Teledyne Respiratory Product T802 Users Manual

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OPERATION MANUAL

MODEL T802

PARAMAGNETIC OXYGEN ANALYZER

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: api-sales@teledyne.com

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

Teledyne Advanced Pollution Instrumentation 14 January 2013

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-

sales@teledyne.com.

NOTICE OF COPYRIGHT

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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iii

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: sda_techsupport@teledyne.com

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

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CONSIGNES DE SÉCURITÉ

Des consignes de sécurité importantes sont fournies tout au long du présent

manuel dans le but d’éviter des blessures corporelles ou d’endommager les

instruments. Veuillez lire attentivement ces consignes. Chaque consigne de

sécurité est représentée par un pictogramme d’alerte de sécurité; ces

pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les

symboles correspondent aux consignes suivantes :

AVERTISSEMENT : Risque de choc électrique

DANGER : Oxydant puissant

AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne

complémentaire pour des renseignements spécifiques

MISE EN GARDE : Surface chaude

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

sans les outils appropriés pourrait entraîner des dommages aux pièces ou à

l’instrument.

Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent

être effectuées uniquement par du personnel de maintenance qualifié.

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

de la mise à la terre sécuritaire de l’instrument.

MISE EN GARDE

Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce

manuel. Si vous utilisez cet instrument d’une autre manière que celle pour

laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible

et entraîner des conséquences dangereuses.

NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz

combustibles!

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WARRANTY

WARRANTY POLICY (02024F)

Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of Teledyne

Instruments, Inc., provides that:

Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should

equipment failure occur, TAPI assures its customers that prompt service and support

will be available.

COVERAGE

After the warranty period and throughout the equipment lifetime, TAPI stands ready

to provide on-site or in-plant service at reasonable rates similar to those of other

manufacturers in the industry. All maintenance and the first level of field

troubleshooting are to be performed by the customer.

NON-TAPI MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by TAPI is warranted and will be repaired

to the extent and according to the current terms and conditions of the respective

equipment manufacturer’s warranty.

PRODUCT RETURN

All units or components returned to Teledyne API should be properly packed for

handling and returned freight prepaid to the nearest designated Service Center.

After the repair, the equipment will be returned, freight prepaid.

The complete Terms and Conditions of Sale can be reviewed at

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

CAUTION – Avoid Warranty Invalidation

Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and packing instructions

and Return Merchandise Authorization (RMA) procedures when returning parts for repair or calibration

may void your warranty. For anti-ESD handling and packing instructions please refer to “Packing

Components for Return to Teledyne API’s Technical Support” in the Primer on Electro-Static

Discharge section of this manual, and for RMA procedures please refer to our Website at

http://www.teledyne-api.com under Customer Support > Return Authorization.

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ABOUT THIS MANUAL

This operation manual, PN 07275, is comprised of multiple documents in

PDF format, as listed below.

Part No. Rev Name/Description

07275 B T802 Operation manual

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

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

06535 A Expendables Kit (located in Appendix B of this manual)

06532 C Repair Request Form (inserted as Appendix C in this manual)

Appendix D Documents:

0738001 A Interconnect List

07380 A Interconnect Diagram

05803 B SCH, PCA 05802, MOTHERBOARD, GEN-5

06698 D SCH, PCA 06697, INTRFC, LCD TCH SCRN

06882 B SCH, LVDS TRANSMITTER BOARD

06731 A SCH, AUXILLIARY-I/O BOARD

Note We recommend that this manual be read in its entirety before any attempt is

made to operate the instrument.

ORGANIZATION

This manual is divided among three main parts and a collection of appendices at

the end:

Part I contains introductory information that includes an overview of the

analyzer, specifications, descriptions of the available options, installation and

connection instructions, and the initial calibration and functional checks.

Part II comprises the operating instructions, which include setup and calibration,

as well as remote operation, and ends with the specifics of calibrating for use in

monitoring within EPA protocol.

Part III provides detailed technical information starting with maintenance,

troubleshooting and service, frequently asked questions, principles of operation, a

primer on electrostatic discharge, and a glossary.

The appendices at the end of the manual provide support information such as

version-specific software documentation, lists of spare parts* and recommended

stocking levels, and schematics.

*Part numbers do not reflect real-time updates – contact Sales or Technical

Support).

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CONVENTIONS USED

In addition to the safety symbols as presented in the Important Safety Information

page, this manual provides special notices related to the safety and effective use

of the analyzer and other pertinent information.

Special Notices appear as follows:

ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY

This special notice provides information to avoid damage to your

instrument and possibly invalidate the warranty.

IMPORTANT IMPACT ON READINGS OR DATA

Could either affect accuracy of instrument readings or cause loss of

data.

Note Pertinent information associated with the proper care, operation or

maintenance of the analyzer or its parts.

REVISION HISTORY

T802 Operation and Maintenance Manual, PN07275

Date Rev DCN Description

2013 January 14 B 6418 Administrative Updates and specs updates

2011 February 18 A 6005 Initial Release

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TABLE OF CONTENTS

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. SETUP MENU 69

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

LIST OF FIGURES

Figure 3-1: Front Panel Layout ......................................................................................................... 25

Figure 3-2. Display Screen and Touch Control................................................................................. 26

Figure 3-3.: Display/Touch Control Screen Mapped to Menu Charts................................................ 28

Figure 3-4: Rear Panel Layout.......................................................................................................... 29

Figure 3-5: Internal Layout................................................................................................................ 31

Figure 3-6: Analog In Connector....................................................................................................... 33

Figure 3-7: Analog Output Connector............................................................................................... 34

Figure 3-8: Current Loop Option Installed ........................................................................................ 35

Figure 3-9: Status Output Connector................................................................................................ 37

Figure 3-10: Control Input Connector ................................................................................................. 38

Figure 3-11: Concentration Alarm Relay ............................................................................................ 39

Figure 3-12: Default Pin Assignments, Rear Panel COM Port Connectors ....................................... 41

Figure 3-13. CPU Connector Pin-Outs for RS-232 Mode................................................................... 42

Figure 3-14: Jumper and Cables for Multidrop Mode ......................................................................... 44

Figure 3-15: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram........................................ 45

Figure 3-16: Pneumatic Connections–Basic Configuration–Using Bottled Span Gas ....................... 48

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

LIST OF TABLES

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

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

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

Table 3-2. Display Screen and Touch Control Description ............................................................. 27

Table 3-3. Rear Panel Component Descriptions............................................................................. 30

Table 3-4. Analog Input Pin Assignments ....................................................................................... 33

Table 3-5: Analog Output Pin-Outs ................................................................................................. 34

Table 3-6: Status Output Signals..................................................................................................... 37

Table 3-7: Control Input Signals ...................................................................................................... 38

Table 3-8: NISTSRMs Available for Traceability of O2 Calibration Gases ....................................... 47

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION

A-1 - T802 Software Menu Trees

A-2 - T802 Setup Variables for Serial I/O

A-3 - T802 Warnings and Test Functions

A-4 - T802 Signal I/O Definitions

A-5 - T802 DAS Functions

A-6 - T802 Terminal Command Designators

A-7 - T802 MODBUS® 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): 858-657-9800

E-MAIL: api-sales@teledyne.com

WEB SITE www.teledyne-api.com

Table 1-1. Analyzer Options

Option Option

Number Description/Notes Reference

Pumps Pumps meet all typical AC power supply standards while exhibiting same pneumatic

performance.

