—
ENTR EXIT
EXIT discards the new
setting
ENTR accepts the
new setting
Press each button repeatedly to
cycle through the available
character set:
0-9, A-Z, space ’ ~ ! # $ % ^ &
* ( ) - _ = +[ ] { } < >\ | ; : , . / ?
7.1.4.2. EDITING DAS TRIGGERING EVENTS
Triggering events define when and how the DAS records a measurement of any
given data channel. The most commonly used triggering events are:
ATIMER: Sampling at regular intervals specified by an automatic timer. Most
trending information is usually stored at such regular intervals, which can be
instantaneous or averaged.
EXITZR, EXITSP, and O2SLPC (exit zero, exit span, O2 slope change):
Sampling at the end of (irregularly occurring) calibrations or when the response
slope changes. These triggering events create instantaneous data points, e.g., for
the new slope and offset (concentration response) values at the end of a
calibration. Zero and slope values are valuable to monitor response drift and to
document when the instrument was calibrated.
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WARNINGS: Some data may be useful when stored if one of several warning
messages appears such as O2TMPW (O2 sensor temperature warning). This is
helpful for trouble-shooting by monitoring when a particular warning occurred.
To edit the list of data parameters associated with a specific data channel, follow
the instruction shown in Section 7.1.4 then press:
Note
DAS Trigger Events are firmware specific; a list of trigger events can
be found in Appendix A-5 of this manual.
7.1.4.3. EDITING DAS PARAMETERS
Data parameters are types of data that may be measured and stored by the DAS.
For each Teledyne API analyzer model, the list of available data parameters is
different, fully defined and not customizable. Appendix A-5 lists firmware
specific data parameters for the T802. DAS parameters include things like O2
concentration measurements, temperatures of the various heaters placed around
the analyzer, pressures and flows of the pneumatic subsystem and other
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diagnostic measurements as well as calibration data such as stability, slope and
offset.
Most data parameters have associated measurement units, such as mV, ppb,
cm³/min, etc., although some parameters have no units (e.g. SLOPE). With the
exception of concentration readings, none of these units of measure can be
changed.
Note
DAS does not keep track of the units (i.e. %) of each concentration value;
therefore, DAS data files may contain concentrations data recorded in more
than one type of unit if the units of measure was changed during data
acquisition.
Each data parameter has user-configurable functions that define how the data are
recorded:
Table 7-3: DAS Data Parameter Functions
FUNCTION
EFFECT
PARAMETER
Instrument-specific parameter name.
INST: Records instantaneous reading.
SAMPLE MODE
AVG: Records average reading during reporting interval.
SDEV: Records the standard deviation of the data points recorded during the reporting
interval.
MIN: Records minimum (instantaneous) reading during reporting interval.
MAX: Records maximum (instantaneous) reading during reporting interval.
PRECISION
0 to 4: Sets the number of digits to the right decimal point for each record.
Example: Setting 4; “399.9865 %”
Setting 0; “400 %”
STORE NUM.
SAMPLES
OFF: Stores only the average (default).
ON: Stores the average and the number of samples used to compute the value of the
parameter. This property is only useful when the AVG sample mode is used. Note
that the number of samples is the same for all parameters in one channel and needs to
be specified only for one of the parameters in that channel.
Users can build a channel by selecting desired parameters from the available
choices.
Data channels can be edited individually from the front panel without affecting
other data channels. However, when editing a data channel, such as during
adding, deleting or editing parameters, all data for that particular channel will be
lost, because the DAS can store only data of one format (number of parameter
columns etc.) for any given channel. In addition, a DAS configuration can only
be uploaded remotely as an entire set of channels. Hence, remote update of the
DAS will always delete all current channels and stored data.
To modify, add or delete a parameter, follow the instruction shown in Section
7.1.4 then press:
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Note
When the STORE NUM SAMPLES feature is turned on, the instrument
will store the number of measurements that were used to compute the
AVG, SDEV, MIN or MAX value but not the actual measurements
themselves.
7.1.4.4. EDITING SAMPLE PERIOD AND REPORT PERIOD
The DAS defines two principal time periods by which sample readings are taken
and permanently recorded:
SAMPLE PERIOD: Determines how often DAS temporarily records a sample
reading of the parameter in volatile memory. SAMPLE PERIOD is only used
when the DAS parameter’s sample mode is set for AVG, SDEV, MIN or MAX
The SAMPLE PERIOD is set to one minute by default and generally cannot be
accessed from the standard DAS front panel menu, but is available via the
instrument’s communication ports by using APICOM or the analyzer’s standard
serial data protocol.
REPORT PERIOD: Sets how often the sample readings stored in volatile
memory are processed, (e.g. average, minimum or maximum are calculated); the
results stored permanently in the instrument’s Disk-on-Module as well as
transmitted via the analyzer’s communication ports. The Report Period may be
set from the front panel. If the INST sample mode is selected, the instrument
stores and reports an instantaneous reading of the selected parameter at the end of
the chosen report period.
Note
In AVG, SDEV, MIN or MAX sample modes (Table 7-3), the settings for
the Sample Period and the Report Period determine the number of
data points used each time the parameters are calculated, stored and
reported to the COMM ports.
The actual sample readings are not stored past the end of the chosen
report period.
When the STORE NUM SAMPLES feature is turned on, the instrument
will store the number of measurements that were used to compute
the AVG, SDEV, MIN or MAX value but not the actual measurements
themselves.
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then press:
The SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to
the beginning and end of the appropriate interval of the instrument’s internal
clock.
If SAMPLE Period were set for one minute, the first reading would occur at the
beginning of the next full minute according to the instrument’s internal clock.
If the Report period were set for one hour, the first report activity would occur at
the beginning of the next full hour according to the instrument’s internal clock.
EXAMPLE:
Given the above settings, if DAS were activated at 7:57:35 the first sample would
occur at 7:58 and the first report would be calculated at 8:00 consisting of data
points for 7:58, 7:59 and 8:00. During the next hour (from 8:01 to 9:00), the
instrument will take a sample reading every minute and include 60 sample
readings.
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7.1.4.5. REPORT PERIODS IN PROGRESS WHEN INSTRUMENT IS POWERED OFF
If the instrument is powered off in the middle of a REPORT PERIOD, the
samples accumulated so far during that period are lost. Once the instrument is
turned back on, the DAS begins taking samples and temporarily storing them in
volatile memory as part of a new REPORT PERIOD. At the end of this
REPORT PERIOD, only the sample readings taken since the instrument was
turned back on will be included in any AVG, SDEV, MIN or MAX calculation.
Also, the STORE NUM SAMPLE feature will report the number of sample
readings taken since the instrument was restarted.
7.1.4.6. EDITING THE NUMBER OF RECORDS
The number of data records in the DAS is limited by the total number of
parameters and channels and other settings in the DAS configuration. Every
additional data channel, parameter, number of samples setting etc. will reduce the
maximum amount of data points somewhat. In general, however, the maximum
data capacity is divided amongst all channels (max: 20) and parameters (max: 50
per channel).
The DAS will check the amount of available data space and prevent the user from
specifying too many records at any given point. If, for example, the DAS
memory space can accommodate 375 more data records, the ENTR key will
disappear when trying to specify more than that number of records. This check
for memory space may also make an upload of a DAS configuration with
APICOM or a terminal program fail, if the combined number of records would be
exceeded. In this case, it is suggested to either try to determine what the
maximum number of records available is using the front panel interface or use
trial-and-error in designing the DAS script or calculate the number of records
using the DAS or APICOM manuals.
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To set the NUMBER OF RECORDS, follow the instruction shown in Section
7.1.4 then press:
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7.1.4.7. RS-232 REPORT FUNCTION
The DAS can automatically report data to the communications ports, where they
can be captured with a terminal emulation program or simply viewed by the user
using the APICOM software.
To enable automatic COM port reporting, follow the instruction shown in
Starting at the EDIT CHANNEL MENU
SETUP X.X
0) CONC: ATIMER 2, 4032, RS232
PREV NEXT
INS DEL EDIT PRNT EXIT
Use the PREV and
NEXT buttons to
scroll to the DATA
CHANNEL to be
edited
SETUP X.X
NAME: CONC
SET> EDIT
EXIT
Continue pressing <SET or SET> until ...
SETUP X.X
RS-232 REPORT:ON
<SET SET> EDIT PRNT
EXIT
SETUP X.X
RS-232 REPORT: ON
EXIT discards the new
OFF
ENTR EXIT
setting
Toggle to turn the
RS-232 REPORT
feature
ENTR accepts the
new setting
ON/OFF
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7.1.4.8. ENABLING / DISABLING THE HOLD OFF FEATURE
The DAS HOLD OFF feature prevents data collection during calibration
operations.
To enable or disable the HOLD OFF, follow the instruction shown in Section
7.1.4 then press:
Starting at the EDIT CHANNEL MENU
SETUP X.X
0) CONC: ATIMER 2, 4032, RS232
PREV NEXT
INS DEL EDIT PRNT EXIT
Press PREV and
NEXT to scroll to the
DATA CHANNEL to
be edited
SETUP X.X
NAME: CONC
SET> EDIT
EXIT
Continue pressing <SET or SET> until ...
SETUP X.X
CAL.HOLD OFF: OFF
<SET SET> EDIT
EXIT
SETUP X.X
CAL.HOLD OFF: OFF
EXIT discards the new
OFF
ENTR EXIT
setting
Toggle to turn the
HOLDOFF feature
ON/OFF
ENTR accepts the
new setting
HOLD OFF also prevents DAS measurements from being made at certain times
when the quality of the analyzer’s O2 measurements may be suspect (e.g. while
the instrument is warming up). In this case, the length of time that the HOLD
OFF feature is active, is determined by the value of the internal variable (VARS),
DAS_HOLD OFF.
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7.1.4.9. THE COMPACT REPORT FEATURE
When enabled, this option avoids unnecessary line breaks on all RS-232 reports.
Instead of reporting each parameter in one channel on a separate line, up to five
parameters are reported in one line.
The COMPACT DATA REPORT generally cannot be accessed from the
standard DAS front panel menu, but is available via the instrument’s
communication ports by using APICOM or the analyzer’s standard serial data
protocol.
7.1.4.10. THE STARTING DATE FEATURE
This option allows specifying a starting date for any given channel when the user
wants to start data acquisition only after a certain time and date. If the
STARTING DATE is in the past (the default condition), the DAS ignores this
setting and begins recording data as defined by the REPORT PERIOD setting.
The STARTING DATE generally cannot be accessed from the standard DAS
front panel menu, but is available via the instrument’s communication ports by
using APICOM or the analyzer’s standard serial data protocol.
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7.1.4.11. DISABLING/ENABLING DATA CHANNELS
Data channels can be temporarily disabled, which can reduce the read/write wear
on the disk-on-module.
press:
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7.2. REMOTE DAS CONFIGURATION
The DAS can be configured and operated remotely via either the APICOM
details on remote operation of the T802 analyzer).
7.2.1. DAS CONFIGURATION VIA APICOM
Figure 7-2 shows an example of APICOM’s main interface, which emulates the
look and functionality of the instrument’s actual front panel. Figure 7-3. shows an
example of APICOM being used to remotely configure the DAS feature.
Figure 7-2:
APICOM Remote Control Program Interface
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Figure 7-3:
APICOM User Interface for Configuring the DAS
Once a DAS configuration is created or edited, it is conveniently saved to your
computer and can be uploaded to any instrument; it can be stored on a computer
for later review, alteration or documentation and archival. Refer to the APICOM
manual for details on these procedures. The APICOM user manual (Teledyne
API PN 058130000) is included in the APICOM installation file, which can be
downloaded at http://www.teledyne-api.com/manuals/.
IMPORTANT
IMPACT ON READINGS OR DATA
Avoid losing data and saved configurations: All data, parameters and
channels will be replaced when uploading a DAS configuration script to
the analyzer through its communication ports. Back up data and the
original DAS configuration before attempting any DAS changes.
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7.2.2. DAS CONFIGURATION VIA TERMINAL EMULATION PROGRAMS
Although Teledyne API recommends the use of APICOM, the DAS can also be
accessed and configured through a terminal emulation program such as
the default DAS configuration, getting familiar with its command structure and
syntax conventions, and then altering a copy of the original file offline before
uploading the new configuration.
Figure 7-4:
DAS Configuration through a Terminal Emulation Program
See Section for configuration commands and their strict syntax. Commands can
be pasted in from of an existing text file, which was first edited offline and then
uploaded through a specific transfer procedure.
IMPORTANT
IMPACT ON READINGS OR DATA
Whereas the editing, adding and deleting of DAS channels and
parameters of one channel through the front-panel control buttons
can be done without affecting the other channels, uploading a DAS
configuration script to the analyzer through its communication ports
will erase all data, parameters and channels by replacing them with
the new DAS configuration. Backup of data and the original DAS
configuration is advised before attempting any DAS changes.
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8. REMOTE OPERATION
This section provides information needed when using external digital and serial
I/O for remote operation. It assumes that the electrical connections have been
made as described in Section 3.3.1.
Your analyzer can be remotely configured, calibrated or queried for stored data
through the serial ports, via either Computer mode (using a personal computer)
or Interactive mode (using a terminal emulation program).
8.1. COMPUTER MODE
Computer Mode is used when the analyzer is connected to a computer with a
dedicated interface program such as APICOM.
8.1.1. REMOTE CONTROL VIA APICOM
APICOM is an easy-to-use, yet powerful interface program that allows the user to
access and control any of Teledyne API’s main line of ambient and stack-gas
instruments from a remote connection through direct cable, modem or Ethernet.
Running APICOM, a user can:
Establish a link from a remote location to the T802 through direct cable
connection via RS-232 modem or Ethernet.
View the instrument’s front panel and remotely access all functions that could
be accessed when standing in front of the instrument.
Remotely edit system parameters and set points.
Download, view, graph and save data for predictive diagnostics or data
analysis.
Check on system parameters for trouble-shooting and quality control.
APICOM is very helpful for initial setup, data analysis, maintenance, and
emulates the look and functionality of the instruments actual front panel.
APICOM is included free of cost with the analyzer and the latest versions can
also be downloaded at http://www.teledyne-api.com/software/.
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8.2. INTERACTIVE MODE
Interactive mode is used with a terminal emulation programs or a “dumb”
computer terminal.
8.2.1. REMOTE CONTROL VIA A TERMINAL EMULATION PROGRAM
Start a terminal emulation programs such as HyperTerminal. All configuration
commands must be created following a strict syntax or be pasted in from a text
file, which was edited offline and then uploaded through a specific transfer
procedure. The commands that are used to operate the analyzer in this mode are
8.2.1.1. HELP COMMANDS IN INTERACTIVE MODE
Table 8-1: Terminal Mode Software Commands
COMMAND
Control-T
Function
Switches the analyzer to terminal mode (echo, edit). If mode flags 1 & 2 are OFF, the
interface can be used in interactive mode with a terminal emulation program.
Control-C
Switches the analyzer to computer mode (no echo, no edit).
CR
A carriage return is required after each command line is typed into the
(carriage return)
terminal/computer. The command will not be sent to the analyzer to be executed until
this is done. On personal computers, this is achieved by pressing the ENTER key.
BS
Erases one character to the left of the cursor location.
(backspace)
ESC
Erases the entire command line.
(escape)
?[ID] CR
This command prints a complete list of available commands along with the definitions
of their functionality to the display device of the terminal or computer being used. The
ID number of the analyzer is only necessary if multiple analyzers are on the same
communications line, such as the multi-drop setup.
Control-P
Restarts the listing of commands.
8.2.1.2. COMMAND SYNTAX
Commands are not case-sensitive and all arguments within one command (i.e. ID
numbers, keywords, data values, etc.) must be separated with a space character.
All Commands follow the syntax:
X [ID] COMMAND <CR>
Where
X
command. Allowed designators are listed in Appendix A-6.
[ID]
Command “? 700” followed by a carriage return would print the list
of available commands for the revision of software currently
installed in the instrument assigned ID Number 700.
COMMAND is the command designator: This string is the name of the command
being issued (LIST, ABORT, NAME, EXIT, etc.). Some commands
may have additional arguments that define how the command is to
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be executed. Press ? <CR> or refer to Appendix A-6 for a list of
available command designators
<CR>
is a carriage return. All commands must be terminated by a
carriage return (usually achieved by pressing the ENTER key on a
computer).
Table 8-2:
Teledyne API Serial I/O Command Types
COMMAND
COMMAND TYPE
Calibration
Diagnostic
C
D
L
Logon
T
Test measurement
Variable
V
W
Warning
8.2.1.3. DATA TYPES
Data types consist of integers, hexadecimal integers, floating-point numbers,
Boolean expressions and text strings.
Integer data: Used to indicate integral quantities such as a number of records, a
filter length, etc.
They consist of an optional plus or minus sign, followed by one or more digits.
For example, +1, -12, 123 are all valid integers.
Hexadecimal integer data: Used for the same purposes as integers.
They consist of the two characters “0x,” followed by one or more hexadecimal
digits (0-9, A-F, a-f), which is the ‘C’ programming language convention.
No plus or minus sign is permitted.
For example, 0x1, 0x12, 0x1234abcd are all valid hexadecimal integers.
Floating-point number: Used to specify continuously variable values such as
temperature set points, time intervals, warning limits, voltages, etc.
They consist of an optional plus or minus sign, followed by zero or more digits,
an optional decimal point and zero or more digits.
At least one digit must appear before or after the decimal point.
Scientific notation is not permitted.
For example, +1.0, 1234.5678, -0.1, 1 are all valid floating-point numbers.
Boolean expressions: Used to specify the value of variables or I/O signals that
may assume only two values.
They are denoted by the keywords ON and OFF.
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Text strings: Used to represent data that cannot be easily represented by other
data types, such as data channel names, which may contain letters and numbers.
They consist of a quotation mark, followed by one or more printable
characters, including spaces, letters, numbers, and symbols, and a final
quotation mark.
For example, “a”, “1”, “123abc”, and “()[]<>” are all valid text strings.
It is not possible to include a quotation mark character within a text string.
Some commands allow you to access variables, messages, and other items. When
using these commands, you must type the entire name of the item; you cannot
abbreviate any names.
8.2.1.4. STATUS REPORTING
Reporting of status messages as an audit trail is one of the three principal uses for
the RS-232 interface (the other two being the command line interface for
controlling the instrument and the download of data in electronic format). You
can effectively disable the reporting feature by setting the interface to quiet mode
Status reports include warning messages, calibration and diagnostic status
messages. Refer to Appendix A-3 for a list of the possible messages.
8.2.1.5. GENERAL MESSAGE FORMAT
All messages from the instrument (including those in response to a command line
request) are in the format:
X DDD:HH:MM [Id] MESSAGE<CRLF>
Where:
X
is a command type designator, a single character indicating the
message type, as shown in the Table 8-2.
DDD:HH:MM is the time stamp, the date and time when the message was
issued. It consists of the Day-of-year (DDD) as a number from 1
to 366, the hour of the day (HH) as a number from 00 to 23, and
the minute (MM) as a number from 00 to 59.
[ID]
is the analyzer ID, a number with 1 to 4 digits.
MESSAGE
is the message content that may contain warning messages, test
measurements, variable values, etc.
<CRLF>
is a carriage return line feed pair, which terminates the message.
The uniform nature of the output messages makes it easy for a host computer to
parse them into an easy structure. Keep in mind that the front panel display does
not give any information on the time a message was issued, hence it is useful to
log such messages for trouble-shooting and reference purposes. Terminal
emulation programs such as HyperTerminal can capture these messages to text
files for later review.
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8.3. REMOTE ACCESS BY MODEM
The T802 can be connected to a modem for remote access. This requires a cable
between the analyzer’s COM port and the modem, typically a DB-9F to DB-25M
cable (available from Teledyne API with PN WR0000024).
Once the cable has been connected, check to make sure:
The DTE-DCE switch on the rear panel is in the DCE position.
The T802 COM port is set for a baud rate that is compatible with the modem,
The Modem is designed to operate with an 8-bit word length with one stop bit.
The MODEM ENABLE communication mode is turned on (Mode 64, see
Section 6.2.1).
Once this is completed, the appropriate setup command line for your modem can
be entered into the analyzer. The default setting for this feature is
AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0
This string can be altered to match your modem’s initialization and can be up to
100 characters long.
To change this setting press:
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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To initialize the modem press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG ACAL DAS RNGE PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
EXIT
EXIT
SETUP X.X
COMMUNICATIONS MENU
ID INET COM1 COM2
SETUP X.X
COM1 MODE:0
<SET SET> EDIT
Continue pressing <SET or SET> until ...
SETUP X.X
COM1: INITIALIZE MODEM
ENTR EXIT
<SET SET> INIT
SETUP X.X
SETUP X.X
INITIALIZING MODE
MODEM INITIALIZED
Test Runs
Automatically
PREV NEXT OFF
EXIT
If there is a problem initializing the
modem the message,
“MODEM NOT INITIALIZED”
will appear.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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8.4. COM PORT PASSWORD SECURITY
In order to provide security for remote access of the T802, a LOGON feature can
be enabled to require a password before the instrument will accept commands.
Once the SECURITY MODE is enabled, the following items apply.
A password is required before the port will respond or pass on commands.
If the port is inactive for one hour, it will automatically logoff, which can also be
achieved with the LOGOFF command.
Three unsuccessful attempts to log on with an incorrect password will cause
subsequent logins to be disabled for 1 hour, even if the correct password is
used.
If not logged on, the only active command is the '?' request for the help screen.
The following messages will be returned at logon:
LOGON SUCCESSFUL - Correct password given
LOGON FAILED - Password not given or incorrect
LOGOFF SUCCESSFUL - Connection terminated successfully
To log on to the T802 analyzer with SECURITY MODE feature enabled, type:
LOGON 940331
Note
To change the default password, use the variable RS-232_PASS issued as
follows:
V RS-232_PASS=NNNNNN
Where N is any numeral between 0 and 9.
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9. CALIBRATION PROCEDURES
This section contains a variety of information regarding the various methods for
calibrating a T802 as well as other supporting information
This section is organized as follows:
Section 9.1 – Before Calibration
This section contains general information you should know before calibrating the
analyzer.
This section describes the procedure for checking the calibration of the T802 and
calibrating the instrument. Also included are instructions for selecting the
reporting range to be calibrated when the T802 analyzer is set to operate in either
the DUAL or AUTO reporting range modes.
This section describes how to judge the effectiveness of a recently performed
calibration.
This section describes how to perform calibrations of the T802’s electronic
systems, including:
adjusting the analyzers internal flow sensor
adjusting the analyzers internal pressure sensor
This section describes how to perform calibrations of the optional CO2 Sensor.
Note
Throughout this Section are various diagrams showing pneumatic
connections between the T802 and various other pieces of equipment such
as calibrators and zero air sources. These diagrams are only intended to be
schematic representations of these connections and do not reflect actual
physical locations of equipment and fitting location or orientation. Contact
your regional EPA or other appropriate governing agency for more detailed
recommendations..
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9.1. BEFORE CALIBRATION
The calibration procedures in this section assume that the range mode, analog
range and units of measure have already been selected for the analyzer. If this
has not been done, please do so before continuing (see Section 5.4 for
instructions).
Note
If any problems occur while performing the following calibration
procedures, refer to Section 11 for troubleshooting tips.
9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES
Calibration of the T802 analyzer requires a certain amount of equipment and
supplies. These include, but are not limited to, the following:
Zero-air source.
Span gas source.
Gas lines - All Gas lines should be Stainless Steel, PTFE (Teflon), glass or
electroless nickel.
A recording device such as a strip-chart recorder and/or data logger (optional).
For electronic documentation, the internal data acquisition system can be
used.
9.1.2. CALIBRATION GASES
9.1.2.1. ZERO AIR
A gas that is similar in chemical composition to the earth’s atmosphere but
scrubbed of all components that might affect the analyzers readings. Teledyne
API recommends using pure N2 when calibrating the zero point of your O2 or
optional CO2 sensor options.