10A External Pump 100V - 120V @ 60 Hz N/A

10B External Pump 220V - 240V @ 50 Hz N/A

10C External Pump 220V - 240V @ 60 Hz N/A

10D External Pump 100V – 120V @ 50 Hz N/A

10E External Pump 100V @ 60 Hz N/A

14 Internal Pump N/A

13 High Voltage Internal Pump 240V @ 50Hz N/A

Rack Mount

Kits Options for mounting the analyzer in standard 19” racks

20A Rack mount brackets with 26 in. chassis slides N/A

20B Rack mount brackets with 24 in. chassis slides N/A

21 Rack mount brackets only (compatible with carrying strap, Option 29) N/A

23 Rack mount for external pump pack (no slides) N/A

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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual Introduction, Features and Options

Option Option

Number 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.

N/A

CAUTION - GENERAL SAFETY HAZARD

THE T802 WEIGHS ABOUT 28 POUNDS (12.7 KG). TAKE CARE TO

AVOID PERSONAL INJURY WHEN LIFTING/CARRYING THE

ANALYZER.

ALSO, DISCONNECT ALL CABLES AND TUBING FROM THE

ANALYZER BEFORE MOVING IT.

Analog Inputs w/USB port Used for connecting external voltage signals from other instrumentation (such as

meteorological instruments).

64B

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

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.

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

42A Expendables Kit for analyzer with a pump, includes a recommended

set of expendables for one year of operation. Appendix B

42D Expendables Kit for analyzer without a pump, includes a

recommended set of expendables for one year of operation. Appendix B

Communication Cables For remote serial, network and Internet communication with the analyzer.

Type Description

60A RS-232

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.

60B RS-232

Shielded, straight-through DB-9F to DB-9F cable of about

1.8 m length.

60C Ethernet

Patch cable, 2 meters long, used for Internet and LAN

communications.

60D USB

Cable for direct connection between instrument (rear

panel USB port) and personal computer.

Sections 3.3.1.8

and 6

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

relay option is different from and in addition to the “Contact Closures”

that come standard on all TAPI instruments.

Section 3.3.1.7

RS-232 Multidrop 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

Number Description/Notes Reference

USB COM Port

64A

Separate option if instrument not configured with Option 64B (analog

inputs). Disabled when using Multidrop or RS-485 communication.

Sections 3.3.1.8 and

6.4

Second Gas Sensor

67A Carbon Dioxide (CO2) Sensor 0-20% Sections 9.5, 12.2,

12.2.1 and 12.3.1

Special Features Built in features, software activated

N/A

Maintenance Mode Switch, located inside the instrument, places the

analyzer in maintenance mode where it can continue sampling, yet

ignore calibration, diagnostic, and reset instrument commands. This

feature is of particular use for instruments connected to Multidrop or

Hessen protocol networks.

Call Technical Support for activation.

N/A

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

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 SPECIFICATION

O2 Sensor

Ranges Min: 0-1% Full scale

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

Zero Noise1 < 0.02% (RMS)

Span Noise1 < 0.05% of reading (RMS)

Lower Detectable Limit2 < 0.04%

Zero Drift3 < ±0.02%/24 hours; < ±0.05%/7 days

Span Drift < ±0.1%/7 days

Accuracy < ±0.1%

Linearity < ±0.1%

Temperature Coefficient < ±0.01%/degree C

CO2 Sensor Option

Ranges Min: 0-1% Full scale

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

Zero Noise1 < 0.02% (RMS)

Span Noise1 < 0.1% of reading (RMS)

Lower Detectable Limit2 < 0.04%

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

Span Drift < ±0.1%/7 days

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

Temperature Coefficient < ±0.01%/degree C

Rise and Fall Time <60 seconds to 95%

Flow Rate 120ml ±20ml/min

Humidity Range 0-95% RH

Pressure Ran

e 25-31 in HG

AC Power 100V – 120V 60 Hz (77W); 220V – 240 V 50 Hz (80W)

Analog Output Ranges All Outputs: 0.1 V, 1 V, 5 V or 10 V

Three outputs convertible to 4-20 mA isolated current loop.

All Ranges with 5% under/over-range

Recorder Offset ± 10%

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

Standard I/O 1 Ethernet: 10/100Base-T

2 RS-232 (300 – 115,200 baud)

2 USB device ports

8 opto-isolated digital status outputs

6 opto-isolated digital control inputs

4 analog outputs

Optional I/O 1 USB com port

1 RS485

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: sda_techsupport@teledyne.com

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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!

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.

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.

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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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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

3.1.1. VENTILATION CLEARANCE

Whether the analyzer is set up on a bench or installed into an instrument rack, be

sure to leave sufficient ventilation clearance.

Table 3-1: Ventilation Clearance

AREA MINIMUM REQUIRED CLEARANCE

Back of the instrument 4 in.

Sides of the instrument 1 in.

Above and below the instrument 1 in.

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

manual for more information.

3.2. INSTRUMENT LAYOUT

Instrument layout shows front panel and display, rear panel connectors, and

internal chassis layout.

3.2.1. FRONT PANEL

Figure 3-1 shows the analyzer’s front panel layout, followed by a close-up of the

display screen in Figure 3-2, which is described in Table 3-3. The two USB ports

on the front panel are provided for the connection of peripheral devices:

 plug-in mouse (not included) to be used as an alternative to the touchscreen

interface

 thumb drive (not included) to download updates to instruction software

(contact TAPI Technical Support for information).

Figure 3-1: Front Panel Layout

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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

indicators before the main display appears, similar to Figure 3-2 above (may or

may not display a Fault alarm). The LEDs on the display screen indicate the

Sample, Calibration and Fault states; also on the screen is the gas concentration

field (Conc), which displays real-time readouts for the primary gas and for the

secondary gas if installed. The display screen also shows what mode the analyzer

is currently in, as well as messages and data (Param). Along the bottom of the

screen is a row of touch control buttons; only those that are currently applicable

will have a label. Table 3-2 provides detailed information for each component of

the screen.

ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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

control buttons.

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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

Table 3-2. Display Screen and Touch Control Description

Field Description/Function

LEDs indicating the states of Sample, Calibration and Fault, as follows:

Name Color State Definition

SAMPLE Green

Off

Blinking

Unit is not operating in sample mode, DAS is disabled.

Sample Mode active; Front Panel Display being updated; DAS data

being stored.

Unit is operating in sample mode, front panel display being updated,

DAS hold-off mode is ON, DAS disabled

CAL Yellow

Off

Blinking

Auto Cal disabled

Auto Cal enabled

Unit is in calibration mode

Status

FAULT Red Off

Blinking

No warnings exist

Warnings exist

Conc Displays the actual concentration of the sample gas currently being measured by the analyzer in the

currently selected units of measure

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

Param Displays a variety of informational messages such as warning messages, operational data, test function

values and response messages during interactive tasks.

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

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

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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

Figure 3-4: Rear Panel Layout

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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

cooling fan Pulls ambient air into chassis through side vents and exhausts through rear.

AC power

connector

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

Model/specs label Identifies the analyzer model number and provides power specs

SAMPLE

Inlet connection to be used for any one of the following:

 Sample gas

 Span gas

 Calibration gas

 Zero air

EXHAUST Connect an exhaust gas line of not more than 10 meters long here that leads outside

the shelter or immediate area surrounding the instrument.

SPAN 1 Not used.

SPAN2/VENT Not used.

ZERO AIR Not used.

RX TX LEDs indicate receive (RX) and transmit (TX) activity on the when blinking.

COM 2 Serial communications port for RS-232 or RS-485.

RS-232 Serial communications port for RS-232 only.

DCE DTE Switch to select either data terminal equipment or data communication equipment

during RS-232 communication.

STATUS For outputs to devices such as Programmable Logic Controllers (PLCs).

ANALOG OUT For voltage or current loop outputs to a strip chart recorder and/or a data logger.

CONTROL IN For remotely activating the zero and span calibration modes.

ALARM Option for concentration alarms and system warnings.

ETHERNET Connector for network or Internet remote communication, using Ethernet cable

ANALOG IN Option for external voltage signals from other instrumentation and for logging these

signals

USB Option for direct connection to personal computer, using USB com cable.

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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

Figure 3-5: Internal Layout

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Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

3.3. CONNECTIONS AND SETUP

This section presents the electrical (Section 3.3.1) and pneumatic (Section 3.3.2)

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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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

3.3.1.2. ANALOG INPUTS (OPTION 64) CONNECTIONS

The Analog In connector is used for connecting external voltage signals from

other instrumentation (such as meteorological instruments) and for logging these

signals in the analyzer’s internal DAS. The input voltage range for each analog

input is 0-10 VDC, and the input impedance is nominally 20kΩ in parallel with

0.1µF.

Figure 3-6: Analog In Connector

Pin assignments for the Analog In connector are presented in Table 3-4.

Table 3-4. Analog Input Pin Assignments

PIN DESCRIPTION DAS

PARAMETER1

1 Analog input # 1 AIN 1

2 Analog input # 2 AIN 2

3 Analog input # 3 AIN 3

4 Analog input # 4 AIN 4

5 Analog input # 5 AIN 5

6 Analog input # 6 AIN 6

7 Analog input # 7 AIN 7

8 Analog input # 8 AIN 8

GND Analog input Ground N/A

1 See Section 7 for details on setting up the DAS.

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

Channel A4 is special. It can be set by the user (see Section 5.9.6) to output any

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.

NALOG OUT

2 A3 A4

+ - + - + - + -

Figure 3-7: Analog Output Connector

Table 3-5: Analog Output Pin-Outs

PIN ANALOG OUTPUT VOLTAGE SIGNAL CURRENT SIGNAL

1 V Out I Out +

2 A1 Ground I Out -

3 V Out I Out +

4 A2 Ground I Out -

5 V Out I Out +

(Only used if CO2

sensor is installed) Ground I Out -

7 V Out NA

8 A4 Ground NA

3.3.1.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP

This option adds isolated, voltage-to-current conversion circuitry to the

analyzer’s analog outputs. 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

outputs can be found in Section 5.9.3.7.

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Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

Figure 3-8: Current Loop Option Installed

CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD

VOLTAGE OUTPUTS

CAUTION

Servicing or handling of circuit components requires electrostatic discharge

(ESD) protection, i.e. ESD grounding straps, mats and containers. Failure to

use ESD protection when working with electronic assemblies will void the

instrument warranty. See Section 0 for more information on preventing ESD

damage.

To convert an output configured for current loop operation to the standard 0 to 5

VDC output operation:

1. Turn off power to the analyzer.

2. If a recording device was connected to the output being modified, disconnect

it.

3. Remove the top cover as follows:

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Section II Operating Instructions Teledyne API T802 Paramagnetic O2 Analyzer Operation Manual

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.

b) Place the second shunt on the two pins next to it (refer to Figure 3-8 for

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

panel labeled STATUS (see Figure 3-4). Pin-outs for this connector are:

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STATUS

1 2 3 4 5 6 7

SYSTEM OK

CONC VALI D

CAL MODE

SPAN CAL

CAL MODE – RANGE 2

Optional CO

CAL

Figure 3-9: Status Output Connector

Table 3-6: Status Output Signals

Rear Panel

Label Status Definition Condition

1 SYSTEM OK ON if no faults are present.

2 CONC VALID

OFF any time the HOLD OFF feature is active, such as during calibration or when

any faults exist invalidating the O2 measurement.

ON if concentration measurement is valid.

3 CAL MODE ON whenever the instrument is being calibrated. The Mode field

4 SPAN CAL ON whenever the instrument’s SPAN point is being calibrated.

5 RANGE2 CAL ON if unit is in high range of either the DUAL or AUTO range modes.

6 CO2 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.

7 & 8 SPARE

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

+ DC POWER + 5 VDC, 300 mA source (combined rating with Control Output, if used).

Digital Ground The ground level from the analyzer’s internal DC power supplies

3.3.1.6. CONNECTING THE CONTROL INPUTS

If you wish to use the analyzer to remotely activate the zero and span calibration

modes, several digital control inputs are provided through a 10-pin connector

labeled CONTROL IN on the analyzer’s rear panel.