CAUTION
GENERAL SAFETY HAZARD
DO NOT vent calibration gases into enclosed areas. Rapid release of pure N2 gas
into an enclosed space can displace oxygen, and therefore represents an
asphyxiation hazard. This may happen with few warning symptoms.
9.1.2.2. SPAN GAS
Span gas is a gas specifically mixed to match the chemical composition of the
type of gas being measured at near full scale of the desired measurement range.
In this case, O2 measurements made with the T802 analyzer, Teledyne API
recommends using 21% O2 in N2 when calibrating the span point of the O2 sensor
option.
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Cylinders of calibrated O2 gas traceable to NIST-Standard Reference Material
specifications (also referred to as SRMs or EPA protocol calibration gases) are
commercially available.
Table 9-1: NISTSRM's Available for Traceability of O2 Calibration Gases
NIST-SRM
2657a
Type
Nominal Concentration
O2 in N2
2%
10 %
21%
0.5%
1%
2658a
O2 in N2
2659a
O2 in N2
2619a1
2620a1
2622a1
2624a1
2744b1
27451
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
CO2 in N2
2%
3%
7%
16%
1 Used to calibrate optional CO2 sensor.
Note
For span point calibration it is generally a good idea to use 80% of the reporting
range for that channel. For instance, if the reporting range of the instrument is
set for 5%, the proper span gas would be 4%.
9.1.3. DATA RECORDING DEVICES
A strip chart recorder, data acquisition system or digital data acquisition system
should be used to record data from the serial or analog outputs of the T802.
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If analog readings are used, the response of the recording system should be
checked against a NIST traceable voltage source or meter.
Data recording devices should be capable of bi-polar operation so that
negative readings can be recorded.
For electronic data recording, the T802 provides an internal data acquisition
system (DAS), which is described in detail in Section 7 APICOM, a remote
control program, is also provided as a convenient and powerful tool for data
handling, download, storage, quick check and plotting (see Section 8.1.1).
9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION
IMPACT ON READINGS OR DATA
IMPORTANT
ZERO/SPAN CALIBRATION CHECKS VS. ZERO/SPAN CALIBRATION
Pressing the ENTR button during the following procedure resets the
stored values for OFFSET and SLOPE and alters the instrument’s
Calibration. This should ONLY BE DONE during an actual calibration
of the T802.
NEVER press the ENTR button if you are only checking calibration.
9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION
Connect the Sources of Zero Air and Span Gas as shown below.
Figure 9-1:
Pneumatic Connections–Basic Configuration–Using Bottled Span Gas
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9.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK
Note
If the ZERO or SPAN menu buttons are not displayed, the measurement
made during this cal check is out of the allowable range allowed for a reliable
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9.2.3. PERFORMING A BASIC MANUAL CALIBRATION
The following section describes the basic method for manually calibrating the
T802.
If the analyzer’s reporting range is set for the DUAL or AUTO range modes, a
step will appear for selecting which range is to be calibrated: RNG1 (LOW) or
RNG2 (HIGH).
Each of these two ranges MUST be calibrated separately.
9.2.3.1. SETTING THE EXPECTED SPAN GAS CONCENTRATION
When setting expected concentration values, consider impurities in your
span gas.
Note
The expected O2 span gas concentration should be 80% of the reporting range of
the instrument (see Section 5.4.1)
The default factory setting is 20.95 %. To set the span gas concentration, press:
Note
For this Initial Calibration it is important to independently verify the PRECISE
Concentration Value of the SPAN gas. If the source of the Span Gas is from a
calibrated bottle, use the exact concentration value printed on the bottle.
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9.2.3.2. ZERO/SPAN POINT CALIBRATION PROCEDURE
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9.3. ASSESSING CALIBRATION QUALITY
After completing one of the calibration procedures described above, it is
important to evaluate the analyzer’s calibration SLOPE and OFFSET
parameters. These values describe the linear response curve of the analyzer. The
values for these terms, both individually and relative to each other, indicate the
quality of the calibration.
To perform this quality evaluation, you will need to record the values of both test
in the DAS channel CALDAT for data analysis, documentation and archival.
Make sure that these parameters are within the limits listed below and frequently
compare them to those values on the Final Test and Checkout Sheet (PN
068350000) that came attached to your manual, which should not be significantly
Table 9-2: Calibration Data Quality Evaluation
FUNCTION
SLOPE
MINIMUM VALUE OPTIMUM VALUE MAXIMUM VALUE
0.700
1.000
0.000
1.300
0.500
OFFSET
-0.500
These values should not be significantly different from the values recorded on the Teledyne API
Final Test and Validation Data Sheet that was shipped with your instrument.
The default DAS configuration records all calibration values in channel
CALDAT as well as all calibration check (zero and span) values in its internal
memory.
Up to 200 data points are stored for up 4 years of data (on weekly calibration
checks) and a lifetime history of monthly calibrations.
Review these data to see if the zero and span responses change over time.
These channels also store the STABIL value (standard deviation of O2
concentration) to evaluate if the analyzer response has properly leveled off
during the calibration procedure
If your instrument has a CO2 sensor option installed this should be calibrated as
well.
9.4. CALIBRATION OF THE T802’S ELECTRONIC
SUBSYSTEMS
9.4.1. PRESSURE CALIBRATION
A sensor at the exit of the sample chamber continuously measures the pressure of
the sample gas. This data is used to compensate the final O2 concentration
calculation for changes in atmospheric pressure and is stored in the CPU’s
memory as the test function PRES (also viewable via the front panel).
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Calibration Procedures
To carry out this adjustment, the current ambient atmospheric pressure must be
known.
Before performing the following pressure calibration, ensure that the pressure
being measured by the analyzer’s internal sensor is equal to ambient atmospheric
pressure by disconnecting:
The sample gas pump and;
The sample gas-line vent from the sample gas inlet on the instrument’s rear
panel.
To cause the analyzer to measure and record a value for PRES, press.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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9.4.2. FLOW CALIBRATION
The flow calibration allows the user to adjust the values of the sample flow rates
as they are displayed on the front panel and reported through COM ports to match
the actual flow rate measured at the sample inlet. This does not change the
hardware measurement of the flow sensors, only the software-calculated values.
To carry out this adjustment, connect an external, sufficiently accurate flow meter
to the sample inlet. Once the flow meter is attached and is measuring actual gas
flow, press:
SAMPLE
RANGE=100.00 %
O2=XXX.XX
SETUP
<TST
TST> CAL
SETUP X.X
PRIMARY SETUP MENU
CFG DAS ACAL RANG PASS CLK MORE EXIT
SETUP X.X
SECONDARY SETUP MENU
COMM VARS DIAG
EXIT
ENTR EXIT
EXIT
SETUP X.X
ENTER PASSWORD:818
8
1
8
DIAG
SIGNAL I/O
PREV NEXT
ENTR
Continue pressing NEXT until ...
DIAG
FLOW CALIBRATION
PREV NEXT
ENTR
EXIT
DIAG FCAL
ACTUAL FLOW: 120 CC/M
0
1
2
0
ENTR EXIT
EXIT discards the new
setting
Toggle to match the actual
flow as measured by the
external flow meter
ENTR accepts the
new setting
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
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9.5. CALIBRATION OF THE OPTIONAL CO2 SENSOR
9.5.1. CO2 CALIBRATION SETUP
The pneumatic connections for calibrating are as follows
Figure 9-2:
CO2 Sensor Calibration Set Up
CO2 SENSOR ZERO GAS: Teledyne API recommends using pure N2 when
calibration the zero point of your CO2 sensor option.
CO2 SENSOR SPAN GAS: Teledyne API recommends using 16% CO2 in N2
9.5.2. SET CO2 SPAN GAS CONCENTRATION
Set the expected CO2 span gas concentration.
This should be equal to the percent concentration of the CO2 span gas of the
selected reporting range (default factory setting = 16%).
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9.5.3. ACTIVATE CO2 SENSOR STABILITY FUNCTION
To change the stability test function from O2 concentration to the CO2 sensor
output, press:
<TST
TST>
SETUP
EXIT
SETUP X.X
CFG DAS ACAL RANG PASS CLK
SETUP X.X
COMM
DIAG ALRM
EXIT
SETUP X.X
EXIT
SETUP X.X
<PREV
0) DAS_HOLD_OFF=15.0 Minutes
JUMP
EDIT PRNT EXIT
Press
3
times to return
to
SETUP X.X
menu
<PREV NEXT> JUMP
PRNT EXIT
ENTR EXIT
ENTR
CO2 and O2
options only
appear if
associated
sensors are
installed.
SETUP X.X
O2
SETUP X.X
CO2 O2
NOTE
Use the same procedure to reset the STB test function to O2 when the CO2 calibration procedure is
complete.
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(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
9.5.4. CO2 ZERO/SPAN CALIBRATION:
To perform the zero/span calibration procedure:
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PART III
–
MAINTENANCE AND SERVICE
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10. MAINTENANCE SCHEDULE & PROCEDURES
The T802 Paramagnetic Oxygen Analyzer utilizes a technology that is non-
depleting and requires very little maintenance. However, there are a minimal
number of simple procedures that when performed regularly will ensure that the
analyzer continues to operate accurately and reliably over its lifetime. Repairs
10.1. MAINTENANCE SCHEDULE
that in certain environments (i.e. dusty, very high ambient pollutant levels) some
maintenance procedures may need to be performed more often than shown.
Note
A Span and Zero Calibration Check (see CAL CHECK REQ’D Column of Table
10-1) must be performed following certain of the maintenance procedure
listed below.
HAZARD
STRONG OXIDIZER
OXYGEN IS A STRONG OXIDIZER.
Before working with the casing open, be sure to turn off power supply, 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 piping. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.
CAUTION
GENERAL SAFETY HAZARD
Risk of electrical shock. Disconnect power before performing any of the following operations
that require entry into the interior of the analyzer.
CAUTION
QUALIFIED PERSONNEL
The operations outlined in this Section are to be performed by qualified maintenance
personnel only.
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Maintenance Schedule & Procedures
Table 10-1. T802 Maintenance Schedule
CAL
DATE PERFORMED
ITEM
ACTION
FREQ
MANUAL
CHECK
REQ’D.
Particulate
Filter
Weekly or as
needed
Replace
10.3.1
No
No
Weekly or after
any
Maintenance or
Repair
Verify Test
Functions
Record and
analyze
11.1.2
10.3.2
10.3.4
10.3.3
Pump
Diaphragm
Replace
Annually
Annually
Yes
No
Perform Flow
Check
Check Flow
Annually or
after any
Maintenance or
Repair
Perform
Leak Check
Verify Leak
Tight
No
Yes if
cleaned
Pneumatic
lines
Examine and
clean
As needed
As needed
Only if
cover
Chassis
Wipe down
removed
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Table 10-2: T802 Test Function Record
DATE RECORDED
OPERATING
FUNCTION
MODE*
O2 ZERO CAL
SAMPLE
STABIL
PRES
SPAN CAL
ZERO CAL
O2SLOPE
O2 OFFSET
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10.2. PREDICTIVE DIAGNOSTICS
The Test Functions can be used to predict failures by looking at how their values
change over time. Initially it may be useful to compare the state of these Test
Functions to the values recorded on the printed record of the final calibration
for taking action as these values change with time. The internal data acquisition
system (DAS) is a convenient way to record and track these changes. Use
APICOM to download and review this data from a remote location.
Table 10-3: Predictive uses for Test Functions
FUNCTION
STABIL
CONDITION
BEHAVIOR
INTERPRETATION
O2 Zero Cal
Increasing
Pneumatic Leaks – instrument & sample system
Pneumatic Leak between sample inlet and Sample Cell
Change in sampling manifold
Increasing > 1”
Dirty particulate filter
Pneumatic obstruction between sample inlet and
sensor
PRES
Sample
Decreasing > 1”
Obstruction in sampling manifold
Pneumatic Leaks
Contaminated zero gas
Increasing
Decreasing
Increasing
Decreasing
OFFSET
SLOPE
Zero Cal
Span Cal
Contaminated zero gas
Pneumatic Leaks – instrument & sample system
Calibration system deteriorating
Calibration system deteriorating
10.3. MAINTENANCE PROCEDURES
The following procedures are to be performed periodically as part of the standard
maintenance of the T802.
10.3.1. REPLACING THE SAMPLE PARTICULATE FILTER
The particulate filter should be inspected often for signs of plugging or
contamination. We recommend that when you change the filter; handle it and the
wetted surfaces of the filter housing as little as possible. Do not touch any part of
the housing, filter element, PTFE retaining ring, glass cover and the o-ring.
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To change the filter:
1. Turn OFF the analyzer to prevent drawing debris into the instrument.
2. Open the T802’s hinged front panel and unscrew the knurled retaining ring on
the filter assembly.
Figure 10-1:
Sample Particulate Filter Assembly
3. Carefully remove the retaining ring, PTFE o-ring, glass filter cover and filter
element.
4. Replace the filter, being careful that the element is fully seated and centered
in the bottom of the holder.
5. Re-install the PTFE o-ring (with the notches up), the glass cover, then screw
on the retaining ring and hand tighten. Inspect the seal between the edge of
filter and the o-ring to assure a proper seal.
6. Re-start the analyzer.
10.3.2. REBUILDING THE SAMPLE PUMP
The diaphragm in the sample pump periodically wears out and must be replaced.
A sample rebuild kit is available – see Appendix B of this manual for the PN of
the pump rebuild kit. Instructions and diagrams are included with the kit.
Always perform a Flow and Leak Check after rebuilding the Sample Pump.
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10.3.3. PERFORMING LEAK CHECKS
HAZARD
STRONG OXIDIZER
OXYGEN IS A STRONG OXIDIZER.
ONLY Perform Leak Checks using N2 gas and after thoroughly purging the analyzer’s
internal pneumatics.
Leaks are the most common cause of analyzer malfunction; Section 10.3.3.1
procedure.
10.3.3.1. VACUUM LEAK CHECK AND PUMP CHECK
This method is easy and fast. It detects, but does not locate most leaks. It also
verifies that the sample pump is in good condition.
1. Turn the analyzer ON, and allow enough time for flows to stabilize.
2. Cap the SAMPLE inlet port.
3. After several minutes, when the pressures have stabilized, note the following.
In the TEST menu, note the SAMPLE PRESSURE reading.
4. If the reading is < 10 in-Hg, the pump is in good condition and there are no
large leaks.
5. Check the sample gas flow. If the flow is <10 cm3/min and stable, there are
no large leaks in the instrument’s pneumatics.
10.3.3.2. PRESSURE LEAK CHECK
If you can’t locate the leak by the above procedure, use the following procedure.
Obtain a leak checker similar to the Teledyne API PN 01960, which contains a
small pump, shut-off valve and pressure gauge. Alternatively, a convenient
source of low-pressure gas is a tank of span gas, with the two-stage regulator
adjusted to less than 15 psi with a shutoff valve and pressure gauge.
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CAUTION
GENERAL SAFETY HAZARD
Do not use bubble solution with vacuum applied to the analyzer. The solution may
contaminate the instrument. Do not exceed 15 PSI pressure.
1. Turn OFF power to the instrument.
2. Install a leak checker or tank of gas as described above on the SAMPLE inlet
at the rear panel.
3. Remove the instrument cover and locate the inlet side of the sample pump.
Remove the flow assembly from the pump and plug it with the appropriate
gas-tight fitting.
4. Pressurize the instrument with the leak checker, allowing enough time to fully
pressurize the instrument through the critical flow orifice. Do not exceed 15
psi pressure. Check each fitting with soap bubble solution, looking for
bubbles. Once the fittings have been wetted with soap solution, do not re-
apply vacuum, as it will suck soap solution into the instrument and
contaminate it. Wipe down and thoroughly dry all parts first.
5. Once the leak has been located and repaired, the leak-down rate should be
< 1 in-Hg (0.4 psi) in 5 minutes after the pressure is shut off.
10.3.4. PERFORMING A SAMPLE FLOW CHECK
HAZARD
STRONG OXIDIZER
ONLY Perform Leak Checks using N2 gas and after thoroughly purging the analyzer’s
internal pneumatics.
CAUTION
GENERAL SAFETY HAZARD
Always use a separate calibrated flow meter capable of measuring flows in the 0 – 1000
cm3/min range to measure the gas flow rate though the analyzer.
DO NOT use the built in flow measurement viewable from the Front Panel of the instrument.
This measurement is only for detecting major flow interruptions such as clogged or plugged
gas lines.
3-4). Ensure that the inlet to the Flow Meter is at atmospheric pressure.
2. Sample flow should be 120 cm3/min 10%.
3. Once an accurate measurement has been recorded by the method described
above, adjust the analyzer’s internal flow sensors (See Section 9.4.2).
Low flows indicate blockage somewhere in the pneumatic pathway, typically a
plugged sintered filter or critical flow orifice in one of the analyzer’s flow control
assemblies. High flows indicate leaks downstream of the Flow Control
Assembly.
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10.3.5. CLEANING THE OPTICAL BENCH
The T802 sensor assembly and optical bench are complex and delicate.
Disassembly and cleaning is not recommended. Please check with the factory
before disassembling the optical bench.
10.3.6. CLEANING EXTERIOR SURFACES OF THE T802
If necessary, the exterior surfaces of the T802 can be cleaned with a clean damp
cloth. Do NOT submerge any part of the instrument and do NOT use any
cleaning solution.
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11. TROUBLESHOOTING AND SERVICE
This section describes a variety of methods for identifying the source of
performance problems with the analyzer. Also included here are procedures that
are used to repair the instrument.
HAZARD
STRONG OXIDIZER
OXYGEN IS A STRONG OXIDIZER.
Before working with the casing open, be sure to turn off power supply, 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 piping. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.
QUALIFIED PERSONNEL ONLY
The operations outlined in this Section must be performed by qualified maintenance
personnel only.
CAUTION
RISK OF ELECTRICAL SHOCK
Some operations need to be carried out with the instrument open and running.
Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to
the analyzer.
Do not drop tools into the analyzer or leave them after your procedures.
Do not shorten or touch electric connections with metallic tools while operating inside
the analyzer.
Use common sense when operating inside a running analyzer.
11.1. GENERAL TROUBLESHOOTING
The T802 paramagnetic O2 analyzer has been designed so that problems can be
rapidly detected, evaluated and repaired. During operation, it continuously
performs diagnostic tests and provides the ability to evaluate its key operating
parameters without disturbing monitoring operations.
A systematic approach to troubleshooting will generally consist of the following
five steps:
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1. Note any WARNING MESSAGES and take corrective action as necessary.
2. Examine the values of all TEST functions and compare them to factory
values. Note any major deviations from the factory values and take
corrective action.
3. Use the internal electronic status LEDs to determine whether the electronic
communication channels are operating properly.
Verify that the DC power supplies are operating properly by checking the
voltage test points on the relay PCA.
Note that the analyzer’s DC power wiring is color-coded and these colors
match the color of the corresponding test points on the relay PCA.
4. SUSPECT A LEAK FIRST!
Technical Support data indicate that the majority of all problems are
eventually traced to leaks in the internal pneumatics of the analyzer or the
diluent gas and source gases delivery systems.
Check for gas flow problems such as clogged or blocked internal/external gas
lines, damaged seals, punctured gas lines, a damaged / malfunctioning
pumps, etc.
vital functions are working (power supplies, CPU, relay PCA, keyboard, etc.).
analyzer.
See the wiring interconnect diagram and interconnect list in Appendix D.
11.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES
The most common and/or serious instrument failures will result in a warning
along with their meaning and recommended corrective action.
It should be noted that if more than two or three warning messages occur at the
same time, it is often an indication that some fundamental analyzer sub-system
(power supply, relay board, motherboard) has failed rather than indication of the
of the specific failures referenced by the warnings. In this case, it is
confirmed before addressing the specific warning messages.
The analyzer will alert the user that a Warning Message is active by flashing the
FAULT LED, displaying the Warning message in the Param field along with the
CLR button (press to clear Warning message). The MSG button displays if there
is more than one warning in queue or if you are in the TEST menu and have not
yet cleared the message. The following display/touchscreen examples provide an
illustration of each:
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Top: the CLR button is available to clear the warning message displayed in the Param field.
Bottom: the MSG button indicates that at least one warning message has not yet been cleared.
The analyzer will also alert the user via the Serial I/O COM port(s).
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To view or clear the various warning messages press:
SAMPLE
TEST
SYSTEM RESET
CAL
O2=XXX.XX
Suppresses the
warning messages
MSG CLR SETUP
SAMPLE
RANGE=100 %
CAL
O2=XXX.XX
MSG returns the active
warnings to the message
field.
<TST TST>
MSG
SETUP
NOTE:
If a warning message persists after
several attempts to clear it, the message
may indicate a real problem and not an
artifact of the warm-up period
SAMPLE
TEST
WARNING
CAL
O2=XXX.XX
Press CLR to clear the current
MSG CLR SETUP
message.
If more than one warning is
active, the next message will take
its place.
SAMPLE
TEST
SYSTEM RESET
CAL
O2=XXX.XX
MSG CLR SETUP
Once the last warning has
been cleared, the RANGE
function will be displayed in
the analyzer’s main
SAMPLE
RANGE=100.00 %
O2=XXX.XX
MESSAGE FIELD.
<TST TST>
CAL
SETUP
Figure 11-1:
Viewing and Clearing Warning Messages
Table 11-1: Warning Messages - Indicated Failures
WARNING
MESSAGE
FAULT CONDITION
POSSIBLE CAUSES
Bad heater
Bad temperature sensor
Bad relay controlling the heater
Entire relay board is malfunctioning
I2C bus malfunction
The O2 cell temp is controlled at 50
O2 CELL TEMP
WARN
2 °C.
NOTE: Box temperature typically runs ~7oc warmer than
ambient temperature.
Poor/blocked ventilation to the analyzer.
Stopped exhaust-fan
BOX TEMP
WARNING
Box Temp is
< 8 °C or > 50 °C.
Ambient temperature outside of specified range
Measured concentration value is too high or low.
Concentration slope value to high or too low
CANNOT DYN
SPAN
Dynamic Span operation failed
Dynamic Zero operation failed
Measured concentration value is too high.
Concentration offset value to high.
CANNOT DYN
ZERO
Failed disk on module
User erased data
CONFIG
INITIALIZED
Configuration and Calibration data
reset to original Factory state.
Failed Disk on Module
User cleared data
DATA INITIALIZED
Data Storage in DAS was erased
Warning only appears on serial I/O COM port(s)
Front panel display will be frozen, blank or will not respond.
Massive failure of mother board
REAR BOARD NOT Motherboard not detected on power
DET
up.
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WARNING
FAULT CONDITION
MESSAGE
POSSIBLE CAUSES
I2C bus failure
Failed relay board
RELAY BOARD
WARN
The CPU cannot communicate with
the Relay Board.
Loose connectors/wiring
Failed sample pump
Blocked sample inlet/gas line
Dirty particulate filter
Leak downstream of critical flow orifice
Failed flow sensor/circuitry
SAMPLE FLOW
WARN
Sample flow rate is < 80 cm3/min or
> 180 cm3/min
If sample pressure is < 15in-Hg:
Blocked particulate filter
Sample Pressure is <15 in-Hg or
> 35 in-Hg
Blocked sample inlet/gas line
Failed pressure sensor/circuitry
If sample pressure is > 35 in-Hg:
Pressurized sample gas. Install vent
Blocked vent line on pressurized sample/zero/span gas
supply
SAMPLE PRES
WARN
Normally 29.92 in-Hg at sea level
decreasing at 1 in-Hg per 1000 ft of
altitude (with no flow – pump
disconnected).
Bad pressure sensor/circuitry
This message occurs at power on. If you have not cycled the
power on your instrument:
Failed +5 VDC power,
The computer has rebooted.
SYSTEM RESET
Fatal error caused software to restart
Loose connector/wiring
11.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS
In addition to being useful as predictive diagnostic tools, the test functions
viewable from the front panel can be used to isolate and identify many
operational problems when combined with a thorough understanding of the
analyzer’s theory of operation (see Section 12).
The acceptable ranges for these test functions are listed in the “Nominal Range”
column of the analyzer Final Test and Validation Data Sheet (PN 068350000)
shipped with the instrument. Values outside these acceptable ranges indicate a
failure of one or more of the analyzer’s subsystems. Functions whose values are
still within the acceptable range but have significantly changed from the
measurement recorded on the factory data sheet may also indicate a failure.
Note
A worksheet has been provided in Appendix C to assist in recording the
value of these test functions. This worksheet also includes expected values
for the various test functions.
The following table contains some of the more common causes for these values to
be out of range.
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Table 11-2: Test Functions - Indicated Failures
TEST FUNCTIONS
INDICATED FAILURE(S)
(As Displayed)
Time of day clock is too fast or slow
To adjust See Section 5.6.
TIME
Battery in clock chip on CPU board may be dead.
Incorrectly configured measurement range(s) could cause response problems with a
Data logger or chart recorder attached to one of the analog output.
RANGE
STABIL
If the Range selected is too small, the recording device will over range.
If the Range is too big, the device will show minimal or no apparent change in readings.
Indicates noise level of instrument or concentration of sample gas (See Section 11.3 for
causes).
PRES
Check for gas flow problems (see Section 11.3).
SAMPLE FL
Temperatures outside of the specified range or oscillating temperatures are cause for
concern
O2 CELL TEMP
If the box temperature is out of range, check fan in the power supply module. Areas to
BOX TEMP WARNING.
BOX TEMP
Values outside range indicate
Contamination of the zero air or span gas supply
Instrument is miscalibrated
O2 SLOPE
Blocked gas flow
Bad/incorrect span gas concentration due.
Values outside range indicate contamination of the zero air supply
O2 OFFSET
11.1.3. DIAG SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O
FUNCTION
The signal I/O diagnostic mode allows access to the digital and analog I/O in the
analyzer. Some of the digital signals can be controlled through the keyboard.
These signals, combined with a thorough understanding of the instruments
ways:
The technician can view the raw, unprocessed signal level of the analyzer’s
critical inputs and outputs.
Many of the components and functions that are normally under algorithmic
control of the CPU can be manually exercised.
The technician can directly control the signal level Analog and Digital Output
signals.
This allows the technician to observe systematically the effect of directly
controlling these signals on the operation of the analyzer. The following
flowchart shows an example of how to use the Signal I/O menu to view the raw
voltage of an input signal or to control the state of an output voltage or control
signal.
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Figure 11-2:
Example of Signal I/O Function
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).
Note
Any I/O signals changed while in the signal I/O menu will remain in effect
ONLY until signal I/O menu is exited. The Analyzer regains control of these
signals upon exit.
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11.2. USING THE INTERNAL ELECTRONIC STATUS LEDS
Several LEDs are located inside the instrument to assist in determining if the
analyzer’s CPU, I2C bus and relay board are functioning properly.
11.2.1. CPU STATUS INDICATOR
DS5, a red LED, that is located on upper portion of the motherboard, just to the
right of the CPU board, flashes when the CPU is running the main program loop.
After power-up, approximately 30 to 60 seconds, DS5 should flash on and off. If
characters are written to the front panel display but DS5 does not flash, then the
program files have become corrupted. If after 30 – 60 seconds neither the DS5 is
flashing or no characters have been written to the front panel display, then the
CPU is bad and must be replaced.
Motherboard
CPU Status LED
Figure 11-3:
CPU Status Indicator
11.2.2. RELAY PCA STATUS INDICATORS
There are sixteen status indicator LEDs located on the Relay PCA. Some are not
used on this model.
11.2.2.1. I2C BUS WATCHDOG STATUS LEDS
The most important is D1 (which indicates the health of the I2C bus).
Table 11-3: Relay PCA Watchdog LED Failure Indications
LED
Function
Fault Status
Indicated Failure(s)
Failed/Halted CPU
Faulty Motherboard, Keyboard or Relay PCA
Faulty Connectors/Wiring between Motherboard,
Keyboard or Relay PCA
Continuously ON
or
Continuously OFF
D1
(Red)
I2C bus Health
(Watchdog Circuit)
Failed/Faulty +5 VDC Power Supply (PS1)
If D1 is blinking, then the other LEDs can be used in conjunction with DIAG
Menu Signal I/O to identify hardware failures of the relays and switches on the
Relay PCA.
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11.2.2.2. RELAY PCA STATUS LED S
D6 (Yellow) O2 Sensor Heater
D5 (Yellow) – CO2 Sensor Heater (only with CO2 option)
D1 (RED)
Watchdog Indicator
Figure 11-4:
Relay PCA Status LEDS Used for Troubleshooting
Table 11-4: Relay PCA Status LED Failure Indications
Status When LED Lit
Status When LED Unlit
LED
Color
Function
(Energized State)
(Default State)
Cycles ON/OFF every 3 Seconds
under direct control of the analyzer’s CPU.
SPARE
D1
Red
Watchdog Circuit
D2-D4
D51
Yellow
Yellow
Green
Green
Green
Green
CO2 Sensor Cell heater
O2 Sensor heater
Heating
Heating
Not Heating
Not Heating
D6
D72
D82
D92
D102
D11 - 16
SPARE
1 Only active when the optional CO2 sensor is installed
2
Not Used
11.3. GAS FLOW PROBLEMS
When troubleshooting flow problems, it is a good idea to first confirm that the
actual flow and not the analyzer’s flow sensor and software are in error, or the
flow meter is in error. Use an independent flow meter to perform a flow check as
pressure sensors as described in Section 11.6.8.
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In general, flow problems can be divided into three categories:
Flow is too high
Flow is greater than zero, but is too low, and/or unstable
Flow is zero (no flow)
When troubleshooting flow problems, it is crucial to confirm the actual flow rate
without relying on the analyzer’s flow display. The use of an independent,
external flow meter to perform a flow check as described in Section 10.3.4 is
essential.
The flow diagrams found in a variety of locations within this manual depicting
the T802 in its standard configuration and with options installed, can help in
trouble-shooting flow problems. For your convenience the diagrams are collected
here.
11.3.1. T802 INTERNAL GAS FLOW DIAGRAMS
Figure 11-5:
T802– Basic Internal Gas Flow
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Figure 11-6:
T802 – Internal Pneumatics with CO2 Sensor Option 67
11.3.2. TYPICAL SAMPLE GAS FLOW PROBLEMS
11.3.2.1. FLOW IS ZERO
The unit displays a SAMPLE FLOW warning message on the front panel display
or the SAMPLE FLOW test function reports a zero or very low flow rate.
Confirm that the sample pump is operating (turning). If not, use an AC voltmeter
to make sure that power is being supplied to the pump. If no power is present at
the electrical leads of the pump, take the following steps:.
1. If AC power is being supplied to the pump, but it is not turning, replace the
pump.
2. If the pump is operating but the unit reports no gas flow, perform a flow check
as described in Section 10.3.4.
3. If no independent flow meter is available:
Disconnect the gas lines from both the sample inlet and the exhaust outlet
on the rear panel of the instrument.
Make sure that the unit is in basic SAMPLE Mode.
Place a finger over a Sample inlet on the rear panel of the instrument.
If gas is flowing through the analyzer, you will feel a vacuum suction at the
inlet.
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4. If gas flows through the instrument when it is disconnected from its sources
of zero air, span gas or sample gas, the flow problem is most likely not
internal to the analyzer. Check to ensure that:
All calibrators/generators are turned on and working correctly.
Gas bottles are not empty or low.
Valves, regulators and gas lines are not clogged or dirty.
11.3.2.2. LOW FLOW
1. Check if the pump diaphragm is in good condition. If not, rebuild the pump
rebuilding kits.
and re-check.
3. Check for the sample filter and the orifice filter for dirt. Replace filters (See
4. Check for partially plugged pneumatic lines. Clean or replace them.
5. Check for plugged or dirty critical flow orifices. Replace them.
11.3.2.3. HIGH FLOW
The most common cause of high flow is a leak in the sample flow control. If no
leaks or loose connections are found in the fittings or the gas line between the
orifice and the pump, replace the critical flow orifice inside the sample flow
control assembly.
11.3.2.4. DISPLAYED FLOW WARNINGS
This warning means that there is inadequate gas flow. There are four conditions
that might cause this:
A leak upstream or downstream of the flow sensor
A flow obstruction upstream or downstream of the flow sensor
Bad Flow Sensor Board
Bad pump
To determine which condition is causing the flow problem, view the sample
pressure and sample flow functions on the front panel display. If the sample
pressure is reading abnormally low, then the cause is likely a flow obstruction
upstream of the flow sensor. First, check the sample filter and make sure it is not
plugged and then systematically check all the other components upstream of the
orifice to ensure that they are not obstructed.
If the sample pressure is reading normal but the sample flow is reading low, then
it is likely that the pump diaphragm is worn or there is an obstruction downstream
of the flow sensor.
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11.3.2.5. ACTUAL FLOW DOES NOT MATCH DISPLAYED FLOW
If the actual flow measured does not match the displayed flow, but is within the
limits of 100-140 cm3/min, adjust the calibration of the flow measurement as
described in Section 10.3.4.
11.3.2.6. SAMPLE PUMP
The sample pump should start immediately after the front panel power switch is
turned ON. With the SAMPLE inlet plugged the test function PRES should read
about 10”-Hg for a pump in good condition. Readings above 10” Hg indicate that
the pump needs rebuilding. If the test function SAMP FL is greater than 10
cm3/min there is a leak in the pneumatic lines.
11.4. CALIBRATION PROBLEMS
11.4.1. MISCALIBRATED
There are several symptoms that can be caused by the analyzer being
miscalibrated. Miscalibration is indicated by out-of-range Slopes and Offsets as
displayed through the test functions and is frequently caused by the following:
Bad span gas: This can cause a large error in the slope and a small error in
the offset. Delivered from the factory, the T802’s slope is within ±15% of
nominal. Bad span gas will cause the analyzer to be calibrated to the wrong
value. If in doubt have the span gas checked by and independent lab.
Contaminated zero gas: Excess H2O can cause a positive or negative offset
and will indirectly affect the slope.
Dilution calibrator not set up correctly or is malfunctioning: This will also
cause the slope, but not the zero, to be incorrect. Again the analyzer is being
calibrated to the wrong value.
Too many analyzers on the manifold: This can cause either a slope or offset
error because ambient gas with its pollutants will dilute the zero or span gas.
11.4.2. NON-REPEATABLE ZERO AND SPAN
As stated earlier, leaks both in the T802 and in the external system are a common
source of unstable and non-repeatable readings.
Don’t forget to consider pneumatic components in the gas delivery system
outside the T802 Such as:
A change in zero air source such as ambient air leaking into zero air line,
or;
A change in the span gas concentration due to zero air or ambient air
leaking into the span gas line.
2. Once the instrument passes a leak check, do a flow check (See Section
10.3.4) to make sure adequate sample is being delivered to the sensor
assembly.
3. Confirm the sample pressure, wheel temperature, bench temperature, and
sample flow readings are correct and have steady readings.
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4. Disconnect the exhaust line from the optical bench near the rear of the
instrument and plug this line into the SAMPLE inlet creating a pneumatic
loop. The concentration (either zero or span) now must be constant. If
readings become quiet, the problem is in the external pneumatics supplies for
sample gas, span gas or zero air.
11.4.3. INABILITY TO SPAN – NO SPAN BUTTON
1. Confirm that the oxygen span gas source is accurate; this can be done by
opening the analyzer’s SAMPLE inlet to ambient air. If the concentration is
not displayed as ~20.9%, there is a problem with the span gas.
3. Make sure that the expected span gas concentration entered into the
instrument during calibration, is the correct span gas concentration and not
too different from expected span value. This can be viewed via the CONC
submenu of the Sample displays.
4. Check to make sure that there is no ambient air or zero air leaking into span
gas line.
11.4.4. INABILITY TO ZERO – NO ZERO BUTTON
1. Confirm that there is a good source of zero air. Dilute a tank of span gas with
the same amount of zero air from two different sources. If the O2
Concentration of the two measurements is different, there is a problem with
one of the sources of zero air.
3. Check to make sure that there is no ambient air leaking into zero air line.
11.5. OTHER PERFORMANCE PROBLEMS
Dynamic problems (i.e. problems which only manifest themselves when the
analyzer is monitoring sample gas) can be the most difficult and time consuming
to isolate and resolve. The following provides an itemized list of the most
common dynamic problems with recommended troubleshooting checks and
corrective actions.
11.5.1. TEMPERATURE PROBLEMS
Individual control loops are used to maintain the set point of the absorption
bench, filter wheel and IR photo-detector temperatures. If any of these
temperatures are out of range or are poorly controlled, the T802 will perform
poorly.
11.5.1.1. BOX TEMPERATURE
The box temperature sensor is mounted to the motherboard and cannot be
disconnected to check its resistance. Rather check the BOX TEMP signal using
parameter will vary with ambient temperature, but at ~30oC (6-7° above room
temperature) the signal should be ~1450 mV.
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11.6. SUBSYSTEM CHECKOUT
failures or performance problems within the analyzer. In most cases this included
a list of possible causes. This describes how to determine individually determine
if a certain component or subsystem is actually the cause of the problem being
investigated.
11.6.1. AC MAINS CONFIGURATION
The analyzer is correctly configured for the AC mains voltage in use if:
1. The Sample Pump is running.
2. If incorrect power is suspected, check that the correct voltage and frequency
is present at the line input on the rear panel.
If the unit is set for 230 VAC and is plugged into 115VAC, or 100VAC the
sample pump will not start, and the heaters will not come up to
temperature.
If the unit is set for 115 or 100 VAC and is plugged into a 230 VAC circuit,
the circuit breaker built into the ON/OFF Switch on the Front Panel will
trip to the OFF position immediately after power is switched on.
11.6.2. DC POWER SUPPLY
If you have determined that the analyzer’s AC mains power is working, but the
unit is still not operating properly, there may be a problem with one of the
instrument’s switching power supplies. The supplies can have two faults, namely
no DC output, and noisy output.
To assist tracing DC Power Supply problems, the wiring used to connect the
various printed circuit assemblies and DC Powered components and the
associated test points on the relay board follow a standard color-coding scheme as
defined in the following table.
Table 11-5:
NAME
DC Power Test Point and Wiring Color Codes
TEST POINT#
TP AND WIRE COLOR
Dgnd
+5V
1
2
3
4
5
6
7
Black
Red
Agnd
Green
Blue
+15V
-15V
Yellow
Purple
Orange
+12V Ret (ground)
+12V
A voltmeter should be used to verify that the DC voltages are correct per the
values in the table below, and an oscilloscope, in AC mode, with band limiting
turned on, can be used to evaluate if the supplies are producing excessive noise (>
100 mV p-p).
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Table 11-6: DC Power Supply Acceptable Levels
CHECK RELAY BOARD TEST POINTS
FROM TEST POINT TO TEST POINT
POWER SUPPLY
ASSY
VOLTAGE
MIN V
MAX V
NAME
Dgnd
#
1
3
3
3
1
6
6
NAME
+5
#
2
PS1
PS1
PS1
PS1
PS1
PS2
PS2
+5
+15
4.85
13.5
5.25
16V
Agnd
+15
4
-15
Agnd
-15V
5
-13.5V
-0.05
-0.05
11.75
-0.05
-16V
0.05
0.05
12.5
0.05
Agnd
Chassis
+12
Agnd
Dgnd
Chassis
+12V
Dgnd
1
Dgnd
N/A
7
+12V Ret
+12V Ret
Dgnd
1
11.6.3. I2C BUS
Operation of the I2C bus can be verified by observing the behavior of D1 on the
Relay Board in conjunction with the performance of the front panel display.
Assuming that the DC power supplies are operating properly and the wiring is
intact, the I2C bus is operating properly if:
D1 on the relay board is flashing, or;
D1 is not flashing but pressing a button on the touchscreen results in a change
to the display.
11.6.4. TOUCHSCREEN INTERFACE
Verify the functioning of the touchscreen by observing the display when pressing
a touchscreen control button. Assuming that there are no wiring problems and
that the DC power supplies are operating properly, if pressing a control button on
the display does not change the display, any of the following may be the problem:
The touchscreen controller may be malfunctioning.
The internal USB bus may be malfunctioning.
You can verify this failure by logging on to the instrument using APICOM or a
terminal program to any of the communications ports. If the analyzer responds to
remote commands and the display changes accordingly, the touchscreen interface
may be faulty.
11.6.5. LCD DISPLAY MODULE
Verify the functioning of the front panel display by observing it when power is
applied to the instrument. Assuming that there are no wiring problems and that
the DC power supplies are operating properly, the display screen should light and
show the splash screen with logo and other indications of its state as the CPU
goes through its initialization process.
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11.6.6. RELAY BOARD
The relay board PCA (04135) can be most easily checked by observing the
condition of the its status LEDs on the relay board, as described in Section
12.5.4.1, and the associated output when toggled on and off through signal I/O
function in the diagnostic menu, See Section 11.1.3.
1. If the front panel display responds to key presses and D1 on the relay board
is NOT flashing then either the wiring between the Keyboard and the relay
board is bad, or the relay board is bad.
2. If D1 on the relay board is flashing and the status indicator for the output in
question (heater power etc.) toggles properly using the signal I/O function,
then the associated control device on the relay board is bad. (Several of the
control devices are in sockets and can be easily replaced).
11.6.7. SENSOR ASSEMBLY
The paramagnetic O2 sensor of your T802 analyzer has no user serviceable parts
11.6.8. PRESSURE/FLOW SENSOR ASSEMBLY
The pressure/flow sensor PCA can be checked with a Voltmeter using the
following procedure which, assumes that the wiring is intact, and that the
motherboard and the power supplies are operating properly:
1. For Pressure related problems:
Measure the voltage across C1 it should be 5 ± 0.25 VDC.
If not then the board is bad.
Measure the voltage across TP4 and TP1.
With the sample pump disabled it should be 4500 mV ±250 mV.
With the pump energized it should be approximately 200 mV less. If
not, then S1, the pressure transducer is bad, the board is bad, or there
is a pneumatic failure preventing the pressure transducer from sensing
the absorption cell pressure properly.
2. For flow related problems:
Measure the voltage across TP2 and TP1 it should be 10 ±0.25 VDC.
If not then the board is bad.
With flow stopped (sample inlet blocked) the voltage should be
approximately 1V.
If the voltage is incorrect, the flow sensor is bad, the board is bad or
there is a leak upstream of the sensor.
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11.6.9. MOTHERBOARD
11.6.9.1. A/D FUNCTIONS
The simplest method to check the operation of the A-to-D converter on the
motherboard is to use the Signal I/O function under the DIAG menu to check the
two A/D reference voltages and input signals that can be easily measured with a
voltmeter.
value of REF_4096_MV and REF_GND.
If both are within 3 mV of nominal (4096 and 0), and are stable, ±0.2 mV
then the basic A/D is functioning properly. If not then the motherboard is
bad.
2. Choose a parameter in the Signal I/O function such as
SAMPLE_PRESSURE or SAMPLE_FLOW.
Compare these voltages at their origin (see interconnect drawing PN
06407 and interconnect list PN 06294 in Appendix D) with the voltage
displayed through the signal I/O function.
If the wiring is intact but there is a large difference between the measured
and displayed voltage (±10 mV) then the motherboard is bad.
11.6.9.2. ANALOG OUTPUTS: CURRENT LOOP
To verify that the analog outputs with the optional current mode output are
working properly, connect a 250 ohm resistor across the outputs and use a
For each step the output should be within 1% of the nominal value listed in the
table below.
Table 11-7: Analog Output Test Function - Nominal Values Current Outputs
OUTPUT RANGE
2 -20
4 -20
NOMINAL OUTPUT VALUES
STEP
%
0
CURRENT
2 mA
5.6
V(250 OHMS)
CURRENT
V(250 OHMS)
1
2
3
4
5
6
0.5V
1.4
2.3
3.2
4.1
5
4
1
20
40
60
80
100
7.2
1.8
2.6
3.4
4.2
5
9.2
10.4
13.6
16.8
20
12.8
16.4
20
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11.6.9.3. STATUS OUTPUTS
The procedure below can be used to test the Status outputs:
1. Connect a jumper between the “D“ pin and the “” pin on the status output
connector.
2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status
output that is being tested.
3. Connect a voltmeter between the “” pin and the pin of the output being
tested (see table below).
inputs and outputs until you get to the output in question. Alternately turn on and
off the output noting the voltage on the voltmeter, it should vary between 0 volts
for ON and 5 volts for OFF.
Table 11-8:
Status Outputs Check
PIN (LEFT TO RIGHT)
STATUS
SYSTEM OK
CONC VALID
O2 ZERO CAL
O2 SPAN CAL
ZERO CAL RNG2
CO2 ZERO CAL
SPARE
1
2
3
4
5
6
7
8
SPARE
11.6.10. CPU
There are two major types of failures associated with the CPU board: complete
failure and a failure associated with the Disk-On-Module (DOM) on the CPU
board. If either of these failures occurs, contact the factory.
For complete failures, assuming that the power supplies are operating properly
and the wiring is intact, the CPU is faulty if on power-on, the watchdog LED on
the motherboard is not flashing.
In some rare circumstances, this failure may be caused by a bad IC on the
motherboard, specifically U57, the large, 44 pin device on the lower right hand
side of the board. If this is true, removing U57 from its socket will allow the
instrument to start up but the measurements will be invalid.
If the analyzer stops during initialization (the front panel display shows a fault or
warning message), it is likely that the DOM, the firmware or the configuration
and data files have been corrupted.
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11.6.11. RS-232 COMMUNICATIONS
11.6.11.1. GENERAL RS-232 TROUBLESHOOTING
Teledyne API analyzers use the RS-232 communications protocol to allow the
instrument to be connected to a variety of computer-based equipment. RS-232
has been used for many years and as equipment has become more advanced,
connections between various types of hardware have become increasingly
difficult. Generally, every manufacturer observes the signal and timing
requirements of the protocol very carefully.
Problems with RS-232 connections usually center around four general areas:
out information.
3. If a modem is being used, additional configuration and wiring rules must be
5. Verify that cable (03596) that connects the serial COM ports of the CPU to
J12 of the motherboard is properly seated
11.6.11.2. TROUBLESHOOTING ANALYZER/MODEM OR TERMINAL OPERATION
These are the general steps for troubleshooting problems with a modem
connected to a Teledyne API analyzer.
1. Check cables for proper connection to the modem, terminal or computer.
2. Check to make sure the DTE-DCE is in the correct position as described in
Section 6.1.
4. Verify that the Ready to Send (RTS) signal is at logic high. The T802 sets
pin 7 (RTS) to greater than 3 volts to enable modem transmission.
5. Make sure the BAUD rate, word length, and stop bit settings between modem
and analyzer match, See Section 8.3.
6. Use the RS-232 test function to send “w” characters to the modem, terminal
or computer; See Section 8.3.
7. Get your terminal, modem or computer to transmit data to the analyzer
(holding down the space bar is one way); the green LED should flicker as the
instrument is receiving data.
8. Make sure that the communications software or terminal emulation software
is functioning properly.
Further help with serial communications is available in a separate manual “RS-
232 Programming Notes” Teledyne API PN 013500000.
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11.6.12. OPTIONAL CO2 SENSOR
There are Two LEDs located on the CO2 sensor PCA.
Figure 11-7:
Location of Diagnostic LEDs on CO2 Sensor PCA
Normal Operation: V8 is not lit – V9 is Blinking
Error State: Both LEDs are blinking.
Check to make sure that the cable to the CO2 sensor is properly connected.
11.7. REPAIR PROCEDURES
This contains procedures that might need to be performed on rare occasions when
a major component of the analyzer requires repair or replacement.
11.7.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY
The critical flow orifice is housed in the flow control assembly (Teledyne API PN
001760400) located on the top of the optical bench. A sintered filter protects the
jewel orifice so it is unusual for the orifice to need replacing, but if it does, or the
filter needs replacement please use the following procedure (see the Spare Parts
list in Appendix B for PNs and kits):
1. Turn off power to the analyzer.
3. Disconnect the pneumatic connection from the flow assembly and the
assembly from the pump.