There are two methods for energizing the control inputs. The internal +5V

available from the pin labeled “+” is the most convenient method (Figure 3-10,

left). However, if full isolation is required, an external 5 VDC power supply

should be used (Figure 3-10, right).

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CONTROL IN

A B C D E F U +

SPAN CAL

CAL MODE

CONTROL IN

A B C D E F U +

5 VDC

Power Supply

Local Power Connections External Power Connections

RANGE2 SPAN

CO2 o

tion CAL

SPAN CAL

CAL MODE

RANGE2 SPAN

CO2 o

tion CAL

Figure 3-10: Control Input Connector

Table 3-7: Control Input Signals

Input # Status Definition ON Condition

A CAL MODE The analyzer is placed in Calibration mode. The mode field of the display

will read O2 CAL R or O2 CAL ZR

B REMOTE SPAN CAL

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.

C RANGE2 CAL The analyzer is placed in span calibration mode as part of performing a High

Span calibration.

D CO2 CAL ONLY available if the optional CO2 is installed. Initiates calibration of the

CO2 sensor CO2 CAL R or CO2 CAL ZR

E & F SPARE

Digital Ground The ground level from the analyzer’s internal DC power supplies (same as

chassis ground)

U External Power input Input pin for +5 VDC required to activate Pins A – F.

+ 5 VDC output

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).

3.3.1.7. CONCENTRATION ALARM RELAY (OPTION 61)

The Teledyne API T-Series analyzers have an option for four (4) “dry contact”

relays on the rear panel of the instrument. This relay option is different from and

in addition to the “Contact Closures” that come standard on all TAPI instruments.

The relays have three pins that have connections on the rear panel (refer Figure

3-11). They are a Common (C), a Normally Open (NO), and a Normally Closed

(NC) pin.

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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 O2 Alarm 1 = xxx %

Alarm 3 Relay O2 Alarm 2 = xxx %

Alarm 2 Relay CO2 Alarm 1 = xxx % (If CO2 option is present)

Alarm 3 Relay 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-

485. In addition to using the appropriate cables (Table 1-1 describes the cable

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.

Configuration: Section 6.3

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.

Configuration: Section 6.4

RS-232 CONNECTION

For RS-232 communications with data terminal equipment (DTE) or with data

communication equipment (DCE) connect the applicable cable option (Table 1-1:

either a DB9-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

device. Adjust the DCE-DTE switch (Figure 3-4) to select DTE or DCE as

appropriate.

Configuration: Section 6.1 (and Section 6.5.2 for Hessen protocol).

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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

3-12).

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Figure 3-13. CPU Connector Pin-Outs for RS-232 Mode

To assist in properly connecting the serial ports to either a computer or a modem,

there are activity indicators just above the RS-232 port. Once a cable is

connected between the analyzer and a computer or modem, both the red and

green LEDs should be on.

 If the lights are not lit, use the small switch on the rear panel to switch it

between DTE and DCE modes

 If both LEDs are still not illuminated, make sure the cable is properly

constructed.

RS-232 MULTIDROP OPTION CONNECTION

When the RS-232 Multidrop option is installed, connection adjustments and

configuration through the menu system are required. This section provides

instructions for the internal connection adjustments, then for external

connections, and ends with instructions for menu-driven configuration.

Note Because the RS-232 Multidrop option uses both the RS232 and

COM2 DB9 connectors on the analyzer’s rear panel to connect the

chain of instruments, COM2 port is no longer available for separate

RS-232 or RS-485 operation.

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ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY

Printed Circuit Assemblies (PCAs) are sensitive to electro-static

discharges too small to be felt by the human nervous system. Failure to

use ESD protection when working with electronic assemblies will void

the instrument warranty. Refer to Section 13 for more information on

preventing ESD 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

Pins 21  22 as indicated in Figure 3-14. (Do this for all but the last

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

(again refer to Figure 3-14):

 J3 on the Multidrop/LVDS PCA to the CPU’s COM1 connector

(Note that the CPU’s COM2 connector is not used in Multidrop)

 J4 on the Multidrop/LVDS PCA to J12 on the motherboard

 J1 on the Multidrop/LVDS PCS to the front panel LCD

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Figure 3-14: Jumper and Cables for Multidrop Mode

(Note: If you are adding an instrument to the end of a previously configured chain,

remove the shunt between Pins 21  22 of JP2 on the Multidrop/LVDS PCA in

the instrument that was previously the last instrument in the chain.)

4. Close the instrument.

5. Referring to Figure 3-15 use straight-through DB9 male  DB9 female

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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Analyzer Analyzer Analyzer Last Analyzer

Female DB9

Male DB9

RS-232

COM2

RS-232

COM2

RS-232

COM2

RS-232

COM2

Host

RS-232 port

Ensure jumper is

installed between

JP2 pins 21



22 in

last instrument of

multidrop chain.

Figure 3-15: RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram

7. BEFORE communicating from the host, power on the instruments and check

that the Machine ID is unique for each (Section 5.7.16.5.2.9).

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).

Note 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 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 Type Nominal Concentration

2657a O2 in N2 2%

2658a O2 in N2 10%

2659a O2 in N2 21%

2619a1 CO2 in N2 0.5%

2620a1 CO2 in N2 1%

2622a1 CO2 in N2 2%

2624a1 CO2 in N2 3%

2744b1 CO2 in N2 7%

27451 CO2 in N2 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

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

inlets/outlets referred to in this section.

See Section 3.3.2 for information regarding the pneumatic setup of T802

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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ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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.

Calibrated N2

100%

Concentration

Calibrated O2

at 20.95% Span

Concentration

VENT

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

analyzer. Please refer to Figure 3-16.

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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.

Note Zero air and span gas flows should be supplied in excess of the 120 cm3/min

demand of the analyzer.

3.3.2.7. INPUT GAS VENTING

The span gas, zero air supply and sample gas line MUST be vented (Figure 3-16)

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

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

IMPORTANT Leak Check:

Run a leak check once the appropriate pneumatic connections

have been made; check all pneumatic fittings for leaks using the

procedures defined in Section 10.3.3.

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3.4. STARTUP, FUNCTIONAL CHECKS, AND INITIAL

CALIBRATION

IMPORTANT IMPACT ON READINGS OR DATA

The analyzer’s cover must be installed to ensure that the

temperatures of the internal components are properly controlled.