4. Remove the fitting and the components as shown in the exploded view
below.
5. Replace the o-rings (PN OR000001) and the sintered filter (PN FL000001).
6. If replacing the critical flow orifice itself (PN 000940700), make sure that the
side with the colored window (usually red) is facing upstream to the flow gas
flow.
7. Apply new Teflon® tape to the male connector threads
8. Re-assemble in reverse order.
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9. After reconnecting the power and pneumatic lines, flow check the instrument
as described in the Section 10.3.4.
Figure 11-8:
Critical Flow Restrictor Assembly / Disassembly
11.7.2. DISK-ON-MODULE REPLACEMENT PROCEDURE
COULD DAMAGE INSTRUMENT AND VOID WARRANTY
ATTENTION
Servicing of circuit components requires electrostatic discharge
protection, i.e. ESD grounding straps, mats and containers. Failure
to use ESD protection when working with electronic assemblies will
information on preventing ESD damage.
Replacing the Disk-on-Module (DOM) will cause loss of all DAS data; it may
also cause loss of some instrument configuration parameters unless the
replacement DOM carries the exact same firmware version. Whenever changing
the version of installed software, the memory must be reset. Failure to ensure that
memory is reset can cause the analyzer to malfunction, and invalidate
measurements. After the memory is reset, the A/D converter must be re-
calibrated, and all information collected in Step 1 below must be re-entered
before the instrument will function correctly. Also, zero and span calibration
should be performed.
1. Document all analyzer parameters that may have been changed, such as
range, auto-cal, analog output, serial port and other settings before replacing
the DOM
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2. Turn off power to the instrument, fold down the rear panel by loosening the
mounting screws.
3. When looking at the electronic circuits from the back of the analyzer, locate
the Disk-on-Module in the right-most socket of the CPU board.
4. The DOM should carry a label with firmware revision, date and initials of the
programmer.
5. Remove the nylon standoff clip that mounts the DOM over the CPU board,
and lift the DOM off the CPU. Do not bend the connector pins.
6. Install the new Disk-on-Module, making sure the notch at the end of the chip
matches the notch in the socket.
7. It may be necessary to straighten the pins somewhat to fit them into the
socket. Press the chip all the way in.
8. Close the rear panel and turn on power to the machine.
9. If the replacement DOM carries a firmware revision, re-enter all of the setup
information.
11.8. FAQ’S
The following is a list from the Teledyne API’s Technical Support Department of
the most commonly asked questions relating to the Model T802 O2 Analyzer.
QUESTION
ANSWER
During certain types of adjustments or configuration operations, the
ENTR button will disappear if you select a setting that is nonsensical
Why does the ENTR button
sometimes disappear on the
Front Panel Display?
(such as trying to set the 24-hour clock to 25:00:00) or out of the
allowable range for that parameter (such as selecting a DAS HOLD
OFF period of more than 20 minutes). Once you adjust the setting in
question to an allowable value, the ENTR button will re-appear.
The instrument disables these buttons when the expected span or
zero value entered by the users is too different from the gas
concentration actual measured value. This is to prevent the
accidental recalibration of the analyzer to an out-of-range response
curve. EXAMPLE: The span set point is 16% but gas concentration
being measured is only 5%.
Why is the ZERO or SPAN
button not displayed during
calibration?
Press the CONC button found under the CAL button of the main
SAMPLE display menus to enter the expected CO2 span
How do I enter or change the
value of my Span Gas?
Why does the analyzer not
respond to span gas
This most commonly occurs for one of the following reasons: - A
difference in circuit ground between the analyzer and the data logger
- A wiring problem or a scale problem with the input to the data
logger. The analog outputs can be manually adjusted to compensate
outputs are not calibrated, which can happen after a firmware
upgrade. - Both the electronic scale and offset of the analog outputs
itself as the metering device during calibrations procedures.
What shall I do if the
concentration on the
instrument's front panel display
does not match the value
recorded or displayed on my
data logger even if both
instruments are properly
calibrated?
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QUESTION
ANSWER
Sample flow is measured by attaching a calibrated rotameter, wet
test meter, or other flow-measuring device to the sample inlet port
when the instrument is operating. The sample flow should be 120
How do I measure the sample
flow?
The default averaging time, optimized for ambient pollution
monitoring, is 60 seconds for stable concentrations and 10 seconds
What is the averaging time for
this instrument?
11.9. TECHNICAL ASSISTANCE
If this manual and its troubleshooting / service sections do not solve your
problems, technical assistance may be obtained from:
Teledyne API, Technical Support,
9480 Carroll Park Drive
San Diego, California 92121-5201USA
Phone: 800-324-5190 (toll free in North America)
Phone: 858-657-9800 (direct)
Fax: 858-657-9816
Email: [email protected]
Website: http://www.teledyne-api.com/
Before you contact Teledyne API’s Technical Support, fill out the problem report
form in Appendix C, which is also available online for electronic submission at
http://www.teledyne-api.com/forms/
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12. PRINCIPLES OF OPERATION
The T802 parametric oxygen analyzer is a microprocessor-controlled analyzer
that determines the percent concentration of molecular oxygen (O2) in a sample
gas drawn through the instrument. It uses a paramagnetic sensor that relies on the
relatively high reactivity of O2 molecules to magnetic fields to generate a current
that is proportional to the amount of O2 present in the sensor chamber.
Calibration of the instrument is performed in software and does not require
physical adjustments to the instrument. During calibration the microprocessor
measures the current state of the O2 Sensor output and various other physical
parameters of the instrument and stores them in memory. The microprocessor
uses these calibration values, measurements made on the sample gas along with
data regarding the current temperature and pressure of the gas to calculate a final
O2 concentration.
The optional CO2 sensor allows the T802 to measure both O2 and CO2
simultaneously. This option includes a CO2 sensor probe, a Logic PCA that
conditions the probe output and issues a 0-5 VDC signal to the analyzer’s CPU
that is used to compute the CO2 concentration. The T802 receives this input,
scales it based on the values of the CO2_SLOPE and CO2_OFFSET Recorded
during calibration (see Section 9.5).
12.1. PARAMAGNETIC OXYGEN MEASUREMENT
12.1.1. MAGNETIC PROPERTIES OF O2 GAS
Molecular oxygen, O2, displays a particularly strong susceptibility to the effect of
magnetic fields. This is due to the behavior of the electrons of the two oxygen
atoms that make up the O2 molecule.
When the electrons in an orbital are paired, they spin in opposite directions from
each other thereby canceling any magnetic field effects. On the other hand,
unpaired electrons, such as those of an O2 molecule, spin in the same direction as
each other, increasing the aggregate magnetic field.
12.1.2. PRINCIPLE OF MEASUREMENT
The type of paramagnetic sensor used in the T802 analyzer is called a magneto-
mechanical sensor. This type of sensor consists of a small dumbbell-shaped body
(a sphere on either end) made of glass and filled with a gas of negative
paramagnetic characteristic (in this case, N2). The dumbbell body is suspended
on a platinum fiber within the magnetic field of a permanent magnet, in such a
way that it is free to rotate. Because the N2 inside the spheres has a small
opposite magnetic charge from the field of the permanent magnet, the
dumbbell’s resting (neutral) position is slightly deflected away from the
strong point of the field.
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Figure 12-1:
Paramagnetic O2 Sensor Design
When sample gas containing oxygen flows into the magneto-mechanical sensor,
the O2 molecules are drawn toward the strong point of the magnetic field. This
causes the N2 filled spheres to deflect even more so that the suspended dumbbell
body pivots on the platinum wire. The more O2 present the further the dumbbell
body is deflected from its neutral position.
The position of the dumbbell is detected by a pair of photocells that receive a
light beam reflected from a mirror attached to the center of the dumbbell body.
As the dumbbell body pivots, the angle of the reflected light beam on the
photocells changes. The resulting potential difference creates a current.
Light
Source
Photocells
Figure 12-2:
Paramagnetic O2 Sensor Block Diagram
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This current is passed to a feedback loop, which generates a second current to a
wire winding (in effect, a small DC electric motor) mounted on the suspended
mirror. The more O2 present, the more the dumbbell and its attached mirror
moves and the more current is needed to move the dumbbell back to it’s zero
position. Finally, sensor measures the amount of current generated by the
feedback control loop which is directly proportional to the concentration of
oxygen within the sample gas mixture.
12.2. NDIR MEASUREMENT OF CO2
The optional CO2 sensor is a silicon based Non-Dispersive Infrared (NDIR)
sensor. It uses a single-beam, dual wavelength measurement method.
An infrared source at one end of the measurement chamber emits IR radiation
into the sensor’s measurement chamber where light at the 4.3 μm wavelength is
partially absorbed by any CO2 present. A special light filter called a Fabry-Perot
Interferometer (FPI) is electronically tuned so that only light at the absorption
wavelength of CO2 is allowed to pass and be detected by the sensor’s IR detector.
A reference measurement is made by electronically shifting the filter band pass
wavelength so that no IR at the CO2 absorption wavelength is let through.
Figure 12-3:
CO2 Sensor Theory of Operation
The sensor computes the ratio between the reference signal and the measurement
signal to determine the degree of light absorbed by CO2 present in the sensor
chamber. This dual wavelength method of measuring CO2 allows the instrument
to compensate for ancillary effects like sensor aging and contamination.
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12.2.1. OPERATION WITHIN THE T802 ANALYZER
Operationally, the CO2 sensor option is transparently integrated into the core
analyzer operation. All functions can be viewed or accessed through the front
panel, just like the functions for O2.
The CO2 concentration is displayed in the upper right-hand corner, alternating
with O2 concentration.
Test functions for CO2 slope and offset are viewable from the front panel along
with the analyzer’s other test functions.
CO2 sensor calibration is performed via the front panel CAL function and is
performed in a nearly identical manner as the standard O2 calibration. See
Stability of the CO2 sensor can be viewed via the front panel (see Section
calibrating the CO2.
12.3. PNEUMATIC OPERATION
CAUTION
GENERAL SAFETY HAZARD
IT IS IMPORTANT THAT THE SAMPLE AIRFLOW SYSTEM IS BOTH LEAK-TIGHT AND NOT
PRESSURIZED OVER AMBIENT PRESSURE.
Regular leak checks should be performed on the analyzer as described in the maintenance
schedule, 10.1.
Procedures for correctly performing leak checks can be found in Section 10.3.3
In pneumatic operation an internal pump evacuates the sample chamber creating a
small vacuum that draws sample gas into the analyzer. Normally the analyzer is
operated with its inlet near ambient pressure either because the sample is directly
drawn at the inlet or a small vent is installed at the inlet. There are several
advantages to this “pull through” configuration.
First the pumping process heats and compresses the sample air complicating
the measurement process. Both heat and pressure affect the accuracy of
paramagnetic O2 measurements.
Additionally, certain physical parts of the pump itself are made of materials that
might chemically react with the sample gas.
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Figure 12-4:
T802 – Internal Pneumatic Flow – Basic Configuration
12.3.1. PNEUMATIC OPERATION OF THE CO2 SENSOR
Pneumatically, the CO2 sensor is placed in line with the sample gas line between
the particulate filter and the analyzer’s sample chamber. It does not alter the gas
flow rate of the sample through the analyzer
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Figure 12-5:
T802 – Internal Pneumatic Flow with CO2 Sensor Option
12.4. FLOW RATE CONTROL
To maintain a constant flow rate of the sample gas through the instrument, the
T802 uses a special flow control assembly located in the exhaust gas line just
before the optional internal pump or connected to the rear panel if using an
external pump. These assemblies consist of:
A critical flow orifice.
Two o-rings: Located just before and after the critical flow orifice, the o-rings
seal the gap between the walls of assembly housing and the critical flow
orifice.
A spring: Applies mechanical force needed to form the seal between the o-
rings, the critical flow orifice and the assembly housing.
A sintered filter: Removes particulates to prevent clogging the orifice
12.4.1. CRITICAL FLOW ORIFICE
The most important component of this flow control assembly is the critical flow
orifice.
Critical flow orifices are a remarkably simple way to regulate stable gas flow
rates. They operate without moving parts by taking advantage of the laws of fluid
dynamics. By restricting the flow of gas though the orifice, a pressure differential
is created. This pressure differential combined with the action of the analyzer’s
pump draws the gas through the orifice.
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As the pressure on the downstream side of the orifice (the pump side) continues
to drop, the speed that the gas flows though the orifice continues to rise. Once
the ratio of upstream pressure to downstream pressure is greater than 2:1, the
velocity of the gas through the orifice reaches the speed of sound. As long as that
ratio stays at least 2:1 the gas flow rate is unaffected by any fluctuations, surges,
or changes in downstream pressure because such variations only travel at the
speed of sound themselves and are therefore cancelled out by the sonic
shockwave at the downstream exit of the critical flow orifice.
CRITICAL
FLOW
ORIFICE
AREA OF
LOW
AREA OF
HIGH
PRESSURE
PRESSURE
Sonic
Shockwave
O-RINGS
SPRING
FILTER
Figure 12-6:
Flow Control Assembly & Critical Flow Orifice
The actual flow rate of gas through the orifice (volume of gas per unit of time),
depends on the size and shape of the aperture in the orifice. The larger the hole,
the more gas molecules, moving at the speed of sound, pass through the orifice.
Because the flow rate of gas through the orifice is only related to the minimum
2:1 pressure differential and not absolute pressure the flow rate of the gas is also
unaffected by degradations in pump efficiency due to age.
The critical flow orifice used in the T802 is designed to provide a flow rate of
120 cm3/min.
12.4.2. PARTICULATE FILTER
The T802 Analyzer comes equipped with a 47 mm diameter, Teflon, particulate
filter with a 1 micron pore size. The filter is accessible through the front panel,
which folds down to allow access, and should be changed according to the
suggested maintenance schedule described in
12.4.3. PNEUMATIC SENSORS
12.4.3.1. SAMPLE PRESSURE SENSOR
An absolute value pressure transducer plumbed to the outlet of the sample
chamber is used to measure sample pressure. The output of the sensor is used to
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compensate the concentration measurement for changes in ambient air pressure.
This sensor is mounted to a printed circuit board with the sample flow sensor on
the sample chamber; see the following section and Figure 3-5.
12.4.3.2. SAMPLE FLOW SENSOR
A thermal-mass flow sensor is used to measure the sample flow through the
analyzer. The sensor is calibrated at the factory with ambient air or N2, but can
be calibrated to operate with samples consisting of other gases such as O2. This
sensor is mounted to a printed circuit board with the Sample Pressure sensor on
the sample chamber; see the previous section and Figure 3-5.
12.5. ELECTRONIC OPERATION
12.5.1. OVERVIEW
Figure 10-9 shows a block diagram of the major electronic components of the
T802.
At its heart the analyzer is a microcomputer (CPU) that controls various internal
processes, interprets data, makes calculations, and reports results using
specialized firmware developed by Teledyne API. It communicates with the user
as well as receives data from and issues commands to a variety of peripheral
devices via a separate printed circuit assembly called the Motherboard.
The motherboard collects data, performs signal conditioning duties and routes
incoming and outgoing signals between the CPU and the analyzer’s other major
components.
Data is generated by a gas-filter-correlation optical bench which outputs an
analog signal corresponding to the concentration of O2 in the sample gas. This
analog signal is converted into digital data by a unipolar, analog-to-digital
converter, located on the motherboard.
A variety of sensors report the physical and operational status of the analyzer’s
major components, again through the signal processing capabilities of the
motherboard. These status reports are used as data for the O2 concentration
calculation and as trigger events for certain control commands issued by the CPU.
They are stored in memory by the CPU and in most cases can be viewed but the
user via the front panel display.
The CPU communicates with the user and the outside world in a variety of
manners:
Through the analyzer’s keyboard and vacuum florescent display over a
clocked, digital, serial I/O bus (using a protocol called I2C);
RS-232 & RS-485 Serial I/O channels;
Via an optional Ethernet communications card:
Various DCV and DCA analog outputs, and
Several sets of Digital I/O channels.
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Finally, the CPU issues commands via a series of relays and switches (also over
the I2C bus) located on a separate printed circuit assembly to control the function
of key electromechanical devices such as heaters..
RS232
Male
COM2
Female
USB COM
port
ANALOG
IN
Ethernet
(I2C Bus)
Status
Outputs Outputs
1 - 8 1 – 6
Control
Analog Outputs
Aout 4
TEST CHANNEL OUTPUT
CO2 (optional)
Aout 3
Optional
Current
Loop
O2 Range 2
Aout 2
Touchscreen
Outputs
O2 Range 1
Aout 1
Display
Flow/Pressure Sensor PCA
Sample Pressure
Sensor
Analog Outputs
(D/A)
External Digital I/O
LVDS
transmitter board
Sample Flow
Sensor
Power Up
Circuit
PC 104
CPU Card
Disk on
Module
A/D
Converter
PC 104 Bus
Flash
Chip
Box
O2
Temperature
Concentration
CPU
Status
LED
MOTHERBOARD
O2 Sensor
Internal
Digital I/O
I2C Bus
Thermistor Interface
O2 Sensor
Temperature
RELAY PCA
CO2 Sensor
Temperature
(Optionl)
Optional CO2
Sensor
BOX
Temperature
I2C
Status
LED
O2 Cell
Heater
Optional CO2
Sensor Heater
Figure 12-7:
T802 Electronic Block Diagram
12.5.2. ELECTRONIC OPERATION OF THE CO2 SENSOR
The CO2 PCA is powered by 12 VDC from the analyzer via the relay card, which
outputs a 0-5 VDC analog signal to the analyzer’s CPU via the motherboard that
corresponds to the concentration of CO2 measured by the probe.
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Figure 12-8:
CO2 Sensor Option PCA Layout and Electronic Connections
12.5.3. CENTRAL PROCESSING UNIT (CPU)
The unit’s CPU card is installed on the motherboard located inside the rear panel.
It is a low power (5 VDC, 720mA max), high performance, Vortex 86SX-based
microcomputer running Windows CE. Its operation and assembly conform to the
PC/104 specification.
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Figure 12-9.
CPU Card
The CPU includes two types of non-volatile data storage: an embedded 2MB
flash chip and a Disk on Module (DOM).
12.5.3.1. DISK-ON-MODULE (DOM)
The DOM is a 44-pin IDE flash disk with a storage capacity up to 128MB. It is
used to store the computer’s operating system, the Teledyne API firmware, and
most of the operational data generated by the analyzer’s internal data acquisition
reading/writing to or from the DOM.
12.5.4. RELAY BOARD
The CPU issues commands via a series of relays and switches located on a
separate printed circuit assembly, called the relay PCA, to control the function of
key electromechanical devices such as heaters. . The relay PCA receives
instructions in the form of digital signals over the I2C bus, interprets these digital
instructions and activates its various switches and relays appropriately.
The relay PCA is located in the right-rear quadrant of the analyzer and is
mounted vertically on the backside of the same bracket as the instrument’s DC
power supplies.
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Status LED’s
(D2 through D16)
Thermocouple
Signal Output
Watchdog
Status LED (D1)
DC Power Supply
Test Points
(JP5)
Thermocouple
Configuration
Jumpers
I2C Connector
Power
Connection
for DC
Heater AC Power
Configuration
Jumpers
(JP7)
Pump AC
Configuration
Jumper
Heaters
Valve Control
Drivers
JP2
Pump Power
Output
Valve Control
Connector
AC Power
IN
(J2)
Connector for
AC Relays
K4 & K5
DC Power
Distribution
Connectors
(J18)
Connector for AC Relays K4 & K5
Figure 12-10: Relay PCA Layout (PN 04135)
CAUTION
ELECTRICAL SHOCK HAZARD
Only those relays actually required by the configuration of the T802 are populated.
A protective retainer plate is installed over the AC power relays to keep them securely
seated in their sockets and prevent accidental contact with those sockets that are not
Never remove this retainer while the instrument is plugged in and turned on. The contacts of
the AC relay sockets beneath the shield carry high AC voltages even when no relays are
present.
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Retainer
Mounting
Screws
AC Relay Retainer
Plate
Figure 12-11: Relay PCA with AC Relay Retainer in Place
12.5.4.1. STATUS LEDS
LEDs located on the Analyzer’s relay PCA, show the current status of various
control functions performed by the relay PCA The three that are used in the T802
Table 12-1: Relay PCA Status LEDs
Status When LED Lit
Status When LED Unlit
LED
Color
Function
(Energized State)
(Default State)
Cycles ON/OFF every 3 Seconds
under direct control of the analyzer’s CPU.
D1
Red
Watchdog Circuit
D2-D4
D51
SPARE
Heating
Heating
Yellow
Yellow
Green
Green
Green
Green
CO2 Sensor Cell heater
O2 Sensor heater
Not Heating
Not Heating
D6
D72
D82
D92
D102
D11 - 16
SPARE
1 Only active when the optional CO2 sensor is installed
2
Not Used.
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D6 (Yellow) O2 Sensor Heater
D5 (Yellow) –CO2 Sensor Heater (only with CO2 option)
D1 (RED)
Watchdog Indicator
Figure 12-12: Status LED Locations – Relay PCA
12.5.4.2. WATCHDOG CIRCUITRY
The most important of the status LEDs on the relay board is the red I2C Bus
watch-dog LED. It is controlled directly by the analyzer’s CPU over the I2C Bus.
Special circuitry on the relay PCA watches the status of D1. Should this LED
ever stay ON or OFF for 30 seconds, indicating that the CPU or I2C bus has
stopped functioning, this Watchdog Circuit automatically shuts off all heaters.
12.5.5. HEATER CONTROL
12.5.5.1. TEMPERATURE CONTROL
At low magnetic field strengths levels, paramagnetic molecules follow Curie's
law to good approximation, which indicates that the susceptibility of
paramagnetic materials is inversely proportional to their temperature.
To minimize the effects of temperature variations on the O2 concentration
measurement the parametric sensor is raised to a high temperature level, 50C. A
cartridge heater implanted into the sensor is the heat source. The temperature of
the sensor is measured by a thermistor also inserted into the sensor body.
12.5.6. MOTHERBOARD
This printed circuit assembly provides a multitude of functions including, A/D
conversion, digital input/output, PC-104 to I2C translation, temperature sensor
signal processing, and serves as a pass-through for the RS-232 and RS-485
signals.
12.5.6.1. A TO D CONVERSION
Analog signals, such as the voltages received from the analyzer’s various sensors,
are converted into digital signals that the CPU can understand and manipulate by
the analog to digital converter (A/D). Under the control of the CPU, this
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functional block selects a particular signal input (e.g. BOX TEMP) and then
converts the selected voltage into a digital word.
The A/D consists of a voltage-to-frequency (V-F) converter, a programmable
logic device (PLD), three multiplexers, several amplifiers and some other
associated devices. The V-F converter produces a frequency proportional to its
input voltage. The PLD counts the output of the V-F during a specified time
period, and sends the result of that count, in the form of a binary number, to the
CPU.
The A/D can be configured for several different input modes and ranges but in
the T802 the A/D is used in uni-polar mode with a +5 V full scale. The converter
includes a 1% over and under-range. This allows signals from –0.05 V to +5.05
V to be fully converted.
For calibration purposes, two reference voltages are supplied to the A/D
converter: Reference Ground and +4.096 VDC. During calibration, the device
measures these two voltages, outputs their digital equivalent to the CPU. The
CPU uses these values to compute the converter’s offset and slope and uses these
factors for subsequent conversions.
12.5.6.2. SENSOR INPUTS
The key analog sensor signals are coupled to the A/D through the master
multiplexer from two connectors on the motherboard. 100K terminating resistors
on each of the inputs prevent cross talk from appearing on the sensor signals.
12.5.6.3. SAMPLE PRESSURE AND FLOW
These are analog signals from two sensors that measure the pressure and flow rate
of the gas stream at the outlet of the sample chamber. This information is used in
two ways. First, the sample pressure is used by the CPU to calculate O2
Concentration. Second, the pressure and flow rate are monitored as a test
function to assist the user in predicting and troubleshooting failures.