If you are unfamiliar with the theory of operation, we recommend that you read

Section 12. For information on navigating the analyzer’s software menus, see the

menu trees 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.

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 Displays blinking

“SAMPLE”

Instrument is in sample mode but is still in the process of

warming up.

Param

(Parameters) N/A

Displays menus,

parameters, and

messages.

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 Off The instrument’s calibration is not enabled.

Fault Red 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

troubleshooting guidelines in Section 11.

To view and clear warning messages, press:

Suppresses the

warning messages

Press CLR to clear the current

message.

If more than one warning is

active, the next message will take

its place.

Once the last warning has

been cleared, the RANGE

function will be displayed in

the analyzer’s main

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

TEST CAL MSG CLR SETUP

SAMPLE SYSTEM RESET

TEST CAL MSG CLR SETUP

SAMPLE SYSTEM RESET

TEST CAL MSG CLR SETUP

SYSTEM SYSTEM RESET

TEST CLR SETUP

MSG returns the active

warnings to the message

field.

STANDBY RANGE=100.00 % O2=XXX.XX

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

BOX TEMP WARN 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 Remote zero calibration failed while the dynamic zero feature was set to turned on

CO2 ALRM1 WARNING1, 2 Concentration alarm 1 is enabled and the measured CO2 level is ≥ the set point.

CO2 ALRM2 WARNING1, 2 Concentration alarm 2 is enabled and the measured CO2 level is ≥ the set point.

CO2 CELL TEMP WARN1 CO2 sensor cell temperature outside of warning limits.

CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased.

DATA INITIALIZED DAS data storage was erased.

O2 ALRM1 WARNING2 Concentration alarm 1 is enabled and the measured O2 level is ≥ the set point.

O2 ALRM2 WARNING2 Concentration alarm 2 is enabled and the measured O2 level is ≥ the set point.

O2 CELL TEMP WARN O2 sensor cell temperature outside of warning limits.

REAR BOARD NOT DET The CPU is unable to communicate with the motherboard.

RELAY BOARD WARN The firmware is unable to communicate with the relay board.

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

SAMPLE PRESS WARN Sample gas pressure outside of operational parameters.

SYSTEM RESET5 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

11.1.2).

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

Section 3.3.2 for instructions for connecting these gas sources.

The initial calibration should be carried out using the same reporting range set up

as used during the analyzer’s factory calibration. This will allow you to compare

your calibration results to the factory calibration as listed on the Final Test and

Validation Data Sheet.

If both available DAS parameters for a specific gas type are being reported via

the instrument’s analog outputs e.g. CONC1 and CONC2 when the DUAL

range mode is activated, separate calibrations should be carried out for each

parameter.

 Use the RNG1 button when calibrating for CONC1 (equivalent to LOW

RANGE).

 Use the RNG2 button when calibrating for CONC2 (equivalent to HIGH

RANGE).

The calibration procedures assume:

 that the zero point and span gases have been adjusted for known

interferents (Section 3.3.2.3)

 that the calibration gas will be supplied through the SAMPLE gas inlet on

the back of the analyzer (see Figure 3-4), and;

 that the pneumatic setup matches that described in Section 3.3.2.4.

Perform the following outline of procedures for each sensor:

1. Verify the Reporting Range settings as presented in Section 3.4.3.1 While it

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.

4. Perform the Zero/Span point calibration presented in Section 3.4.3.4.

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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of the instrument to finish readying the analyzer for operation. See Section 9.5

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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Verify/change these settings by pressing:

3.4.3.1. REPORTING RANGE SETTINGS

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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:

EXAMPLE

SAMPLE RANGE=100.00 % O2=XXX.XX

< TST TST > CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X RANGE CONTROL MENU

MODE SET DIL EXIT

SETUP X.X O2 DIL FACTOR:1.0 Gain

0 0 0 0 1 .0 ENTR EXIT

SETUP X.X O2 DIL FACTOR 10.0 Gain

0 0 0 1 0 .0 ENTR EXIT

Toggle these buttons to

set the dilution factor.

This is the number by

which the analyzer will

multiply the O2

concentration of the gas

passing through the

reaction cell.

EXIT ignores the

new setting.

ENTR accepts the

new setting.

SETUP X.X CO2 DIL FACTOR:1.0 Gain

0 0 0 0 1 .0 ENTR EXIT

Only appears if the

optional CO2sensor

is installed.

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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.

O2 M-P CAL O2 SPAN CONC:20.95 %

0 2 0 .9 5 ENTR EXIT

SAMPLE GAS TO CAL:O2

O2 CO2 ENTR EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL CALZ CALS SETUP

O2 M-P CAL RANGE=100.00 % O2=XXX.XX

<TST TST> ZERO SPAN CONC EXIT

SAMPLE RANGE TO CAL:RNG1

RNG1 RNG2 ENTR EXIT

The O2span concentration value is

automatically default to

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 O2calibration

gas.

EXIT ignores the new

setting and returns to

the previous display.

ENTR accepts the new

setting and returns to

the

CONCENTRATION

MENU.

Only appears if either

the optional CO2sensor

is installed.

Only appears if the

analyzer is set for

DUAL range mode

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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.

O2 M-P CAL This is the basic calibration mode of the instrument and is activated by pressing the CAL key.

SETUP [X.X] 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”

CAL O2 Z[type] 2 & 3 Unit is performing O2 ZERO calibration procedure.

CAL O2 S[type] 2 & 3 Unit is performing O2 SPAN calibration procedure

CAL CO2 Z[type] 2 & 3 Unit is performing CO2 ZERO calibration procedure (when the optional CO2 sensor is installed).

CAL CO2 S[type] 2 & 3 Unit is performing CO2 SPAN calibration procedure (when the optional CO2 sensor is installed).

DIAG Mode 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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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

11.1.2).

To view these TEST functions, press,

Figure 4-2: Viewing Test Functions

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.

Note 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

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.

See Section 5.4.1 for more information.

CO2 Range1 CO2 RANGE % The range setting for the optional CO2 Sensor

Stability STABIL %

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.

Sample Pressure PRES In-Hg-A The absolute pressure of the Sample gas as measured by a

pressure sensor located inside the sample chamber.

Sample Flow SAMPLE FL cm3/min Sample mass flow rate as measured by the flow rate sensor in the

sample gas stream.

O2 Sensor

Slope O2 SLOPE - O2 slope, computed during zero/span calibration.

O2 Sensor Offset O2 OFFSET - O2 offset, computed during zero/span calibration.

Box Temperature BOX TEMP C The temperature inside the analyzer chassis.

O2 Cell

Temperature O2 CELL TEMP C The current temperature of the O2 sensor measurement cell.

CO2 Cell

Temperature1

CO2 CELL

TEMP C The current temperature of the CO2 sensor measurement cell.

CO2 Sensor

Slope1 CO2 SLOPE - CO2 slope, computed during zero/span calibration.

CO2 Sensor

Offset 1 CO2 OFFSET - CO2 offset, computed during zero/span calibration.

Current Time TIME - The current time. This is used to create a time stamp on DAS

readings, and by the AUTOCAL feature to trigger calibration events.

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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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

menu (Section 5.5) to prevent unauthorized or inadvertent configuration

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

MODE OR FEATURE MENU

ITEM DESCRIPTION MANUAL

SECTION

Analyzer Configuration CFG Lists key hardware and software configuration information 5.1

Auto Cal Feature ACAL (Special configuration; consult factory). 11.9

Internal Data Acquisition DAS Used to set up the DAS system and view recorded data 7

Analog Output Reporting

Range Configuration RNGE Used to configure the output signals generated by the

instruments Analog outputs. 5.4

Calibration Password

Security PASS Turns the calibration password feature ON/OFF 5.5

Internal Clock Configuration CLK Used to Set or adjust the instrument’s internal clock 5.6

Advanced SETUP features MORE This button accesses the instrument’s secondary setup

See

Table 6-5

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4.4.2. SECONDARY SETUP MENU (SETUP>MORE)

Table 6-5: Secondary Setup Mode Features and Functions

MODE OR FEATURE MENU

ITEM DESCRIPTION MANUAL

SECTION

External Communication

Channel Configuration COM

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.

5.7

System Status Variables VARS

Used to view various variables related to the instruments current

operational status

 Changes made to any variable will not be recorded in the

instrument’s memory until the ENTR key is pressed.

 Pressing the EXIT key ignores the new setting.

5.8

System Diagnostic Features

and

Analog Output Configuration

DIAG

Used to access a variety of functions that configure, test or

diagnose problems with a variety of the analyzer’s basic

systems.

Most notably, the menus to configure the output signals

generated by the instruments Analog outputs, are located here.

5.9

Alarm Limit Configuration1 ALRM Used to turn the instrument’s two alarms on and off as well as

set the trigger limits for each. 5.10

1 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:

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL SETUP

SETUP X.X SUPPORT: TELEDYNE-API.COM

PREV NEXT EXIT

Press EXIT at

any time to

return to the

SETUP menu

Press NEXT or PREV to scroll through the

following list of Configuration information:

MODEL TYPE, NUMBER AND NAME

PART NUMBER

SERIAL NUMBER

SOFTWARE REVISION

LIBRARY REVISION

OS REVISION

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

Use the SETUP>DAS menu to capture and record data. Refer to Section 7 for

configuration and operation details.

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5.4. SETUP  RNGE: ANALOG OUTPUT REPORTING RANGE

CONFIGURATION

5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING

RANGES

Functionally, the 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).

CONC RANGE1

Only active if the Optional CO

Sensor is installed

NALOG OUT

A1 A2 A3 A4

+ - + - + - + -

concentration

outputs

HIGH range when DUAL

mode is selected

Test Channel

LOW range when DUAL

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.

The output, labeled A4 is special. It can be set by the user (See Section 5.9.6) to

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

3.3.1.5).

To select the Analog Output Range Type press:

Upper span limit setting for the individual range modes are shared. Resetting the

span limit in one mode also resets the span limit for the corresponding range in

the other modes as follows:

SNGL DUAL AUTO

Range  Range1  Low Range

Range2  High Range

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5.4.3.1. RNGE  MODE  SNGL: CONFIGURING THE 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)

101 Configuration/Maintenance Access to Primary and Secondary SETUP Menus when PASSWORD is

enabled

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:

SETUP X.X PRIMARY SETUP MENU

CFG DAS RNGE PASS CLK MORE EXIT

SYSTEM PASSWORD ENABLE: OFF

OFF ENTR EXIT

SETUP X.X PASSWORD ENABLE: ON

ON ENTR EXIT

Toggle this

button to

enable, disable

password

feasture EXIT discards the new

setting

ENTR accepts the

new setting

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL SETUP

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Example: If all passwords are enabled, the following keypad sequence would be

required to enter the SETUP menu:

SYSTEM ENTER SETUP PASS:0

1 0 1 ENTREXIT

SYSTEM ENTER SETUP PASS:0

0 0 0 ENTR EXIT

EXAMPLE: This

password enables the

SETUP mode

Press individual

buttons to set

number

Analyzer enters selected menu

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL SETUP

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

This section introduces the communications setup menu; Section 6 provides the

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

manually or via DHCP. Please see Section 6.3 for configuration details.

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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

panel. Section 6.1 provides DCE DTE information.

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)

NO. VARIABLE DESCRIPTION ALLOWED

SETTINGS

VARS

Default

settings

0 DAS_HOLD_OFF

Changes the internal Data Acquisition System (DAS) HOLD

OFF timer:

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.

May be set for

intervals

between

0.5 – 20 min

15 min.

1 STABIL_GAS1 Selects which gas measurement is displayed when the

STABIL test function is selected. O2; CO2 O2

2 TPC_ENABLE

NOTE: It is strongly recommended that this variable

NOT be changed.

ON enables, OFF disables temperature and pressure

compensation

ON, OFF ON

3 DYN_ZERO

Special configuration;

consult factory

[Automatically adjusts offset and slope of the O2 response

when performing a zero point calibration during an AutoCal.] [ON, OFF] [OFF]

4 DYN_SPAN

Special configuration;

consult factory

[Automatically adjusts offset and slope of the O2 response

when performing a zero point calibration during an AutoCal.] [ON, OFF] [OFF]

5 CONC_PRECISION

Allows the user to set the number of significant digits to the

right of the decimal point display of concentration and

stability values.

AUTO, 1, 2,

3, 4 AUTO

6 CLOCK_ADJ 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 0 sec

7 SERVICE_CLEAR

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.

ON, OFF OFF

8 TIME_SINCE_SVC Displays time in hours since last service (restarted by the

SERVICE_CLEAR Variable). 0-50,000 0

9 SVC_INTERVAL Sets the interval in hours between service reminders. 0-100,000 0

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.