12.5.6.4. THERMISTOR INTERFACE
This circuit provides excitation, termination and signal selection for several
negative-coefficient, thermistor temperature sensors located inside the analyzer;
there is a thermistor for the O2 sample chamber housing, which reports the
current temperature of the chamber housing to the CPU as part of the bench
heater control loop. Another thermistor, attached to the motherboard, measures
the analyzer’s inside temperature (box temperature). This information is stored
by the CPU and can be viewed by the user for troubleshooting purposes via the
12.5.6.5. ANALOG OUTPUTS
The analyzer comes equipped with four analog outputs: A1, A2, A3 and A4.
The type of data and electronic performance of these outputs are configurable by
A/D converter through a Loop-back circuit. This permits the voltage outputs to
be calibrated by the CPU without need for any additional tools or fixtures.
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12.5.6.6. EXTERNAL DIGITAL I/O
This External Digital I/O performs status outputs and control inputs.
STATUS OUTPUTS
CONTROL INPUTS
Logic-Level voltages are output through an optically isolated 8-pin connector
located on the rear panel of the analyzer. These outputs convey good/bad and
on/off information about certain analyzer conditions. They can be used to
interface with certain types of programmable devices (See Section 3.3.1.5).
By applying +5VDC power supplied from an external source such as a PLC or
contact closures on the rear panel.
12.5.6.7. I2C DATA BUS
I2C is a two-wire, clocked, digital serial I/O bus that is used widely in commercial
and consumer electronic systems. A transceiver on the motherboard converts
data and control signals from the PC-104 bus to I2C. The data is then fed to the
keyboard/display interface and finally onto the relay board.
12.5.6.8. POWER UP CIRCUIT
This circuit monitors the +5V power supply during start-up and sets the Analog
outputs, external digital I/O ports, and I2C circuitry to specific values until the
CPU boots and the instrument software can establish control.
12.5.6.9. POWER SUPPLY / CIRCUIT BREAKER
The analyzer operates on 100 VAC, 115 VAC or 230 VAC power at either 50Hz
or 60Hz. Individual units are set up at the factory to accept any combination of
through a standard IEC 320 power receptacle located on the rear panel of the
instrument. From there it is routed through the On/Off switch located in the
lower right corner of the Front Panel. A 6.75 Amp circuit breaker is built into the
ON/OFF Switch.
AC power is distributed directly to the sample gas pump.
AC Line power is stepped down and converted to DC power by two DC power
supplies. One supplies +12 VDC, while a second supply provides +5 VDC and
±15 VDC for logic and analog circuitry. All DC voltages are distributed via the
relay board.
CAUTION
GENERAL SAFETY HAZARD
Should the AC power circuit breaker trip, investigate and correct the condition causing
this situation before turning the analyzer back on.
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SENSOR SUITES
AC POWER
DC POWER
LOGIC DEVICES
ANALOG
(e.g. CPU, I2C bus,
Touchscreen,
SENSORS
(e.g. Temp Sensor,
Pressure Sensor,
Flow Sensor)
MotherBoard, etc.)
Pre-Amplifiers
& Amplifiers
O2 Sensor
PS 1
+5 VDC
±15 VDC
PUMP
ON / OFF
SWITCH
AC HEATERS
COOLING
FAN(S)
PS 2
(+12 VDC)
Solenoid
Drivers
RELAY PCA
AC
POWER IN
CO2 SENSOR PCA
(when optional CO2
sensor installed)
OPTIONAL
CO2 SENSOR
Figure 12-13: Power Distribution Block Diagram
12.5.7. FRONT PANEL TOUCH SCREEN/DISPLAY INTERFACE
Users can input data and receive information directly through the front panel
touchscreen display. The LCD display is controlled directly by the CPU board.
The touchscreen is interfaced to the CPU by means of a touchscreen controller
that connects to the CPU via the internal USB bus and emulates a computer
mouse.
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Figure 12-14: Front Panel and Display Interface Block Diagram
12.5.7.1. LVDS TRANSMITTER BOARD
The LVDS (low voltage differential signaling) transmitter board converts the
parallel display bus to a serialized, low voltage, differential signal bus in order to
transmit the video signal to the LCD interface PCA..
12.5.7.2. FRONT PANEL TOUCH SCREEN/DISPLAY INTERFACE PCA
The front panel touchscreen/display interface PCA controls the various functions
of the display and touchscreen. For driving the display it provides connection
between the CPU video controller and the LCD display module. This PCA also
contains:
power supply circuitry for the LCD display module
a USB hub that is used for communications with the touchscreen controller
and the two front panel USB device ports
the circuitry for powering the display backlight
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12.5.8. SOFTWARE OPERATION
The T802 Analyzer is at its heart a high performance, VortexX86-based
microcomputer running Windows CE. Inside Windows CE special software
developed by Teledyne API interprets user commands via the various interfaces,
performs procedures and tasks, stores data in the CPU’s various memory devices
and calculates the concentration of the sample gas.
Windows CE
API FIRMWARE
Memory Handling
Analyzer Operations
Calibration Procedures
Configuration Procedures
Autonomic Systems
DAS Records
Calibration Data
System Status Data
PC/104 BUS
Diagnostic Routines
ANALYZER
HARDWARE
Interface Handling
Sensor Input Data
Display Messages
Touchscreen
Measurement
Algorithm
Analog Output Data
RS232 & RS485
External Digital I/O
PC/104 BUS
Linearization Table
Figure 12-15: Basic Software Operation
12.5.9. ADAPTIVE FILTER
The T802 software processes the O2 concentration signal after it is digitized by
the motherboard, through an adaptive filter built into the software. Unlike other
analyzers that average the output signal over a fixed time period, the T802
averages over a set number of samples, where each sample is 1 second. This is
technique is known as boxcar averaging. During operation, the software
automatically switches between two different length filters based on the
conditions at hand. Once triggered, the short filter remains engaged for a fixed
time period to prevent chattering.
During conditions of constant or nearly constant concentration the software, by
default, computes an average of the last 60 samples or 1 minute. This provides
the calculation portion of the software with smooth stable readings. If a rapid
change in concentration is detected the filter switches to 10 samples or 10
seconds measurement moving average to allow the analyzer to respond more
quickly.
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Two conditions must be simultaneously met to switch to the short filter. First, the
instantaneous concentration must exceed the average in the long filter by a fixed
amount (default setting is <2%). Second, the instantaneous concentration must
exceed the average in the long filter by a portion, or percentage, of the average in
the long filter (also <2%by default).
If necessary, these boxcar lengths as well as the threshold levels can be altered
but with corresponding tradeoffs in rise time and signal-to-noise ratio (contact
Teledyne- API Technical Support for more information).
12.5.10. CALIBRATION - SLOPE AND OFFSET
Calibration of the analyzer is performed exclusively in software.
During instrument calibration the user enters expected values for zero and span
via the front panel keypad and commands the instrument to make readings of
calibrated sample gases for both levels. The readings taken are adjusted,
linearized, and compared to the expected values. With this information the
software computes values for instrument slope and offset and stores these values
in memory for use in calculating the O2 concentration of the sample gas.
The instrument slope and offset values recorded during the last calibration are
available for viewing from the from the front panel (See Section 3.4.2)
12.5.11. TEMPERATURE AND PRESSURE COMPENSATION
Changes in ambient pressure can have a noticeable effect on the O2 and optional
CO2 concentration calculations. To account for this, the T802 software includes a
feature which allows the instrument to compensate both the O2 and optional CO2
calculations based on changes in ambient pressure. Both sensors are housed
inside temperature controlled manifolds. This minimizes temperature effects on
the measured concentrations.
12.5.12. INTERNAL DATA ACQUISITION SYSTEM (DAS)
The DAS is designed to implement predictive diagnostics that stores trending
data for users to anticipate when an instrument will require service. Large
amounts of data can be stored in non-volatile memory and retrieved in plain text
format for further processing with common data analysis programs. The DAS
has a consistent user interface in all Teledyne API analyzers. New data
parameters and triggering events can be added to the instrument as needed.
Depending on the sampling frequency and the number of data parameters the
DAS can store several months of data, which are retained even when the
instrument is powered off or a new firmware is installed. The DAS permits users
to access the data through the instrument’s front panel or the remote interface.
The latter can automatically download stored data for further processing. For
information on using the DAS, refer to Section 7
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13. A PRIMER ON ELECTRO-STATIC DISCHARGE
Teledyne API considers the prevention of damage caused by the discharge of
static electricity to be extremely important part of making sure that your analyzer
continues to provide reliable service for a long time. This section describes how
static electricity occurs, why it is so dangerous to electronic components and
assemblies as well as how to prevent that damage from occurring.
13.1. HOW STATIC CHARGES ARE CREATED
Modern electronic devices such as the types used in the various electronic
assemblies of your analyzer, are very small, require very little power and operate
very quickly. Unfortunately, the same characteristics that allow them to do these
things also make them very susceptible to damage from the discharge of static
electricity. Controlling electrostatic discharge begins with understanding how
electro-static charges occur in the first place.
Static electricity is the result of something called triboelectric charging which
happens whenever the atoms of the surface layers of two materials rub against
each other. As the atoms of the two surfaces move together and separate, some
electrons from one surface are retained by the other.
Materials
Makes
Contact
Materials
Separate
+
+
+
+
PROTONS = 3
ELECTRONS = 2
PROTONS = 3
ELECTRONS = 4
PROTONS = 3
ELECTRONS = 3
PROTONS = 3
ELECTRONS = 3
NET CHARGE = -1
NET CHARGE = +1
NET CHARGE = 0
NET CHARGE = 0
Figure 13-1:
Triboelectric Charging
If one of the surfaces is a poor conductor or even a good conductor that is not
grounded, the resulting positive or negative charge cannot bleed off and becomes
trapped in place, or static. The most common example of triboelectric charging
happens when someone wearing leather or rubber soled shoes walks across a
nylon carpet or linoleum tiled floor. With each step, electrons change places and
the resulting electro-static charge builds up, quickly reaching significant levels.
Pushing an epoxy printed circuit board across a workbench, using a plastic
handled screwdriver or even the constant jostling of StyrofoamTM pellets during
shipment can also build hefty static charges
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Table 13-1:
Static Generation Voltages for Typical Activities
MEANS OF GENERATION
65-90% RH
1,500V
250V
10-25% RH
35,000V
12,000V
6,000V
Walking across nylon carpet
Walking across vinyl tile
Worker at bench
100V
Poly bag picked up from bench
1,200V
20,000V
Moving around in a chair padded
with urethane foam
1,500V
18,000V
13.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE
Damage to components occurs when these static charges come into contact with
an electronic device. Current flows as the charge moves along the conductive
circuitry of the device and the typically very high voltage levels of the charge
overheat the delicate traces of the integrated circuits, melting them or even
vaporizing parts of them. When examined by microscope the damage caused by
electro-static discharge looks a lot like tiny bomb craters littered across the
landscape of the component’s circuitry.
News estimates that approximately 60% of device failures are the result of
damage due to electro-static discharge.
Table 13-2:
Sensitivity of Electronic Devices to Damage by ESD
DAMAGE SUSCEPTIBILITY VOLTAGE
RANGE
DEVICE
DAMAGE BEGINS
OCCURRING AT
CATASTROPHIC
DAMAGE AT
MOSFET
10
30
100
1800
100
VMOS
NMOS
60
GaAsFET
EPROM
60
2000
100
100
JFET
140
7000
SAW
Op-AMP
CMOS
150
190
200
300
300
300
500
500
500
500
2500
3000
2500
3000
7000
500
Schottky Diodes
Film Resistors
This Film Resistors
ECL
SCR
1000
2500
Schottky TTL
Potentially damaging electro-static discharges can occur:
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Any time a charged surface (including the human body) discharges to a
device. Even simple contact of a finger to the leads of a sensitive device or
assembly can allow enough discharge to cause damage. A similar discharge
can occur from a charged conductive object, such as a metallic tool or fixture.
When static charges accumulated on a sensitive device discharges from the
device to another surface such as packaging materials, work surfaces,
machine surfaces or other device. In some cases, charged device
discharges can be the most destructive.
A typical example of this is the simple act of installing an electronic assembly
into the connector or wiring harness of the equipment in which it is to
function. If the assembly is carrying a static charge, as it is connected to
ground a discharge will occur.
Whenever a sensitive device is moved into the field of an existing electro-
static field, a charge may be induced on the device in effect discharging the
field onto the device. If the device is then momentarily grounded while within
the electrostatic field or removed from the region of the electrostatic field and
grounded somewhere else, a second discharge will occur as the charge is
transferred from the device to ground.
13.3. COMMON MYTHS ABOUT ESD DAMAGE
I didn’t feel a shock so there was no electro-static discharge: The human
nervous system isn’t able to feel a static discharge of less than 3500 volts.
Most devices are damaged by discharge levels much lower than that.
I didn’t touch it so there was no electro-static discharge: Electro Static
charges are fields whose lines of force can extend several inches or
sometimes even feet away from the surface bearing the charge.
It still works so there was no damage: Sometimes the damaged caused by
electro-static discharge can completely sever a circuit trace causing the
device to fail immediately. More likely, the trace will be only partially
occluded by the damage causing degraded performance of the device or
worse, weakening the trace. This weakened circuit may seem to function fine
for a short time, but even the very low voltage and current levels of the
device’s normal operating levels will eat away at the defect over time causing
the device to fail well before its designed lifetime is reached.
These latent failures are often the most costly since the failure of the
equipment in which the damaged device is installed causes down time,
lost data, lost productivity, as well as possible failure and damage to
other pieces of equipment or property.
Static Charges can’t build up on a conductive surface: There are two
errors in this statement.
Conductive devices can build static charges if they are not grounded.
The charge will be equalized across the entire device, but without access
to earth ground, they are still trapped and can still build to high enough
levels to cause damage when they are discharged.
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A charge can be induced onto the conductive surface and/or discharge
triggered in the presence of a charged field such as a large static charge
clinging to the surface of a nylon jacket of someone walking up to a
workbench.
As long as my analyzer is properly installed, it is safe from damage
caused by static discharges: It is true that when properly installed the
chassis ground of your analyzer is tied to earth ground and its electronic
components are prevented from building static electric charges themselves.
This does not prevent discharges from static fields built up on other things,
like you and your clothing, from discharging through the instrument and
damaging it.
13.4. BASIC PRINCIPLES OF STATIC CONTROL
It is impossible to stop the creation of instantaneous static electric charges. It is
not, however difficult to prevent those charges from building to dangerous levels
or prevent damage due to electro-static discharge from occurring.
13.4.1. GENERAL RULES
Only handle or work on all electronic assemblies at a properly set up ESD station.
Setting up an ESD safe workstation need not be complicated. A protective mat
properly tied to ground and a wrist strap are all that is needed to create a basic
anti-ESD workstation.
Protective Mat
Wrist Stra
Ground Point
Figure 13-2:
Basic Anti-ESD Workbench
For technicians that work in the field, special lightweight and portable anti-ESD
kits are available from most suppliers of ESD protection gear. These include
everything needed to create a temporary anti-ESD work area anywhere.
Always wear an Anti-ESD wrist strap when working on the electronic
assemblies of your analyzer. An anti-ESD wrist strap keeps the person
wearing it at or near the same potential as other grounded objects in the work
area and allows static charges to dissipate before they can build to
dangerous levels. Anti-ESD wrist straps terminated with alligator clips are
available for use in work areas where there is no available grounded plug.
Also, anti-ESD wrist straps include a current limiting resistor (usually around
one meg-ohm) that protects you should you accidentally short yourself to the
instrument’s power supply.
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Simply touching a grounded piece of metal is insufficient. While this
may temporarily bleed off static charges present at the time, once you stop
touching the grounded metal new static charges will immediately begin to re-
build. In some conditions, a charge large enough to damage a component
can rebuild in just a few seconds.
Always store sensitive components and assemblies in anti-ESD storage
bags or bins: Even when you are not working on them, store all devices
and assemblies in a closed anti-Static bag or bin. This will prevent induced
charges from building up on the device or assembly and nearby static fields
from discharging through it.
Use metallic anti-ESD bags for storing and shipping ESD sensitive
components and assemblies rather than pink-poly bags. The famous,
pink-poly bags are made of a plastic that is impregnated with a liquid
(similar to liquid laundry detergent) which very slowly sweats onto the
surface of the plastic creating a slightly conductive layer over the
surface of the bag.
While this layer may equalize any charges that occur across the
whole bag, it does not prevent the build up of static charges. If
laying on a conductive, grounded surface, these bags will allow
charges to bleed away but the very charges that build up on the
surface of the bag itself can be transferred through the bag by
induction onto the circuits of your ESD sensitive device. Also, the
liquid impregnating the plastic is eventually used up after which the
bag is as useless for preventing damage from ESD as any ordinary
plastic bag.
Anti-Static bags made of plastic impregnated with metal (usually
silvery in color) provide all of the charge equalizing abilities of the
pink-poly bags but also, when properly sealed, create a Faraday
cage that completely isolates the contents from discharges and the
inductive transfer of static charges.
Storage bins made of plastic impregnated with carbon (usually
black in color) are also excellent at dissipating static charges and
isolating their contents from field effects and discharges.
Never use ordinary plastic adhesive tape near an ESD sensitive device
or to close an anti-ESD bag. The act of pulling a piece of standard
plastic adhesive tape, such as Scotch® tape, from its roll will generate
a static charge of several thousand or even tens of thousands of volts
on the tape itself and an associated field effect that can discharge through
or be induced upon items up to a foot away.
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13.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND
MAINTENANCE
13.4.2.1. WORKING AT THE INSTRUMENT RACK
When working on the analyzer while it is in the instrument rack and plugged into
a properly grounded power supply
1. Attach you anti-ESD wrist strap to ground before doing anything else.
Use a wrist strap terminated with an alligator clip and attach it to a bare
metal portion of the instrument chassis.
This will safely connect you to the same ground level to which the
instrument and all of its components are connected.
2. Pause for a second or two to allow any static charges to bleed away.
3. Open the casing of the analyzer and begin work. Up to this point, the closed
metal casing of your analyzer has isolated the components and assemblies
inside from any conducted or induced static charges.
4. If you must remove a component from the instrument, do not lay it down on a
non-ESD preventative surface where static charges may lie in wait.
5. Only disconnect your wrist strap after you have finished work and closed the
case of the analyzer.
13.4.2.2. WORKING AT AN ANTI-ESD WORK BENCH
When working on an instrument of an electronic assembly while it is resting on a
anti-ESD workbench
1. Plug you anti-ESD wrist strap into the grounded receptacle of the work
station before touching any items on the work station and while standing at
least a foot or so away. This will allow any charges you are carrying to bleed
away through the ground connection of the workstation and prevent
discharges due to field effects and induction from occurring.
2. Pause for a second or two to allow any static charges to bleed away.
3. Only open any anti-ESD storage bins or bags containing sensitive devices or
assemblies after you have plugged your wrist strap into the workstation.
Lay the bag or bin on the workbench surface.
Before opening the container, wait several seconds for any static charges
on the outside surface of the container to be bled away by the
workstation’s grounded protective mat.
4. Do not pick up tools that may be carrying static charges while also touching
or holding an ESD sensitive Device.
Only lay tools or ESD-sensitive devices and assemblies on the conductive
surface of your workstation. Never lay them down on any non-ESD
preventative surface.
5. Place any static sensitive devices or assemblies in anti-static storage bags or
bins and close the bag or bin before unplugging your wrist strap.
6. Disconnecting your wrist strap is always the last action taken before leaving
the workbench.
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13.4.2.3. TRANSFERRING COMPONENTS FROM RACK TO BENCH AND BACK
When transferring a sensitive device from an installed Teledyne API analyzer to
an Anti-ESD workbench or back:
1. Follow the instructions listed above for working at the instrument rack and
workstation.
2. Never carry the component or assembly without placing it in an anti-ESD bag
or bin.
3. Before using the bag or container allow any surface charges on it to
dissipate:
If you are at the instrument rack, hold the bag in one hand while your wrist
strap is connected to a ground point.
If you are at an anti-ESD workbench, lay the container down on the
conductive work surface.
In either case wait several seconds.
4. Place the item in the container.
5. Seal the container. If using a bag, fold the end over and fastening it with anti-
ESD tape.
Folding the open end over isolates the component(s) inside from the
effects of static fields.
Leaving the bag open or simply stapling it shut without folding it closed
prevents the bag from forming a complete protective envelope around the
device.
6. Once you have arrived at your destination, allow any surface charges that
may have built up on the bag or bin during travel to dissipate:
Connect your wrist strap to ground.
If you are at the instrument rack, hold the bag in one hand while your wrist
strap is connected to a ground point.
If you are at a anti-ESD workbench, lay the container down on the
conductive work surface
In either case wait several seconds
7. Open the container.
13.4.2.4. OPENING SHIPMENTS FROM TELEDYNE API’S TECHNICAL SUPPORT
Packing materials such as bubble pack and Styrofoam pellets are extremely
efficient generators of static electric charges. To prevent damage from ESD,
Teledyne API ships all electronic components and assemblies in properly sealed
ant-ESD containers.
Static charges will build up on the outer surface of the anti-ESD container during
shipping as the packing materials vibrate and rub against each other. To prevent
these static charges from damaging the components or assemblies being shipped
make sure that you:
Always unpack shipments from Teledyne API Technical Support by:
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
1. Opening the outer shipping box away from the anti-ESD work area
2. Carry the still sealed ant-ESD bag, tube or bin to the anti-ESD work area
Support above when opening the anti-ESD container at the work station
4. Reserve the anti-ESD container or bag to use when packing electronic
components or assemblies to be returned to Teledyne API
13.4.2.5. PACKING COMPONENTS FOR RETURN TO TELEDYNE API TECHNICAL
SUPPORT
Always pack electronic components and assemblies to be sent to Teledyne API
Technical Support in anti-ESD bins, tubes or bags.
CAUTION – ESD HAZARD
DO NOT use pink-poly bags.
NEVER allow any standard plastic packaging materials to touch the electronic
component/assembly directly. This includes, but is not limited to, plastic bubble-
pack, Styrofoam peanuts, open cell foam, closed cell foam, and adhesive tape
DO NOT use standard adhesive tape as a sealer. Use ONLY anti-ESD tape
Never carry the component or assembly without placing it in an anti-ESD bag or
bin.
1. Before using the bag or container allow any surface charges on it to
dissipate:
If you are at the instrument rack, hold the bag in one hand while your wrist
strap is connected to a ground point.
If you are at an anti-ESD workbench, lay the container down on the
conductive work surface.
In either case wait several seconds.
2. Place the item in the container.
3. Seal the container. If using a bag, fold the end over and fastening it with anti-
ESD tape.
Folding the open end over isolates the component(s) inside from the
effects of static fields.
Leaving the bag open or simply stapling it shut without folding it closed
prevents the bag from forming a complete protective envelope around the
device.
Note
If you do not already have an adequate supply of anti-ESD bags or containers
available, Teledyne API’s Technical Support department will supply them
above for working at the instrument rack and workstation.
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
A Primer on Electro-Static Discharge
GLOSSARY
Note: Some terms in this glossary may not occur elsewhere in this manual.