SETUP X.X 6) CLOCK_ADJUST=0 Sec/Day

PREV NEXT JUMP EDIT ENTR EXIT SETUP X.X CLOCK_ADJUST=0 Sec/Day

+0 0 ENTR EXIT Enter sign and number of

seconds per day the clock

gains (-) or loses(+)

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL MSG SETUP

SETUP X.X 0) DAS_HOLD_OFF=15.0 Minutes

PREV NEXT JUMP EDIT PRNT EXIT

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

PASSWORD

In all cases:

EXIT discards the new

setting

ENTR accepts the

new setting

SETUP X.X 3) DYN_ZERO=OFF

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X 4) DYN_SPAN=OFF

PREV NEXT JUMP EDIT PRNT EXIT

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

(MAX = 20 minutes).

SETUP X.X 5) CONC_PRECISION=AUTO

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X CONC_PRECISION=AUTO

AUTO1234 ENTREXIT

Use these buttons to select

the precision of the O2

concentration display

SETUP X.X 1) STABIL_GAS=O2

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X STABIL_GAS=NO

O2 CO2 ENTR EXIT Use these buttons to select

which gas will be reported

by the STABIL test function

(CO2 is only available if

the optional CO2 sensor is

installed)

SETUP X.X 2) TPC_ENABLE=ON

PREV NEXT JUMP EDIT PRNT EXIT

SETUP X.X TPC_ENABLE:ON

ON ENTR EXIT

Toggle to turn on or turn

OFF temperature pressure

compensation.

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5.9. SETUP  MORE  DIAG: DIAGNOSTICS FUNCTIONS

A series of diagnostic tools is grouped together under the

SETUPMOREDIAG menu. These tools can be used in a variety of

troubleshooting and diagnostic procedures and are referred to in many places of

the maintenance and trouble-shooting sections of this manual.

The various operating modes available under the DIAG menu are:

Table 5-3: Diagnostic Mode (DIAG) Functions

DIAG SUBMENU SUBMENU FUNCTION Front Panel Mode

Indicator

MANUAL

SECTION

SIGNAL I/O

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).

DIAG I/O 11.1.3

ANALOG OUTPUT

When entered, the analyzer performs an analog

output step test. This can be used to calibrate a

chart recorder or to test the analog output accuracy.

DIAG AOUT 11.6.9.2

ANALOG I/O

CONFIGURATION

This submenu allows the user to configure the

analyzer’s analog output channels, including

choosing what parameter will be output on each

channel. Instructions that appear here allow

adjustment and calibration of the voltage signals

associated with each output as well as calibration of

the analog to digital converter circuitry on the

motherboard.

DIAG AIO 5.9.3

PRESSURE

CALIBRATION1

This function is used to calibrate the Sample

Pressure sensor. DIAG PCAL 9.4.1

FLOW

CALIBRATION1

This function is used to calibrate the sample gas

flow. DIAG FCAL 9.4.2

TEST CHAN

OUTPUT

Selects one of the available test channel signals to

output over the A4 analog output channel. DIAG TCHN 5.9.6

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

<TST TST> CAL MSG SETUP

SETUP X.X PRIMARY SETUP MENU

CFG DAS ACAL 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

DIAG SIGNAL I/O

PREV NEXT ENTR EXIT

EXIT returns to the

SECONDARY SETUP

ENTR Activates the

selected DIAG

submenu

DIAG ANALOG OUTPUT

PREV NEXT ENTR EXIT

DIAG ANALOG I/O CONFIGURATION

PREV NEXT ENTR EXIT

DIAG FLOW CALIBRATION

PREV NEXT ENTR EXIT

DIAG TEST CHANNEL OUTPUT

PREV ENTR EXIT

DIAG PRESSURE CALIBRATION

PREV NEXT 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

troubleshooting purposes (Section 11.1.3). Refer to Appendix A for a complete

list of the parameters available for review under this menu.

IMPORTANT IMPACT ON READINGS OR DATA

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:

EXAMPLE

DIAG SIGNAL I / O

PREV NEXT JUMP ENTR EXIT

DIAG I / O 0) EXT_ZERO_CAL=OFF

PREV NEXT JUMP PRNT EXIT

Press JUMP to go

directly to a specific

signal

See Appendix A-4 for

a complete list of

available SIGNALS

DIAG I / O JUMP TO: 12

1 2 ENTR EXIT

EXAMPLE:

Enter 12 to Jump to

12) ST_SYSTEM_OK=ON

DIAG I / O 12) ST_SYSTEM_OK = ON

PREV NEXT JUMP ON PRNT EXIT

Exit to return

to the

DIAG menu

Press NEXT & PREV to

move between signal

types.

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

currently measured concentrating of O2 (see Section 5.4.2).

 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

current value of one of several test functions (see Table 5-8).

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

AOUT

CALIBRATED

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.

These values are stored in the memory and applied to the output signals by the CPU

automatically.

CONC_OUT_1

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

output level

 AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature

 CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this

one channel only.

CONC_OUT_2  Same as for CONC_OUT_1 but for analog channel A2 but only if Auto or Dual

range is selected (Oxygen high range, RNG2)

CONC_OUT_3  Same as for CONC_OUT_1 but for analog channel A3 but only if the optional CO2

sensor is installed.

TEST OUTPUT  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

XIN8

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.

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:

DIAG AIO AIN CALIBRATED: YES

<SET CAL EXIT

DIAG AIO TEST_OUTPUT: 5V,OVR, CAL

<SET SET> EDIT EXIT

DIAG AIO CONC_OUT_3: 5V, OVR, CAL

<SET SET> EDIT EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL MSG SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

SETUP X.X ENTER PASSWORD:818

8 1 8 ENTR EXIT

AIO Configuration Submenu

DIAG SIGNAL I/O

NEXT ENTR EXIT

Continue pressing NEXT until ...

DIAG ANALOG I/O CONFIGURATION

PREV NEXT ENTR EXIT

DIAG AIO AOUTS CALIBRATED: NO

SET> CAL EXIT

DIAG AIO CONC_OUT_1: 5V, OVR, CAL

<SET SET> EDIT EXIT

DIAG AIO CONC_OUT_2: 5V, OVR, CAL

<SET SET> EDIT EXIT

Toggle these

buttons to enter

the correct

PASSWORD

Adjusts the signal output

for Analog Output A1

Adjusts the signal output

for Analog Output A2

Scrolls to the parameter to be

output on the TEST channel and

adjusts its signal output

Adjusts the signal output

for Analog Output A3

(CO2Sensor Only)

(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 MINIMUM OUTPUT MAXIMUM OUTPUT

0.1V 0-100 mVDC -5 mVDC 105 mVDC

1V 0-1 VDC -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

CONFIGURATION submenu (see Section 5.9.3) then press,

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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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5.9.3.3. ENABLING OR DISABLING THE AUTOCAL FOR AN INDIVIDUAL ANALOG

OUTPUT

To enable or disable the AutoCal feature for an individual analog output, elect

the ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

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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

each analog output is enabled. (See Section 5.9.3.3)).