Term
10BaseT
Description/Definition
an Ethernet standard that uses twisted (“T”) pairs of copper wires to transmit at
10 megabits per second (Mbps)
100BaseT
APICOM
ASSY
CAS
same as 10BaseT except ten times faster (100 Mbps)
name of a remote control program offered by Teledyne-API to its customers
Assembly
Code-Activated Switch
CE
Converter Efficiency, the percentage of light energy that is actually converted into
electricity
CEM
Continuous Emission Monitoring
Chemical formulas that may be included in this document:
CO2
C3H8
CH4
H2O
HC
carbon dioxide
propane
methane
water vapor
general abbreviation for hydrocarbon
HNO3
H2S
NO
nitric acid
hydrogen sulfide
nitric oxide
NO2
NOX
NOy
nitrogen dioxide
nitrogen oxides, here defined as the sum of NO and NO2
nitrogen oxides, often called odd nitrogen: the sum of NOX plus other compounds such as
HNO3 (definitions vary widely and may include nitrate (NO3), PAN, N2O and other
compounds as well)
NH3
O2
ammonia
molecular oxygen
O3
ozone
SO2
sulfur dioxide
cm3
metric abbreviation for cubic centimeter (replaces the obsolete abbreviation “cc”)
CPU
Central Processing Unit
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Term
Description/Definition
DAC
DAS
Digital-to-Analog Converter
Data Acquisition System
DCE
DHCP
Data Communication Equipment
Dynamic Host Configuration Protocol. A protocol used by LAN or Internet
servers to automatically set up the interface protocols between themselves and
any other addressable device connected to the network
DIAG
DOM
Diagnostics, the diagnostic settings of the analyzer.
Disk On Module, a 44-pin IDE flash drive with up to 128MB storage capacity for
instrument’s firmware, configuration settings and data
DOS
Disk Operating System
DRAM
DR-DOS
DTE
Dynamic Random Access Memory
Digital Research DOS
Data Terminal Equipment
EEPROM
Electrically Erasable Programmable Read-Only Memory also referred to as a
FLASH chip or drive
ESD
Electro-Static Discharge
Electrical Test
ETEST
Ethernet
a standardized (IEEE 802.3) computer networking technology for local area
networks (LANs), facilitating communication and sharing resources
FEP
Fluorinated Ethylene Propylene polymer, one of the polymers that Du Pont
markets as Teflon®
Flash
FPI
non-volatile, solid-state memory
Fabry-Perot Interferometer : a special light filter typically made of a transparent
plate with two reflecting surfaces or two parallel, highly reflective mirrors
I2C bus
IC
a clocked, bi-directional, serial bus for communication between individual
analyzer components
Integrated Circuit, a modern, semi-conductor circuit that can contain many basic
components such as resistors, transistors, capacitors etc in a miniaturized
package used in electronic assemblies
IP
Internet Protocol
IZS
LAN
LCD
Internal Zero Span
Local Area Network
Liquid Crystal Display
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
A Primer on Electro-Static Discharge
Term
Description/Definition
LED
LPM
Light Emitting Diode
Liters Per Minute
MOLAR MASS
the mass, expressed in grams, of 1 mole of a specific substance. Conversely,
one mole is the amount of the substance needed for the molar mass to be the
same number in grams as the atomic mass of that substance.
EXAMPLE: The atomic weight of Carbon is 12 therefore the molar mass of
Carbon is 12 grams. Conversely, one mole of carbon equals the amount of
carbon atoms that weighs 12 grams.
Atomic weights can be found on any Periodic Table of Elements.
NDIR
NIST-SRM
PC
Non-Dispersive Infrared
National Institute of Standards and Technology - Standard Reference Material
Personal Computer
PCA
Printed Circuit Assembly, the PCB with electronic components, ready to use
Personal Computer / Advanced Technology
PC/AT
PCB
Printed Circuit Board, the bare board without electronic component
PFA
Per-Fluoro-Alkoxy, an inert polymer; one of the polymers that Du Pont markets
as Teflon®
PLC
Programmable Logic Controller, a device that is used to control instruments
based on a logic level signal coming from the analyzer
PLD
PLL
PMT
Programmable Logic Device
Phase Lock Loop
Photo Multiplier Tube, a vacuum tube of electrodes that multiply electrons
collected and charged to create a detectable current signal
P/N (or PN)
PSD
Part Number
Prevention of Significant Deterioration
PTFE
Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases
that may react on other surfaces; one of the polymers that Du Pont markets as
Teflon®
PVC
Poly Vinyl Chloride, a polymer used for downstream tubing
Rdg
Reading
RS-232
specification and standard describing a serial communication method between
DTE (Data Terminal Equipment) and DCE (Data Circuit-terminating Equipment)
devices, using a maximum cable-length of 50 feet
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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual
Term
Description/Definition
RS-485
specification and standard describing a binary serial communication method
among multiple devices at a data rate faster than RS-232 with a much longer
distance between the host and the furthest device
SAROAD
SLAMS
SLPM
Storage and Retrieval of Aerometric Data
State and Local Air Monitoring Network Plan
Standard Liters Per Minute of a gas at standard temperature and pressure
Standard Temperature and Pressure
STP
TCP/IP
Transfer Control Protocol / Internet Protocol, the standard communications
protocol for Ethernet devices
TEC
TPC
USB
Thermal Electric Cooler
Temperature/Pressure Compensation
Universal Serial Bus: a standard connection method to establish communication
between peripheral devices and a host controller, such as a mouse and/or
keyboard and a personal computer or laptop
VARS
V-F
Variables, the variable settings of the instrument
Voltage-to-Frequency
Z/S
Zero / Span
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A – Version Specific Software Documentation
APPENDIX A-1: Software Menu Trees, Software Versions 1.0.3 (T-Series)/A.3 (E-Series).................................... 3
APPENDIX A-2: Setup Variables For Serial I/O, Software Versions 1.0.3 (T-Series)/A.3 (E-Series) ...................... 9
APPENDIX A-3: Warnings and Test Measurements, Software Versions 1.0.3 (T-Series)/A.3 (E-Series) ............. 17
APPENDIX A-4: Signal I/O Definitions, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)................................... 20
APPENDIX A-5: DAS Triggering Events, Parameters, Software Version s 1.0.3 (T-Series)/A.3 (E-Series).......... 24
APPENDIX A-6: Terminal Command Designators, Software Versions 1.0.3 (T-Series)/A.3 (E-Series) ................ 27
APPENDIX A-7: MODBUS® Register Map, Software Versions 1.0.3 (T-Series)/A.3 (E-Series) ............................ 29
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
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A-2
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A-1: Software Menu Trees, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
SAMPLE
CLR1
TEST1
CAL
MSG1
SETUP
CO22
Press to
cycle
<TST
TST>
O2
through the
active
warning
messages.
LOW4 HIGH4
RANGE=[Value] % 1
O2 RN1=[Value] % 1
O2 RN2=[Value] % 1
CO2 RNG=[Value]%2
Press to
clear an
active
warning
messages.
STABIL=[Value] %
ZERO SPAN
CONC
PRES=[Value]IN-HG-A
SAMP FL=[Value]CC/M
O2 SLOPE=[Value]
O2 OFFSET=[Value]MV
CO2 SLOPE=[Value]2
CO2 OFFSET=[Value]MV2
O2 CELL TEMP=[Value]ºC
CO2 CELL TEMP=[Value]ºC2
BOX TEMP=[Value]ºC
TEST=[Value]MV5
O2
CO22
PRIMARY SETUP
MENU
CFG
ACAL
DAS
RNGE
PASS
CLK
MORE
TIME=[HH:MM:SS]
1 Only appears when warning messages are active.
2 Only appears if analyzer is equipped with CO2 sensor option.
3 Only appears on units with alarm option enabled.
SECONDARY
SETUP MENU
4 Only appears if the Range Mode is set of DUAL or AUTO
5 Only appears if analog output A4 is actively reporting a TEST FUNCTION
COMM
VARS
DIAG
ALAR3
ACAL is a special configuration; consult factory.
Figure A-1: Basic Sample Display Menu
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
SAMPLE
SETUP
MORE
CFG
ACAL
DAS
RNGE
PASS
CLK
Go to iDAS
Menu Tree
<TST
TST>
ON
OFF
MODEL TYPE AND NUMBER
PART NUMBER
TIME
DATE
SERIAL NUMBER
SOFTWARE REVISION
LIBRARY REVISION
DIL1
iCHIP SOFTWARE REVISION
SET
MODE
Go to
HESSEN PROTOCOL
REVISION2
SECONDARY SETUP
O2 RANGE #14
O2 RANGE #24
CO2 RANGE3
Menu Tree
CPU TYPE & OS REVISION
SNGL DUAL AUTO
DATE FACTORY
CONFIGURATION SAVED
1 Only appears if Dilution option is active.
2 Only appears if Hessen protocol is active.
3 CO2 mode only appears if analyzer is equipped
with the related sensor option.
4 Only appears if the DUAL or AUTO range
modes are selected.
ACAL is a special configuration; consult factory.
Figure A-2: Primary Setup Menu (Except DAS)
A-4
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Appendix A
SAMPLE
SETUP
CFG
ACAL
DAS
RNGE
PASS
MORE
CLK
VIEW
EDIT
ENTER PASSWORD: 818
PREV NEXT
CONC
EDIT1
PREV NEXT
INS
DEL
PRNT
PNUMTC
CALDAT
DETAIL
FAST
CONC
PNUMTC
CALDAT
DETAIL
FAST
YES NO
VIEW
<SET SET> NEXT NX10
PV10 PREV NEXT NX10
PRM>
<PRM
Create/edit the name of the channel
NAME
EVENT
Selects the data point to be viewed
PARAMETERS
REPORT PERIOD
NUMBER OF RECORDS
RS-232 REPORT
CHANNEL ENABLE
CAL MODE
Cycles through
parameters assigned
to this DAS channel
PREV NEXT
Sets the time lapse between
each report
YES1 NO
Cycles through list
of available trigger
events2
ON
EDIT1
PRNT
PREV NEXT
INS
DEL
OFF
NO
YES1
Cycles through list of
currently active
parameters for this
channel
YES NO
Sets the maximum number of
records recorded by this channel
<SET SET> EDIT PRNT
1 Editing an existing DAS channel will erase any
data stored on the channel options.
PARAMETER
SAMPLE MODE
PRECISION
2 Changing the event for an existing DAS channel
DOES NOT erase the data stored on the
channel.
ACAL is a special configuration; consult factory.
PREV NEXT
INST
AVG
MIN
MAX
Cycles through list of available &
currently active parameters for this
channel
Figure A-4: Primary Setup Menu (DAS)
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Go to
COMM / Hessen
Menu Tree
6
6
6
Go to
Menu Tr
1
E-Series: only appears if optional Ethernet PCA is
installed. When Ethernet PCA is present COM2
submenu disappears.
2
3
Only appears if HESSEN PROTOCOL mode is ON
(See COM1 & COM2 – MODE submenu above).
instrument IP, gateway ip & subnet mask are only
editable when DHCP is OFF.
4 Although TCP PORT is editable regardless of the dhcp
state, do not change the setting for this property.
5
HOST NAme is only editable when DHCP is ON.
6
ACAL is a special configuration; consult factory.
T-Series only.
Figure A-5: Secondary Setup Menu (COMM & VARS)
A-6
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
SAMPLE
SETUP
ACAL
CFG
DAS RNGE PASS CLK
MORE
DIAG
COMM
VARS
HESN2
ID
INET1
COM1
COM2
ENTER PASSWORD: 818
ENTER PASSWORD: 818
ENTER PASSWORD: 818
<SET
SET>
EDIT
Go to COMM / VARS Menu
Go to COMM / VARS Menu
Go to DIAG Menu Tree
Tree
Tree
VARIATION
RESPONSE MODE
GAS LIST
STATUS FLAGS
TYPE1
TYPE2
BCC
TEXT
CMD
PREV
NEXT
INS
DEL
PRNT
EDIT
O2, 110, REPORTED
CO2, 111, REPORTED
YES NO
GAS TYPE
GAS ID
REPORTED
<SET
SET>
O2
ON
1
E-Series: only appears if Ethernet Option is installed.
Only appears if HESSEN PROTOCOL mode is ON.
ACAL is a special configuration; consult factory.
2
OFF
CO2
Set/create unique gas ID number
Figure A-6: Secondary Setup Menu - HESSEN Submenu
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Figure A-7: Secondary Setup Menu (DIAG)
A-8
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A-2: Setup Variables For Serial I/O, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-1: Setup Variables
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
Low Access Level Setup Variables (818 password)
DAS_HOLD_OFF
Minutes
—
15
0.5–20
O2 3,
CO2 1
Duration of DAS hold off period.
STABIL_GAS
O2 5
CO2 4
Selects gas for stability
measurement. Enclose value in
double quotes (") when setting
from the RS-232 interface.
TPC_ENABLE
—
ON
OFF, ON
ON enables temperature and
pressure compensation; OFF
disables it.
DYN_ZERO
—
—
—
OFF
OFF, ON
OFF, ON
ON enables contact closure
dynamic zero; OFF disables it.
DYN_SPAN
OFF
ON enables contact closure
dynamic span; OFF disables it.
CONC_PRECISION
AUTO
AUTO,
Number of digits to display to the
right of the decimal point for
concentrations on the display.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
0,
1,
2,
3,
4
CLOCK_ADJ
Sec./Day
—
0
-60–60
Time-of-day clock speed
adjustment.
SERVICE_CLEAR8
OFF
OFF
ON resets the service interval
timer.
ON
TIME_SINCE_SVC8
SVC_INTERVAL8
Hours
Hours
0
0
0–500000
0–100000
Time since last service.
Sets the interval between service
reminders.
Medium Access Level Setup Variables (929 password)
DAYLIGHTSAVING_ENABLE8
—
ON
OFF, ON
Enables/disables automatic
Daylight Savings Time change.
LANGUAGE_SELECT
—
ENGL
ENGL,
SECD,
EXTN
Selects the language to use for
the user interface. Enclose value
in double quotes (“) when setting
from the RS-232 interface.
MAINT_TIMEOUT
LATCH_WARNINGS8
CONV_TIME
Hours
—
2
0.1–100
Time until automatically
switching out of software-
controlled maintenance mode.
ON
33 MS
ON, OFF
ON enables latching warning
messages; OFF disables
latching.
—
33 MS, 66 MS, Conversion time for O2 and CO2
detector channels. Enclose value
in double quotes (“) when setting
from the RS-232 interface.
133 MS,
266 MS,
533 MS,
1 SEC, 2 SEC
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
NEG_CONC_SUPPRESS
—
OFF
OFF, ON
ON pegs negative concentrations
at zero; OFF permits negative
concentrations
O2_DWELL3
Seconds
—
1
0.1–30
ON, OFF
1–500
Dwell time before taking each
sample.
O2_FILT_ADAPT3
O2_FILT_SIZE3
O2_FILT_ASIZE3
O2_FILT_DELTA3
O2_FILT_PCT3
O2_FILT_DELAY3
O2_DIL_FACTOR3
ON
60
10
2
ON enables O2 adaptive filter;
OFF disables it.
Samples
Samples
%
O2 moving average filter size in
normal mode.
1–500
O2 moving average filter size in
adaptive mode.
0.1–100
0.1–100
0–300
Absolute change in O2
concentration to shorten filter.
%
2
Relative change in O2
concentration to shorten filter.
Seconds
—
20
1
Delay before leaving O2 adaptive
filter mode.
0.1–1000
Dilution factor for O2. Used only if
is dilution enabled with
FACTORY_OPT variable.
O2_CELL_SET3
ºC
50
30–70
O2 sensor cell temperature set
point and warning limits.
Warnings:
45–55
10
O2_CELL_CYCLE3
O2_CELL_PROP3
O2_CELL_INTEG3
O2_CELL_DERIV3
O2_STD_CELL_TEMP3
O2_STD_CELL_PRESS3
CO2_DWELL 1
Seconds
—
0.5–30
0–10
O2 cell temperature control cycle
period.
1
O2 cell PID temperature control
proportional coefficient.
—
0.1
0–10
O2 cell PID temperature control
integral coefficient.
—
0 (disabled)
0–10
O2 cell PID temperature control
derivative coefficient.
ºK
323
28.50
1
1–500
1.00–50.00
0.1–30
ON, OFF
1–300
1–300
0.1–10
0.1–100
0–300
Standard O2 cell temperature for
temperature compensation.
"Hg
Standard O2 cell pressure for
pressure compensation.
Seconds
—
Dwell time before taking each
sample.
CO2_FILT_ADAPT 1
CO2_FILT_SIZE 1
CO2_FILT_ASIZE 1
CO2_FILT_DELTA 1
CO2_FILT_PCT 1
ON
48
ON enables CO2 adaptive filter;
OFF disables it.
Samples
Samples
%
CO2 moving average filter size in
normal mode.
12
CO2 moving average filter size in
adaptive mode.
2
Absolute change in CO2
concentration to shorten filter.
%
10
Relative change in CO2
concentration to shorten filter.
CO2_FILT_DELAY 1
Seconds
90
Delay before leaving CO2
adaptive filter mode.
A-10
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
CO2_DIL_FACTOR 1
—
ºC
1
0.1–1000
Dilution factor for CO2. Used only
if is dilution enabled with
FACTORY_OPT variable.
CO2_CELL_SET 1
50
30–70
CO2 sensor cell temperature set
point and warning limits.
Warnings:
45–55
10
CO2_CELL_CYCLE 1
CO2_CELL_PROP 1
CO2_CELL_INTEG 1
CO2_CELL_DERIV 1
CO2_STD_CELL_TEMP 1
CO2_STD_CELL_PRESS 1
O2_TARG_SPAN13
Seconds
0.5–30
0–10
CO2 cell temperature control
cycle period.
—
—
—
ºK
"Hg
%
1
CO2 cell PID temperature control
proportional coefficient.
0.1
0–10
CO2 cell PID temperature control
integral coefficient.
0 (disabled)
323
0–10
CO2 cell PID temperature control
derivative coefficient.
1–500
1.00–50.00
0.1–100
Standard CO2 cell temperature
for temperature compensation.
28.50
20.95
Standard CO2 cell pressure for
pressure compensation.
Target O2 concentration during
span calibration of range 1.
O2_SLOPE13
O2_OFFSET13
CO2_TARG_SPAN11
—
%
%
1
0.5–2
O2 slope for range 1.
O2 offset for range 1.
0
-10–10
0.1–1000
12
Target CO2 concentration during
span calibration of range 1.
CO2_SLOPE11
CO2_OFFSET11
O2_TARG_SPAN25
—
%
%
1
0.5–5
CO2 slope for range 1.
CO2 offset for range 1.
0
-10–10
0.1–100
20.95
Target O2 concentration during
span calibration of range 2.
O2_SLOPE25
O2_OFFSET25
CO2_TARG_SPAN24
—
%
%
1
0.5–2
O2 slope for range 2.
O2 offset for range 2.
0
-10–10
0.1–1000
12
Target CO2 concentration during
span calibration of range 2.
CO2_SLOPE24
CO2_OFFSET24
RANGE_MODE
—
%
—
1
0.5–5
CO2 slope for range 2.
CO2 offset for range 2.
0
-10–10
SNGL,
DUAL,
AUTO
SNGL
Range control mode. Enclose
value in double quotes (“) when
setting from the RS-232
interface.
CONC_RANGE1
CONC_RANGE2
CONC_RANGE3 2
%
%
%
100
100
15
0.1–500
0.1–500
0.1–500
D/A concentration range 1
D/A concentration range 2
D/A concentration range 3
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
SAMP_FLOW_SET
cc/m
120
0–6000
Sample flow set point for flow
calculation and warning limits.
Warnings:
80–180
1
SAMP_FLOW_SLOPE
SAMP_PRESS_SET
—
0.5–1.5
0–100
Sample flow slope correction
factor (adjusted flow = measured
flow x slope).
"Hg
29.92
Warnings:
15–35
30
Sample pressure set point for
pressure compensation and
warning limits.
BOX_SET
ºC
5–60
Box temperature warning limits.
Set point is not used.
Warnings:
8–50
RS232_MODE
BitFlag
0
0–65535
RS-232 COM1 mode flags. Add
values to combine flags.
1 = quiet mode
2 = computer mode
4 = enable security
8 = enable hardware
handshaking
16 = enable Hessen protocol 8
32 = enable multi-drop
64 = enable modem
128 = ignore RS-232 line errors
256 = disable XON / XOFF
support
512 = disable hardware FIFOs
1024 = enable RS-485 mode
2048 = even parity, 7 data bits, 1
stop bit
4096 = enable command prompt
8192 = even parity, 8 data bits, 1
stop bit
16384 = enable dedicated
MODBUS ASCII protocol
32678 = enable dedicated
MODBUS RTU or TCP protocol
BAUD_RATE
—
115200
300,
RS-232 COM1 baud rate.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
1200,
2400,
4800,
9600,
19200,
38400,
57600,
115200
A-12
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
MODEM_INIT
—
“AT Y0 &D0
Any character
in the allowed
character set.
Up to 100
characters
long.
RS-232 COM1 modem
&H0 &I0 S0=2
&B0 &N6 &M0
E0 Q1 &W0”
initialization string. Sent verbatim
plus carriage return to modem on
power up or manually. Enclose
value in double quotes (“) when
setting from the RS-232
interface.
RS232_MODE2
BAUD_RATE2
BitFlag
—
0
0–65535
RS-232 COM2 mode flags.
(Same settings as
RS232_MODE.)
19200
300,
RS-232 COM2 baud rate.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
1200,
2400,
4800,
9600,
19200,
38400,
57600,
115200
MODEM_INIT2
—
“AT Y0 &D0
Any character
in the allowed
character set.
Up to 100
characters
long.
RS-232 COM2 modem
&H0 &I0 S0=2
&B0 &N6 &M0
E0 Q1 &W0”
initialization string. Sent verbatim
plus carriage return to modem on
power up or manually. Enclose
value in double quotes (“) when
setting from the RS-232
interface.
RS232_PASS
Password
940331
802
0–999999
0–9999
RS-232 log on password.
MACHINE_ID
ID
—
Unique ID number for instrument.
COMMAND_PROMPT
“Cmd> ”
Any character
in the allowed
character set.
Up to 100
characters
long.
RS-232 interface command
prompt. Displayed only if enabled
with RS232_MODE variable.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
TEST_CHAN_ID
—
NONE
Diagnostic analog output ID.
Enclose value in double quotes
(“) when setting from the RS-232
NONE,
SAMPLE
PRESSURE interface.
,
SAMPLE
FLOW,
O2 CELL
TEMP 3,
CO2 CELL
TEMP 1,
CHASSIS
TEMP
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
REMOTE_CAL_MODE
—
—
O2 RANGE1 5
O2 RANGE1 3, Range to calibrate during
O2 RANGE2 5,
contact-closure and Hessen
calibration. Enclose value in
double quotes (“) when setting
from the RS-232 interface.
CO2 RANGE1
4
CO2 RANGE1
1
,
CO2 RANGE2
4
PASS_ENABLE
STABIL_FREQ
OFF
10
OFF, ON
1–300
2–40
ON enables passwords; OFF
disables them.
Seconds
Samples
—
Stability measurement sampling
frequency.
STABIL_SAMPLES
SERIAL_NUMBER
25
Number of samples in
concentration stability reading.
Any character
in the allowed
character set.
Up to 100
Unique serial number for
“00000000 ”
instrument. Enclose value in
double quotes (“) when setting
from the RS-232 interface.
characters
long.
DISP_INTENSITY
—
—
HIGH
ON
HIGH,
MED,
LOW,
DIM
Front panel display intensity.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
I2C_RESET_ENABLE
OFF, ON
I2C bus automatic reset enable.
A-14
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
CLOCK_FORMAT
—
“TIME=%H:%
M:%S”
Any character
in the allowed
character set.
Up to 100
Time-of-day clock format flags.
Enclose value in double quotes
(“) when setting from the RS-232
interface.
characters
long.
“%a” = Abbreviated weekday
name.
“%b” = Abbreviated month name.
“%d” = Day of month as decimal
number (01 – 31).
“%H” = Hour in 24-hour format
(00 – 23).
“%I” = Hour in 12-hour format (01
– 12).
“%j” = Day of year as decimal
number (001 – 366).
“%m” = Month as decimal
number (01 – 12).
“%M” = Minute as decimal
number (00 – 59).
“%p” = A.M./P.M. indicator for
12-hour clock.
“%S” = Second as decimal
number (00 – 59).
“%w” = Weekday as decimal
number (0 – 6; Sunday is 0).
“%y” = Year without century, as
decimal number (00 – 99).
“%Y” = Year with century, as
decimal number.
“%%” = Percent sign.
ALARM_TRIGGER
Cycles
3
1–100
Number of times concentration
must exceed limit to trigger
alarm.
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Setup Variable
Numeric
Units
Default
Value
Value Range
Description
FACTORY_OPT
BitFlag
0
0–0x7fffffff
Factory option flags. Add values
to combine flags.
1 = enable dilution factor
2 = display units in concentration
field
4 = enable software-controlled
maintenance mode
8 = enable switch-controlled
maintenance mode
16 = enable concentration
alarms
32 = enable Internet option7
16384 = enable external analog
inputs 6
1
T-Series/E-Series: 801, 803, or 802 with CO2 option.
T-Series/E-Series: 802 with CO2 option or 803.
T-Series/E-Series: 802 or 803.
T-Series/E-Series: 801 or 803.
T-Series/E-Series: 802 only.
2
3
4
5
6
7
8
T-Series external analog input option.
E Series internet option.
T-Series only
A-16
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A-3: Warnings and Test Measurements, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-2: Warning Messages
Name 1
Message Text
Warnings
Description
WSYSRES
SYSTEM RESET
Instrument was power-cycled or the CPU
was reset.
WDATAINIT
DATA INITIALIZED
Data storage was erased.
WCONFIGINIT
CONFIG INITIALIZED
Configuration storage was reset to factory
configuration or erased.
WO2ALARM1 3
WO2ALARM2 3
WCO2ALARM1 2
O2 ALARM 1 WARN
O2 ALARM 2 WARN
CO2 ALARM 1 WARN
O2 concentration alarm limit #1 exceeded
O2 concentration alarm limit #2 exceeded
CO2 concentration alarm limit #1
exceeded
WCO2ALARM2 2
WSAMPFLOW
WSAMPPRESS
CO2 ALARM 2 WARN
SAMPLE FLOW WARN
SAMPLE PRESS WARN
CO2 concentration alarm limit #2
exceeded
Sample flow outside of warning limits
specified by SAMP_FLOW_SET variable.
Sample pressure outside of warning limits
specified by SAMP_PRESS_SET
variable.
WBOXTEMP
BOX TEMP WARNING
O2 CELL TEMP WARN
Chassis temperature outside of warning
limits specified by BOX_SET variable.
WO2CELLTEMP 3
O2 sensor cell temperature outside of
warning limits specified by O2_CELL_SET
variable.
WCO2CELLTEMP 2
CO2 CELL TEMP WARN
CO2 sensor cell temperature outside of
warning limits specified by
CO2_CELL_SET variable.
WDYNZERO
CANNOT DYN ZERO
CANNOT DYN SPAN
REAR BOARD NOT DET
RELAY BOARD WARN
FRONT PANEL WARN
ANALOG CAL WARNING
Contact closure zero calibration failed
while DYN_ZERO was set to ON.
WDYNSPAN
Contact closure span calibration failed
while DYN_SPAN was set to ON.
WREARBOARD
WRELAYBOARD
WFRONTPANEL
Rear board was not detected during
power up.
Firmware is unable to communicate with
the relay board.
Firmware is unable to communicate with
the front panel.
WANALOGCAL
The A/D or at least one D/A channel has
not been calibrated.
1
The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”.
T-Series/E-Series: 801, 803 or 802 with CO2 option.
T-Series/E-Series: 802 or 803.
2
3
4
T-Series/E-Series: 801 or 803.
5
T-Series/E-Series: 802 only.
6
T-Series/E-Series: 803 only.
7
T-Series/E-Series: 802 with CO2 option.
T-Series/E-Series: 801 or 802 without CO2 option.
External analog input option.
8
10
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Table A-3: Test Measurements
Name 1
Message Text
Description
Test Measurements
O2RANGE 5
O2 RNG=500.0 %
D/A range in single or auto-range modes.
D/A 1 range in independent range mode.
D/A 2 range in independent range mode.
D/A 3 range.
CO2RANGE 4
O2RANGE1 5
CO2RANGE1 4
O2RANGE2 5
CO2RANGE2 4
O2RANGE 6
CO2 RNG = 500.0 %
O2 RN1=500.0 %
CO2 RN1=500.0 %
O2 RN2=500.0 %
CO2 RN2=500.0 %
O2 RNG=100 %
CO2RANGE 7
CO2 RNG=100 %
STABIL=0.0 % 8
STABILITY
Concentration stability.
O2 STB=0.0 % 2 or
CO2 STB=0.0 % 2
PRES=29.9 IN-HG-A
SAMP FL=100 CC/M
O2 SLOPE=0.980
SAMPPRESS
SAMPFLOW
O2SLOPE 3
Sample pressure.
Sample flow rate.
O2 slope, computed during zero/span
calibration.
O2OFFSET 3
CO2SLOPE 2
CO2OFFSET 2
O2 OFST=1.79 %
CO2 SLOPE=1.0000
CO2 OFST=0.00 %
O2 offset, computed during zero/span
calibration.
CO2 slope, computed during zero/span
calibration.
CO2 offset, computed during zero/span
calibration.
O2CELLTEMP 3
CO2CELLTEMP 2
BOXTEMP
O2 3
O2 CELL TEMP=50.2 C
CO2 CELL TEMP=50.2 C
BOX TEMP=35.5 C
O2=0.00 %
O2 sensor cell temperature.
CO2 sensor cell temperature.
Internal chassis temperature.
O2 concentration.
CO2 2
CO2=0.00 %
CO2 concentration.
TESTCHAN
TEST=3721.1 MV
Value output to TEST_OUTPUT analog
output, selected with TEST_CHAN_ID
variable.
XIN1 10
XIN2 10
XIN3 10
XIN4 10
XIN5 10
XIN6 10
XIN7 10
XIN8 10
AIN1=37.15 EU
AIN2=37.15 EU
AIN3=37.15 EU
AIN4=37.15 EU
AIN5=37.15 EU
AIN6=37.15 EU
AIN7=37.15 EU
AIN8=37.15 EU
External analog input 1 value in
engineering units.
External analog input 2 value in
engineering units.
External analog input 3 value in
engineering units.
External analog input 4 value in
engineering units.
External analog input 5 value in
engineering units.
External analog input 6 value in
engineering units.
External analog input 7 value in
engineering units.
External analog input 8 value in
engineering units.
A-18
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Name 1
Message Text
Description
Test Measurements
CLOCKTIME
TIME=10:38:27
Current instrument time of day clock.
1
The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”.
T-Series/E-Series: 801, 803, or 802 with CO2 option.
T-Series/E-Series: 802 or 803.
2
3
4
T-Series/E-Series: 801 or 803.
5
T-Series/E-Series: 802 only.
6
T-Series/E-Series: 803 only.
7
T-Series/E-Series: 802 with CO2 option.
T-Series/E-Series: 801 or 802 without CO2 option.
External analog input option.
8
10
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
APPENDIX A-4: Signal I/O Definitions, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-4:
Signal I/O Definitions
Signal Name
Bit or Channel
Number
Description
Internal inputs, U7, J108, pins 9–16 = bits 0–7, default I/O address 322 hex
0–7 Spare
Internal outputs, U8, J108, pins 1–8 = bits 0–7, default I/O address 322 hex
0–5
6
Spare
I2C_RESET
1 = reset I2C peripherals
0 = normal
I2C_DRV_RST
7
0 = hardware reset 8584 chip
1 = normal
Control inputs, U11, J1004, pins 1–6 = bits 0–5, default I/O address 321 hex
EXT_CAL_MODE
EXT_CAL_SPAN
EXT_CAL_RANGE2
EXT_CAL_CO2 1
0
1
2
3
0 = go into calibration mode
1 = exit calibration mode and go into measure mode
0 = calibrate span
1 = calibrate zero
0 = calibrate range #2
1 = calibrate range #1
0 = calibrate CO2
1 = calibrate O2
4–5
6–7
Spare
Always 1
Control inputs, U14, J1006, pins 1–6 = bits 0–5, default I/O address 325 hex
0–5
6–7
Spare
Always 1
Control outputs, U17, J1008, pins 1–8 = bits 0–7, default I/O address 321 hex
0–7 Spare
Control outputs, U21, J1008, pins 9–12 = bits 0–3, default I/O address 325 hex
0–3 Spare
Alarm outputs, U21, J1009, pins 1–12 = bits 4–7, default I/O address 325 hex
ST_SYSTEM_OK2,
MB_RELAY_36 3
4
5
6
7
1 = system OK
0 = any alarm condition or in diagnostics mode
Controlled by MODBUS coil register
1 = conc. limit 1 exceeded
ST_CONC_ALARM_1,
MB_RELAY_37 3
0 = conc. OK
Controlled by MODBUS coil register
ST_CONC_ALARM_2,
MB_RELAY_38 3
1 = conc. limit 2 exceeded
0 = conc. OK
Controlled by MODBUS coil register
ST_AUTO_RANGE2,
MB_RELAY_39 3
1 = auto-range 2 in use
0 = auto-range 1 in use
Controlled by MODBUS coil register
A-20
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Signal Name
Bit or Channel
Number
Description
A status outputs, U24, J1017, pins 1–8 = bits 0–7, default I/O address 323 hex
ST_SYSTEM_OK
ST_CONC_VALID
0
0 = system OK
1 = any alarm condition
0 = conc. valid
1
1 = warnings or other conditions that affect validity of
concentration
ST_CAL_MODE
ST_CAL_SPAN
ST_CAL_RANGE2
ST_CAL_CO2 1
2
0 = in calibration mode
1 = in measure mode
0 = calibrating span
1 = calibrating zero
0 = calibrating range 2
1 = calibrating range 1
0 = calibrating CO2
1 = calibrating O2
Spare
3
4
5
6–7
B status outputs, U27, J1018, pins 1–8 = bits 0–7, default I/O address 324 hex
0–7 Spare
Front panel I2C keyboard, default I2C address 4E hex
MAINT_MODE
LANG2_SELECT
SAMPLE_LED
CAL_LED
5 (input)
0 = maintenance mode
1 = normal mode
0 = select second language
1 = select first language (English)
0 = sample LED on
1 = off
6 (input)
8 (output)
9 (output)
10 (output)
14 (output)
0 = cal. LED on
1 = off
FAULT_LED
0 = fault LED on
1 = off
AUDIBLE_BEEPER
0 = beeper on (for diagnostic testing only)
1 = off
Relay board digital output (PCF8575), default I2C address 44 hex
RELAY_WATCHDOG
0
Alternate between 0 and 1 at least every 5 seconds to keep
relay board active
1–3
4
Spare
CO2_CELL_HEATER 2
O2_CELL_HEATER 4
CAL_VALVE 6
0 = CO2 sensor cell heater on
1 = off
5
6
7
0 = O2 sensor cell heater on
1 = off
0 = let cal. gas in
1 = let sample gas in
0 = let O2 span gas in
1 = let zero gas in
O2_SPAN_VALVE 4, 6
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A-21
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Signal Name
Bit or Channel
Number
Description
CO2_SPAN_VALVE 2, 6
VENT_VALVE 6
8
9
0 = let CO2 span gas in
1 = let zero gas in
0 = open vent valve
1 = close vent valve
Spare
10–15
Rear board primary MUX analog inputs
0–3
4
Spare
Temperature MUX
Spare
5
O2_CONC_SENSOR 4
SAMPLE_PRESSURE
6
O2 concentration sensor
Sample pressure
7
8
Spare
REF_4096_MV
9
4.096V reference from MAX6241
Sample flow rate
SAMPLE_FLOW
CO2_CONC_SENSOR 2
10
11
12–13
14
15
CO2 concentration sensor
Spare (thermocouple input?)
DAC MUX
REF_GND
Ground reference
Rear board temperature MUX analog inputs
BOX_TEMP
0
Internal box temperature
Spare
1
CO2_CELL_TEMP 2
O2_CELL_TEMP 4
2
CO2 sensor cell temperature
Spare
3
4
O2 sensor cell temperature
Spare
5–7
Rear board DAC MUX analog inputs
DAC_CHAN_1
DAC_CHAN_2
DAC_CHAN_3
DAC_CHAN_4
0
1
2
3
DAC channel 0 loopback
DAC channel 1 loopback
DAC channel 2 loopback
DAC channel 3 loopback
Rear board analog outputs
CONC_OUT_1,
DATA_OUT_1
CONC_OUT_2,
DATA_OUT_2
CONC_OUT_3 1
DATA_OUT_3
TEST_OUTPUT,
DATA_OUT_4
0
1
2
3
Concentration output #1,
Data output #1
Concentration output #2,
Data output #2
Concentration output #3,
Data output #3
Test measurement output,
Data output #4
A-22
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Signal Name
Bit or Channel
Number
Description
External analog input board, default I2C address 5C hex
XIN1 7
XIN2 7
XIN3 7
XIN4 7
XIN5 7
XIN6 7
XIN7 7
0
1
2
3
4
5
6
7
External analog input 1
External analog input 2
External analog input 3
External analog input 4
External analog input 5
External analog input 6
External analog input 7
External analog input 8
XIN8 7
1
T-Series/E-Series: 803 or 802 with CO2 option.
T-Series/E-Series: 801 or 803.
MODBUS option.
2
3
4
5
6
7
T-Series/E-Series: 802 or 803.
future
Future valve option.
T-Series: External analog input option.
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A-23
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
APPENDIX A-5: DAS Triggering Events, Parameters, Software Version s 1.0.3 (T-Series)/A.3 (E-Series)
Table A-5: DAS Trigger Events
Name
Description
ATIMER
Automatic timer expired
EXO2ZR 3
EXO2SP 3
EXO2MP 3
O2SLPC 3
EXCO2Z 1
EXCO2S 1
EXCO2M 1
CO2SLC 1
EXITDG
Exit O2 zero calibration mode
Exit O2 span calibration mode
Exit O2 multi-point calibration mode
O2 slope and offset recalculated
Exit CO2 zero calibration mode
Exit CO2 span calibration mode
Exit CO2 multi-point calibration mode
CO2 slope and offset recalculated
Exit diagnostic mode
CONC1W
CONC2W
O2TMPW 3
CO2TMW 1
SFLOWW
SPRESW
Concentration limit 1 exceeded
Concentration limit 2 exceeded
O2 sensor cell temperature warning
CO2 sensor cell temperature warning
Sample flow warning
Sample pressure warning
BTEMPW
Box temperature warning
1
T-Series/E-Series: 801, 803 or 802 with CO2 option.
future.
2
3
T-Series/E-Series: 802 or 803.
A-24
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Table A-6: DAS Parameters
Name
Description
Units
O2SLP1 2
O2 slope for range #1
O2 slope for range #2
O2 offset for range #1
O2 offset for range #2
CO2 slope for range #1
CO2 slope for range #2
CO2 offset for range #1
CO2 offset for range #2
—
—
%
%
—
—
%
%
%
O2SLP2 4
O2OFS1 2
O2OFS2 4
CO2SL1 1
CO2SL2 3
CO2OF1 1
CO2OF2 3
O2ZSC1 2
O2 concentration for range #1 during zero/span calibration, just
before computing new slope and offset
O2ZSC2 4
CO2ZS1 1
CO2ZS2 3
O2 concentration for range #2 during zero/span calibration, just
before computing new slope and offset
%
%
%
CO2 concentration for range #1 during zero/span calibration, just
before computing new slope and offset
CO2 concentration for range #2 during zero/span calibration, just
before computing new slope and offset
O2CNC1 2
O2CNC2 4
CO2CN1 1
CO2CN2 3
STABIL
O2 concentration for range #1
O2 concentration for range #2
CO2 concentration for range #1
CO2 concentration for range #2
Concentration stability #1
%
%
%
%
%
O2TEMP 2
O2 sensor cell temperature
C
O2DUTY 2
O2 sensor cell temperature controller duty cycle
Fraction
(0.0 = off,
1.0 = on full)
CO2TMP 1
CO2DTY 1
CO2 sensor cell temperature
C
CO2 sensor cell temperature controller duty cycle
Fraction
(0.0 = off,
1.0 = on full)
cc/m
SMPFLW
SMPPRS
BOXTMP
REFGND
RF4096
Sample flow
Sample pressure
“Hg
Internal box temperature
Ground reference (REF_GND)
4096 mV reference (REF_4096_MV)
C
mV
mV
07275B DCNE64r1ro8 r! Unknown document property name.Error! Unknown document property name.
A-25
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Name
Description
Units
XIN1 5
External analog input 1 value
Volts
XIN1SLPE 5
XIN1OFST 5
XIN2 5
XIN2SLPE 5
XIN2OFST 5
XIN3 5
XIN3SLPE 5
XIN3OFST 5
XIN4 5
XIN4SLPE 5
XIN4OFST 5
XIN5 5
XIN5SLPE 5
XIN5OFST 5
XIN6 5
XIN6SLPE 5
XIN6OFST 5
XIN7 5
XIN7SLPE 5
XIN7OFST 5
XIN8 5
External analog input 1 slope
External analog input 1 value
External analog input 2 value
External analog input 2 slope
External analog input 2 value
External analog input 3 value
External analog input 3 slope
External analog input 3 value
External analog input 4 value
External analog input 4 slope
External analog input 4 value
External analog input 5 value
External analog input 5 slope
External analog input 5 value
External analog input 6 value
External analog input 6 slope
External analog input 6 value
External analog input 7 value
External analog input 7 slope
External analog input 7 value
External analog input 8 value
External analog input 8 slope
External analog input 8 value
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
eng unit / V
eng unit
Volts
XIN8SLPE 5
XIN8OFST 5
eng unit / V
eng unit
1
T-Series/E-Series: 801, 803 or 802 with CO2 option.
T-Series/E-Series: 802 or 803.
2
3
4
5
T-Series/E-Series: 801 or 803.
T-Series/E-Series: 802 only.
T-Series: External analog input option.
A-26
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A-6: Terminal Command Designators, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-7: Terminal Command Designators
COMMAND
? [ID]
ADDITIONAL COMMAND SYNTAX
DESCRIPTION
Display help screen and commands list
Establish connection to instrument
Terminate connection to instrument
Display test(s)
LOGON [ID]
LOGOFF [ID]
password
SET ALL|name|hexmask
LIST [ALL|name|hexmask] [NAMES|HEX]
name
Print test(s) to screen
T [ID]
Print single test
CLEAR ALL|name|hexmask
SET ALL|name|hexmask
LIST [ALL|name|hexmask] [NAMES|HEX]
name
Disable test(s)
Display warning(s)
Print warning(s)
W [ID]
Clear single warning
CLEAR ALL|name|hexmask
ZERO|LOWSPAN|SPAN [1|2]
ASEQ number
Clear warning(s)
Enter calibration mode
Execute automatic sequence
Compute new slope/offset
Exit calibration mode
C [ID]
COMPUTE ZERO|SPAN
EXIT
ABORT
Abort calibration sequence
Print all I/O signals
LIST
name[=value]
Examine or set I/O signal
Print names of all diagnostic tests
Execute diagnostic test
Exit diagnostic test
LIST NAMES
ENTER name
EXIT
RESET [DATA] [CONFIG] [exitcode]
PRINT ["name"] [SCRIPT]
RECORDS ["name"]
Reset instrument
D [ID]
Print DAS configuration
Print number of DAS records
REPORT ["name"] [RECORDS=number] [FROM=<start
date>][TO=<end date>][VERBOSE|COMPACT|HEX]
(Print DAS records)(date format: MM/DD/YYYY(or YY)
[HH:MM:SS]
Print DAS records
CANCEL
Halt printing DAS records
Print setup variables
LIST
name[=value [warn_low [warn_high]]]
name="value"
Modify variable
Modify enumerated variable
Print instrument configuration
Enter/exit maintenance mode
Print current instrument mode
Upload DAS configuration
Upload single DAS channel
Delete DAS channels
V [ID]
CONFIG
MAINT ON|OFF
MODE
DASBEGIN [<data channel definitions>] DASEND
CHANNELBEGIN propertylist CHANNELEND
CHANNELDELETE ["name"]
The command syntax follows the command type, separated by a space character. Strings in [brackets] are
optional designators. The following key assignments also apply.
07275B DCNE64r1ro8 r! Unknown document property name.Error! Unknown document property name.
A-27
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Table A-8: Terminal Key Assignments
TERMINAL KEY ASSIGNMENTS
Abort line
ESC
CR (ENTER)
Ctrl-C
Execute command
Switch to computer mode
COMPUTER MODE KEY ASSIGNMENTS
LF (line feed)
Ctrl-T
Execute command
Switch to terminal mode
A-28
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
APPENDIX A-7: MODBUS® Register Map, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
MODBUS Register
Address
Description
Units
(dec., 0-based)
MODBUS Floating Point Input Registers
(32-bit IEEE 754 format; read in high-word, low-word order; read-only)
0 4
2 6
4 4
6 6
8 4
O2 slope for range 1
O2 slope for range 2
O2 offset for range 1
O2 offset for range 2
—
—
%
%
%
O2 concentration for range 1 during zero/span calibration, just
before computing new slope and offset
10 6
O2 concentration for range 2 during zero/span calibration, just
before computing new slope and offset
%
12 4
14 6
16 4
18 4
20
O2 concentration for range 1
O2 concentration for range 2
O2 sensor cell temperature
O2 sensor cell temperature control duty cycle
Concentration stability
%
%
C
Fraction
%
22
Sample flow
cc/m
“Hg
C
24
Sample pressure
26
Internal box temperature
Ground reference (REF_GND)
4096 mV reference (REF_4096_MV)
CO2 slope for range 1
28
mV
mV
—
30
100 1
102 5
104 1
106 5
108 1
CO2 slope for range 2
—
CO2 offset for range 1
%
CO2 offset for range 2
%
CO2 concentration for range 1 during zero/span calibration, just
before computing new slope and offset
%
110 5
CO2 concentration for range 2 during zero/span calibration, just
before computing new slope and offset
%
112 1
114 5
116 1
118 1
CO2 concentration for range 1
%
CO2 concentration for range 2
%
CO2 sensor cell temperature
C
CO2 sensor cell temperature control duty cycle
Fraction
Error! Unknown document property name.Error! Unknown document property name.
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
MODBUS Register
Address
Description
Units
(dec., 0-based)
130 7
External analog input 1 value
Volts
132 7
134 7
136 7
138 7
140 7
142 7
144 7
146 7
148 7
150 7
152 7
154 7
156 7
158 7
160 7
162 7
164 7
166 7
168 7
170 7
172 7
174 7
176 7
External analog input 1 slope
External analog input 1 offset
External analog input 2 value
External analog input 2 slope
External analog input 2 offset
External analog input 3 value
External analog input 3 slope
External analog input 3 offset
External analog input 4 value
External analog input 4 slope
External analog input 4 offset
External analog input 5 value
External analog input 5 slope
External analog input 5 offset
External analog input 6 value
External analog input 6 slope
External analog input 6 offset
External analog input 7 value
External analog input 7 slope
External analog input 7 offset
External analog input 8 value
External analog input 8 slope
External analog input 8 offset
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
Volts
eng unit /V
eng unit
MODBUS Floating Point Holding Registers
(32-bit IEEE 754 format; read/write in high-word, low-word order; read/write)
0 4
2 6
100 1
102 5
Maps to O2_TARG_SPAN1 variable; target conc. for range 1
Maps to O2_TARG_SPAN2 variable; target conc. for range 2
Maps to CO2_TARG_SPAN1 variable; target conc. for range 1
Maps to CO2_TARG_SPAN2 variable; target conc. for range 2
%
%
%
%
A-30
Error! Unknown document property name.Error! Unknown document property name.
Error!
Unknown document property name.Error! Unknown document property name.
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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
Appendix A
Units
MODBUS Register
Address
Description
(dec., 0-based)
MODBUS Discrete Input Registers
(single-bit; read-only)
0
Box temperature warning
1 4
O2 cell temperature warning
2
Sample flow warning
3
Sample pressure warning
4
System reset warning
5
Rear board communication warning
Relay board communication warning
Front panel communication warning
Analog calibration warning
6
7
8
9
Dynamic zero warning
10
Dynamic span warning
11
Invalid concentration
12 4
13 4
14 4
15
In O2 zero calibration mode
In O2 span calibration mode
In O2 multi-point calibration mode
System is OK (same meaning as SYSTEM_OK I/O signal)
O2 concentration alarm limit #1 exceeded
O2 concentration alarm limit #2 exceeded
In Hessen manual mode
16
17
18
100 1
101 1
102 1
103 1
104 1
105 1
CO2 cell temperature warning
In CO2 zero calibration mode
In CO2 span calibration mode
In CO2 multi-point calibration mode
CO2 concentration alarm limit #1 exceeded
CO2 concentration alarm limit #2 exceeded
Error! Unknown document property name.Error! Unknown document property name.
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Appendix A
Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)
MODBUS Register
Address
Description
Units
(dec., 0-based)
MODBUS Coil Registers
(single-bit; read/write)
0
Maps to relay output signal 36 (MB_RELAY_36 in signal I/O list)
Maps to relay output signal 37 (MB_RELAY_37 in signal I/O list)
Maps to relay output signal 38 (MB_RELAY_38 in signal I/O list)
Maps to relay output signal 39 (MB_RELAY_39 in signal I/O list)
Triggers O2 zero calibration of range 1 (on enters cal.; off exits cal.)
Triggers O2 span calibration of range 1 (on enters cal.; off exits cal.)
Triggers O2 zero calibration of range 2 (on enters cal.; off exits cal.)
Triggers O2 span calibration of range 2 (on enters cal.; off exits cal.)
Triggers CO2 zero calibration of range 1 (on enters cal.; off exits cal.)
Triggers CO2 span calibration of range 1 (on enters cal.; off exits cal.)
Triggers CO2 zero calibration of range 2 (on enters cal.; off exits cal.)
Triggers CO2 span calibration of range 2 (on enters cal.; off exits cal.)
1
2
3
20 3,4
21 3,4
22 6,4
23 6,4
24 1,3
25 1,3
26 5,3
27 5,3
1
T-Series/E-Series: 801, 803 or 802 with CO2 option.
future.
2
3
Set DYN_ZERO or DYN_SPAN variables to ON to enable calculating new slope or offset. Otherwise a calibration check
is performed.
4
5
6
7
T-Series/E-Series: 802 or 803.
T-Series/E-Series: 801 or 803.
T-Series/E-Series: 802 only.
T-Series: External analog input option.
A-32
Error! Unknown document property name.Error! Unknown document property name.
Error!
Unknown document property name.Error! Unknown document property name.
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APPENDIX B - Spare Parts
Use of replacement parts other than those supplied by Teledyne Advanced
Note
Note
Pollution Instrumentation (TAPI) may result in non-compliance with European
standard EN 61010-1.
Due to the dynamic nature of part numbers, please refer to the TAPI Website at
http://www.teledyne-api.com or call Customer Service at 800-324-5190 for more
recent updates to part numbers.
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B-2
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T80X Spare Parts List
(Ref: 072690000A DCN6431, 2012 April 12)
PARTNUMBER
000940700
001763500
003290000
009690200
009690300
016290000
016300800
037860000
040010000
040030100
042410500
043420000
045230200
055100200
058021100
066970000
067240000
067300000
067300100
067300200
067900000
068810000
069500000
072150000
072740000
072750000
072760000
073770100
073780100
073790100
CN0000073
CN0000458
CN0000520
FL0000001
FM0000004
HE0000017
HW0000005
HW0000020
HW0000036
HW0000101
HW0000453
HW0000685
KIT000219
KIT000253
KIT000254
OP0000030
DESCRIPTION
CD, ORIFICE, .005 YELLOW
ASSY, FLOW CTL, 110CC, 1/4" ELBOW‐B
THERMISTOR, BASIC (VENDOR ASSY)(KB)
AKIT, TFE FLTR ELEM (FL19,100=1) 47mm
AKIT, TFE FLTR ELEM (FL19, 30=1) 47mm
WINDOW, SAMPLE FILTER, 47MM (KB)
ASSY, SAMPLE FILTER, 47MM, ANG BKT, 1UM
ORING, TEFLON, RETAINING RING, 47MM (KB)
ASSY, FAN REAR PANEL (B/F)
PCA, PRESS SENSORS (1X), w/FM4
ASSY, PUMP, INT
ASSY, HEATER/THERM, O2 SEN
PCA, RELAY CARD
ASSY, OPTION, PUMP, 240V *
PCA, MOTHERBD, GEN 5‐ICOP
PCA, INTRF. LCD TOUCH SCRN, F/P
CPU, PC‐104, VSX‐6154E, ICOP *(KB)
PCA, AUX‐I/O BD, ETHERNET, ANALOG & USB
PCA, AUX‐I/O BOARD, ETHERNET
PCA, AUX‐I/O BOARD, ETHERNET & USB
LCD MODULE, W/TOUCHSCREEN(KB)
PCA, LVDS TRANSMITTER BOARD
PCA, SERIAL & VIDEO INTERFACE BOARD
ASSY. TOUCHSCREEN CONTROL MODULE
MANUAL, T801, OPERATORS
MANUAL, T802, OPERATORS
MANUAL, T803, OPERATORS
DOM, w/SOFTWARE, STD, T801 *
DOM, w/SOFTWARE, STD, T802 *
DOM, w/SOFTWARE, STD, T803 *
POWER ENTRY, 120/60 (KB)
PLUG, 12, MC 1.5/12‐ST‐3.81 (KB)
PLUG, 10, MC 1.5/10‐ST‐3.81 (KB)
FILTER, SS (KB)
FLOWMETER (KB)
HTR, 12W/120V (50W/240V), CE AP (KB)
FOOT
SPRING
TFE TAPE, 1/4" (48 FT/ROLL)
ISOLATOR
SUPPORT, CIRCUIT BD, 3/16" ICOP
LATCH, MAGNETIC, FRONT PANEL
AKIT, 4‐20MA CURRENT OUTPUT
ASSY & TEST, SPARE PS37
ASSY & TEST, SPARE PS38
OXYGEN TRANSDUCER, PARAMAGNETIC
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T80X Spare Parts List
(Ref: 072690000A DCN6431, 2012 April 12)
OR0000001
OR0000094
PU0000022
RL0000015
SW0000006
SW0000025
SW0000059
WR0000008
ORING, 2‐006VT *(KB)
ORING, 2‐228V, 50 DURO VITON(KB)
REBUILD KIT, FOR PU20 & 04241 (KB)
RELAY, DPDT, (KB)
SWITCH, THERMAL, 60 C (KB)
SWITCH, POWER, CIRC BREAK, VDE/CE *(KB)
PRESSURE SENSOR, 0‐15 PSIA, ALL SEN
POWER CORD, 10A(KB)
B-4
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M802E Expendables Kit, PN06535A (DCN5390)
M802E without a pump Expendables Kit
Description
Part Number
006190600
AKIT, EXP, 802E W/O PUMP, 1UM
This kit contains the following items (labor incl.)
009690300
FL0000001
HW0000020
OR0000001
AKIT, TFE FLTR ELEMENT, 47MM, 1UM (30)
FILTER, SS
SPRING
ORING, SAMPLE FLOW
M802E with a pump Expendables Kit
Part Number
Description
006190500
AKIT, EXP, 802E W/ PUMP, 1UM
This kit contains the following items (labor incl.)
009690300
FL0000001
HW0000020
NOTE01-23
OR0000001
PU0000022
AKIT, TFE FLTR ELEMENT, 47MM, 1UM (30)
FILTER, SS
SPRING
SERVICE NOTE, HOW TO REBUILD KNF PUMP
ORING, SAMPLE FLOW
REBUILD KIT, FOR PU20 & 04241 (KB)
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B-6
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Appendix C
Warranty/Repair Questionnaire
T80X, M80XE
(06532C DCN 5798)
CUSTOMER: _______________________________ PHONE: _____________________________________
CONTACT NAME: ___________________________ FAX NO. _____________________________________
SITE ADDRESS: ___________________________________________________________________________
MODEL TYPE: ______________ SERIAL NO.: ________________ FIRMWARE REVISION: ____________
Are there any failure messages? _______________________________________________________________
________________________________________________________________________________________________________________________________
________________________________________________________________________ (Continue on back if necessary)
PLEASE COMPLETE THE FOLLOWING TABLE:
PARAMETER
RECORDED VALUE
ACCEPTABLE VALUE
0-100%
1
%
O2 RANGE
1
50 ± 5
ºC
O2 CELL TEMP
1
1.0 ± 0.3
O2 SLOPE
1
-10 to 10%
0 to 20%
O2 OFFSET
1
%
CO2 RANGE
1
50 ± 5
ºC
CO2 CELL TEMP
1
1.0 ± 0.3
CO2 SLOPE
1
-10 to 10%
0.2% with zero air
ambient ± 1
120 ± 20
CO2 OFFSET
%
STABIL
PRESS
in-Hg-A
3
SAMPLE FLOW
BOX TEMP
cm /min
ambient ± 5ºC
ºC
following values are under the signal i/o submenu
mV
mV
4096mV ±2 mV and Must be Stable
0± 0.5 and Must be Stable
REF_4096_MV
REF_GND
1 Not all models are equipped with both an O2 and a CO2 sensor.
Cap the SAMPLE inlet and record the flow rate and pressure readings:
What is PRESS____________________in-Hg-A
What is the SAMPLE FLOW__________ cc/min
What are the failure symptoms? __________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
What test have you done trying to solve the problem? ________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
TELEDYNE API CUSTOMER SERVICE
EMAIL: [email protected]
PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816
C-1
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Appendix C
Warranty/Repair Questionnaire
T80X, M80XE
(06532C DCN 5798)
____________________________________________________________________________________
If possible, please include a portion of a strip chart pertaining to the problem. Circle pertinent data.
OTHER NOTES:____________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Thank you for providing this information. Your assistance enables Teledyne API to respond faster to the
problem that you are encountering.
TELEDYNE API CUSTOMER SERVICE
EMAIL: [email protected]
PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816
C-2
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APPENDIX D – Wire List and Electronic Schematics
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T80X Interconnect List
(Reference: 073800100A DCN6418)
FROM
TO
Cable PN Signal
036490100 CBL ASSY, AC POWER
AC Line
Assembly
PN
J/P Pin Assembly
PN
J/P
Pin
Power Switch
Power Switch
Shield
SW0000025
SW0000025
L
N
AC Neutral
Power Grnd
Power Grnd
Power Entry
Power Entry
Power Switch
Power Switch
Power Entry
PS2 (+12)
PS2 (+12)
PS2 (+12)
PS1 (+5, ±15)
PS1 (+5, ±15)
PS1 (+5, ±15)
CN0000073
CN0000073
SW0000025
SW0000025
Chassis
AC Line Switched
AC Neu Switched
Power Grnd
AC Line Switched
AC Neu Switched
Power Grnd
AC Line Switched
AC Neu Switched
Power Grnd
L
PS2 (+12)
PS0000038
PS0000038
PS0000038
PS0000037
PS0000037
PS0000037
045230100
045230100
045230100
SK2
SK2
SK2
SK2
SK2
SK2
J1
1
3
2
1
3
2
1
3
2
N
PS2 (+12)
CN0000073
PS2 (+12)
PS0000038 SK2
PS0000038 SK2
PS0000038 SK2
PS0000037 SK2
PS0000037 SK2
PS0000037 SK2
1
3
2
1
3
2
PS1 (+5, ±15)
PS1 (+5, ±15)
PS1 (+5, ±15)
Relay Board
Relay Board
Relay Board
J1
J1
038290000 CBL ASSY, DC POWER TO MOTHERBOARD
DGND
+5V
AGND
+15V
AGND
-15V
+12V RET
+12V
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
045230100
045230100
045230100
045230100
045230100
045230100
045230100
045230100
045230100
J7
J7
J7
J7
J7
J7
J7
J7
J7
1
2
3
4
5
6
7
8
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
J15
J15
J15
J15
J15
J15
J15
J15
J15
1
2
3
4
5
6
7
8
9
Chassis Gnd
10 Motherboard
040230000 CBL, I2C, RELAY BOARD TO MOTHERBOARD
I2C Serial Clock
I2C Serial Data
I2C Reset
Motherboard
Motherboard
Motherboard
Motherboard
058021100 P107
058021100 P107
058021100 P107
058021100 P107
3
5
2
6
Relay Board
Relay Board
Relay Board
Relay Board
045230100
045230100
045230100
045230100
P3
P3
P3
P3
1
2
4
5
I2C Shield
041050000 CBL, INTERFACE BOARD TO MOTHERBOARD
Kbd Interupt
DGND
SDA
SCL
Shld
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
066970000
066970000
066970000
066970000
066970000
J2
J2
J2
J2
J2
7
2
5
6
Motherboard
Motherboard
Motherboard
Motherboard
058021100
058021100
058021100
058021100
058021100
J106
J106
J106
J106
J106
1
8
2
6
5
10 Motherboard
041760000 CBL, DC POWER TO RELAY BOARD
DGND
+5V
+15V
AGND
-15V
+12V RET
+12V
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
045230100
045230100
045230100
045230100
045230100
045230100
045230100
P8
P8
P8
P8
P8
P8
P8
1
2
4
5
6
7
8
Power Supply Triple
PS0000037
PS0000037
PS0000037
PS0000037
PS0000037
PS0000038
PS0000038
J1
J1
J1
J1
J1
J1
J1
3
1
6
4
5
3
1
Power Supply Triple
Power Supply Triple
Power Supply Triple
Power Supply Triple
Power Supply Single
Power Supply Single
046710000 CBL, MOTHERBOARD TO XMITTER BD (MULTIDROP OPTION)
GND
RX0
RTS0
TX0
CTS0
RS-GND0
RTS1
CTS1/485-
RX1
TX1/485+
RS-GND1
RX1
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
P12
P12
P12
P12
P12
P12
P12
P12
P12
P12
P12
P12
P12
P12
2
Xmitter bd w/Multidrop 069500000
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
2
14
13
12
11
10
8
6
9
7
5
14 Xmitter bd w/Multidrop 069500000
13 Xmitter bd w/Multidrop 069500000
12 Xmitter bd w/Multidrop 069500000
11 Xmitter bd w/Multidrop 069500000
10 Xmitter bd w/Multidrop 069500000
8
6
9
7
5
9
7
5
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
9
7
5
TX1/485+
RS-GND1
063750000 CBL, CO2, O2 SENSOR THERM/HTR
O2-L
O2-N
Shield
O2TA
Relay Board
Relay Board
Relay Board
O2 sensor therm./htr
O2 sensor therm./htr
045230100
045230100
045230100
043420000
043420000
P18
P18
P18
P1
P1
P1
9
O2 sensor therm./htr
043420000
043420000
043420000
058021100
058021100
058021100
058021100
040400000
040400000
040400000
040400000
040400000
040400000
P1
P1
P1
P27
P27
P27
P27
P1
P2
P3
P4
P5
4
2
10 O2 sensor therm./htr
12 O2 sensor therm./htr
3
1
2
1
1
1
2
3
4
5
Motherboard
Motherboard
Motherboard
Motherboard
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
4
11
6
13
4
6
3
1
2
O2TB
CO2THA
CO2THB
CO2-11B
CO2-12B
CO2-11A
CO2TS1
CO2TS2
CO2-12A
CO2 sensor therm./htr 041920000
CO2 sensor therm./htr 041920000
P1
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
Relay Board
045230100
045230100
045230100
045230100
045230100
045230100
P18
P18
P18
P18
P18
P18
P6
5
07275B DCN6418
D-3
Download from Www.Somanuals.com. All Manuals Search And Download.
T80X Interconnect List
(Reference: 073800100A DCN6418)
FROM
TO
Cable PN Signal
Assembly
PN
J/P Pin Assembly
PN
J/P
Pin
066470000 CBL, CO2 & O2 SENSORS DC PWR
O2 SIGNAL -
O2 SIGNAL +
Shield
DGND
+5V
+12V RET
+12V
Motherboard
Motherboard
Motherboard
O2 Sensor
O2 Sensor
CO2 Sensor
CO2 Sensor
058021100 P109
058021100 P109
058021100 P109
7
1
9
5
6
O2 Sensor
O2 Sensor
OP0000030
OP0000030
P1
P1
9
10
OP0000030
OP0000030
OP0000033
OP0000033
P1
P1
Relay Board
Relay Board
045230100
045230100
045230100
045230100
P5
P5
P5
P5
1
2
7
8
P1 GND Relay Board
P1
L
Relay Board
066830000 CBL, FLOW MODULE
DGND
+5V
DGND
+5V
+12V RET
+12V
P/Flow Sensor AGND
P/Flow Sensor +15V
Pressure signal 1
Pressure signal 2
Flow signal 1
Shield
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
Relay Board
Relay Board
Relay Board
Relay Board
P/Flow Sensor board 040030100
P/Flow Sensor board 040030100
P/Flow Sensor board 040030100
P/Flow Sensor board 040030100
CO2 Sensor
CO2 Sensor
066970000
066970000
066970000
066970000
045230100
045230100
045230100
045230100
P14
P14
P14
P14
P11
P11
P11
P11
P1
P1
P1
P1
P1
8
1
2
3
7
8
3
4
2
4
5
S
V
O
Relay Board
Relay Board
Relay Board
Relay Board
Chassis fan
Chassis fan
P/Flow Sensor board
P/Flow Sensor board
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
045230100
045230100
045230100
045230100
040010000
040010000
040030100
040030100
058021100
058021100
058021100
058021100
058021100
058021100
P10
P10
P11
P11
P1
P1
P1
P1
P110
P110
P110
P110
P110
P110
1
2
1
2
1
2
3
6
6
5
4
12
3
9
CO2+
CO2-
OP0000033
OP0000033
P1
06737
06738
CBL, I2C to AUX I/O (ANALOG IN OPTION)
ATX-
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
058021100 J106
058021100 J106
058021100 J106
058021100 J106
058021100 J106
058021100 J106
058021100 J106
1
2
3
4
5
6
8
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
067300000
067300000
067300000
067300000
067300000
067300000
067300000
J2
J2
J2
J2
J2
J2
J2
1
2
3
4
5
6
8
ATX+
LED0
ARX+
ARX-
LED0+
LED1+
CBL, CPU COM to AUX I/O (MULTIDROP OPTION)
RXD
DCD
DTR
TXD
DSR
GND
CTS
RTS
RI
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
1
2
3
4
5
6
7
8
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
Xmitter bd w/Multidrop 069500000
J3
J3
J3
J3
J3
J3
J3
J3
J3
1
2
3
4
5
6
7
8
10
067240000 COM1 10 Xmitter bd w/Multidrop 069500000
06738
CBL, CPU COM to AUX I/O (USB OPTION)
RXD
DCD
DTR
TXD
DSR
GND
CTS
RTS
RI
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
067240000 COM1
1
2
3
4
5
6
7
8
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
J3
J3
J3
J3
J3
J3
J3
J3
J3
1
2
3
4
5
6
7
8
10
067240000 COM1 10 Aux I/O PCA
06739
CBL, CPU ETHERNET TO AUX I/O
ATX-
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
CPU PCA
067240000 LAN
067240000 LAN
067240000 LAN
067240000 LAN
067240000 LAN
067240000 LAN
067240000 LAN
067240000 LAN
1
2
3
4
5
6
7
8
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
J2
J2
J2
J2
J2
J2
J2
J2
1
2
3
4
5
6
7
8
ATX+
LED0
ARX+
ARX-
LED0+
LED1
LED1+
06741
07482
CBL, CPU USB TO FRONT PANEL
GND
LUSBD3+
LUSBD3-
CPU PCA
CPU PCA
CPU PCA
CPU PCA
067240000 USB
067240000 USB
067240000 USB
067240000 USB
8
6
4
2
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
066970000
066970000
066970000
066970000
J9
J9
J9
J9
VCC
CBL, HDMI, T-SERIES
LCD Interface PCA
066970000
J15
Transmitter PCA
068810000
J1
D-4
07275B DCN6418
Download from Www.Somanuals.com. All Manuals Search And Download.
ꢆ
ꢁ
Analog
Out J1020
Status
Out J1017
Control
In J1004
RS-232
J1013
RS-485
J1010 & 1011
ꢀ
ꢂ
ꢃ
ꢀ
ꢂ
ꢃ
06739
CN4 CN3
Motherboard
058021100
CN5
CPU 06724
J27
DOM
CP34
J3
J4
06738
04671
USB OPT
AC POWER
ENTRANCE
MD OPT
06375
J1
06738
MD OPT
J12
06746
CO2 Sensor
Therm
04342
P1
036490100
J15 J107
J106
J110
J109
CO2 Sensor
04023
OP33
CO2 Sensor
J1 801-Standard
ANALOG IN OPT
06760
AC POWER
SWITCH
Heater
04040
P1
P1
802-Option
03829
803-Standard
06737
O2 Sensor
Press/Flow
O2 Sensor
Therm/Htr
04342
OP30
PCA J1
J7
J3
J1 801-N/A
0400301
802-Standard
803-Standard
JP6
06647
PS1 (+5, /15)
SK1
Htr Config Plug
04030XXXX
J18
Fan
PS37
J5
SK2
J1
04001
04176
RELAY BOARD
0452301
PS2 (+12)
PS38
SK1
SK2
J8
J1
J10
J11
06683
JP5
JP7
TC Prog Plug
04976XXXX
Pump Config Plug
J20
07482
04289XXXX
04105
06741
J14
J15
J9
LCD Interface
J2
Int Pump
0424105
LCD w/Touchscreen
06790
06697
Cntrl Mod
J10
J2
KEY:
ꢀꢁꢂꢃꢄꢅꢆ ꢇꢈꢉꢊꢄ ꢅꢃꢁꢂꢇꢂ ꢅꢃꢄꢋꢃꢊꢁꢂꢃꢌꢇ ꢌꢂꢇꢊꢍꢃ ꢆꢃ
ꢎꢏꢐꢃꢉꢅꢑꢃꢄꢋꢃꢋꢒꢓꢈꢄꢊꢊꢂꢑꢃꢄꢅꢃꢋꢊꢇꢄꢔꢊꢂꢋꢊꢃ
TELEDYNE
Advanced Pollution Instrumentation
1. All part numbers in Italic identify
cables that are refered to in the
accompanying document 073800100
2. All items in Dashed boxes are
optional.
ꢔ
ꢅꢆꢄꢑꢂꢅꢔꢂꢃꢆ ꢇꢃꢇꢂꢆꢂꢇꢂꢅꢔꢂꢃ ꢅꢕꢍꢖꢃꢃ
A Teledyne Technologies Company
ꢗꢅꢉꢒꢊꢁ ꢇꢄꢘꢂꢑꢃꢒꢋꢂꢃꢓꢍꢃꢉꢅꢍ ꢅꢂꢃꢆ ꢇꢃꢉꢅꢍꢃ
ꢊꢁꢂꢇꢃꢌꢒꢇꢌ ꢋꢂꢋꢃꢄꢋꢃꢌꢇ ꢁꢄꢊꢂꢑꢖꢃꢃꢊꢁꢄꢋꢃ
ꢑ
ꢔꢒꢈꢂꢅꢊꢃ ꢇꢃꢉꢅꢃꢄꢅꢆ ꢇꢈꢉꢊꢄ ꢅꢃꢔ ꢅꢊꢉꢄꢅꢂꢑꢃ
ꢄꢅꢃꢄꢊꢃꢈꢉꢍꢃꢅ ꢊꢃꢓꢂꢃꢑꢒꢌꢕꢄꢔꢉꢊꢂꢑꢃꢙꢄꢊꢁ ꢒꢊꢃ
ꢌꢇ ꢌꢂꢇꢃꢉꢒꢊꢁ ꢇꢄꢘꢉꢊꢄ ꢅꢖ
ꢄ
ꢄ
ꢃ
ꢅ
ꢆ
ꢁ
07275B DCN6418
D-5
Download from Www.Somanuals.com. All Manuals Search And Download.
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