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

(See Section 5.9.3.3).

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,

10 or 1 count increments. See Figure 3-7 for pin assignments and diagram of the

analog output connector.

+DC Gnd

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

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

FULL

SCALE

ZERO

TOLERANCE

SPAN

VOLTAGE

SPAN

TOLERANCE

MINIMUM

ADJUSTMENT

(1 count)

0.1 VDC ±0.0005V 90 mV ±0.001V 0.02 mV

1 VDC ±0.001V 900 mV ±0.001V 0.24 mV

5 VDC ±0.002V 4500 mV ±0.003V 1.22 mV

10 VDC ±0.004V 4500 mV ±0.006V 2.44 mV

To adjust the signal levels of an analog output channel manually, select the

ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

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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-

20 milliamp signal (See Section 3.3.1.4).

 The outputs can be ordered scaled to any set of limits within that 0-20 mA

range, however most current loop applications call for either 0-20 mA or 4-20

mA range spans.

 All current loop outputs have a + 5% over range. Ranges whose lower limit is

set above 1 mA also have a –5 under range.

To switch an analog output from voltage to current loop, follow the instructions

in Section 5.9.3.1 (select CURR from the list of options on the “Output Range”

menu).

Adjustment of the signal zero and span levels of the current loop output is done

by raising or lowering the voltage output of the D-to-A converter circuitry on the

analyzer’s motherboard. This raises or lowers the signal level produced by the

current loop option circuitry.

The software allows this adjustment to be made in 100, 10 or 1 count increments.

Since the exact amount by which the current signal is changed per D-to-A count

varies from output-to-output and instrument–to–instrument, you will need to

measure the change in the signal levels with a separate, current meter placed in

series with the output circuit. See Figure 3-7 for pin assignments and diagram of

the analog output connector.

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

CAUTION - GENERAL SAFETY HAZARD

Do not exceed 60 V peak voltage between current loop outputs and instrument ground.

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To adjust the zero and span signal levels of the current outputs, select the

ANALOG I/O CONFIGURATION submenu (see Section 5.9.3) then press:

An alternative method for measuring the output of the Current Loop converter is

to connect a 250 ohm 1% resistor across the current loop output in lieu of the

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current meter (see Figure 3-7 for pin assignments and diagram of the analog

output connector). This allows the use of a voltmeter connected across the

resistor to measure converter output as VDC or mVDC.

+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: Current Loop Output Check

% FS Voltage across

Resistor for 2-20 mA

Voltage across

Resistor for 4-20 mA

0 500 mVDC 1000 mVDC

100 5000 mVDC 5000 mVDC

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5.9.4. 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

CONFIGURATION submenu (see Section 5.9.3) then press:

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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

CONFIGURATION submenu (see Section 5.9.3) then press:

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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 DESCRIPTION ZERO FULL SCALE

NONE Test Channel is turned off

SAMPLE PRESSURE

The absolute pressure of the Sample gas as

measured by a pressure sensor located inside

the sample chamber.

0 "Hg 40 "Hg

SAMPLE FLOW Sample mass flow rate as measured by the

flow rate sensor in the sample gas stream. 0 cm3/m 1000 cm3/m

O2 CELL TEMP The temperature of the gas inside the O2

sensor sample chamber. 0C 70C

CO2 CELL TEMP The temperature of the gas inside the optional

CO2 sensor sample chamber. 0C 70C

CHASSIS TEMP The temperature inside the analyzer chassis. 0C 70C

Once a function is selected, the instrument not only begins to output a signal on

the analog output, but also adds TEST to the list of test functions viewable via

the front panel display.

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

<TST TST> CAL SETUP

DIAG TEST CHAN:NONE

PREV NEXT ENTR EXIT

DIAG SIGNAL I/O

PREV NEXT ENTR EXIT

DIAG TEST CHAN OUTPUT

PREV NEXT ENTR EXIT

Continue pressing NEXT until ...

Toggle these buttons

to choose a mass flow

controller TEST

channel parameter DIAG TEST CHANNEL:SAMPLE PRESSURE

PREV NEXT ENTR EXIT EXIT discards the new

setting

ENTR accepts the

new setting

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

PASSWORD

(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

CONFIGURATION submenu (see Section 5.9.3) then press:

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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 AIO

IN1 GAIN:1.00V/V

SET> EDIT EXIT

DIAG ANALOG I / O CONFIGURATION

PREV NEXT ENTR EXIT

DIAG AIO AOUTS CALIBRATED: NO

< SET SET> CAL EXIT

DIAG AIO XIN1 GAIN:1.00V/V

+ 0 0 1 .0 0 ENTR EXIT

Press to change

Gain value

DIAG AIO XIN1:1.00,0.00,V,OFF

< SET SET> EDIT EXIT

Press SET> to scroll to the first

channel. Continue pressing SET>

to view each of 8 channels.

Pressing ENTR records the new setting

and returns to the previous menu.

Pressing EXIT ignores the new setting and

returns to the previous menu.

Press EDIT at any channel

to to change Gain, Offset,

Units and whether to display

the channel in the Test

functions (OFF/ON).

DIAG AIO XIN1 OFFSET:0.00V

< SET SET> EDIT EXIT

DIAG AIO XIN1 UNITS:V

< SET SET> EDIT EXIT

DIAG AIO XIN1 DISPLAY:OFF

< SET EDIT EXIT

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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

output connector on the instrument’s back panel (See Section 3.3.1.5). If the O2

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 LIMIT SET POINT1

O2 ALARM1 Disabled 10.00 %

O2 ALARM2 Disabled 30.0 %

CO2 ALARM11 Disabled 5.000 %1

CO2 ALARM21 Disabled 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

different modes, listed in Table 6-1. As modes are selected, the analyzer sums

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

MODE1 ID DESCRIPTION

QUIET 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 2 Computer mode inhibits echoing of typed characters and is used when the port is

communicating with a computer operated control program.

HESSEN

PROTOCOL 16 The Hessen communications protocol is used in some European countries. TELEDYNE

API PN 02252 contains more information on this protocol.

E, 8, 1 8192 When turned on this mode switches the COM port settings from

● NO PARITY; 8 data bits; 1 stop bit to EVEN PARITY; 8 data bits; 1 stop bit.

E, 7, 1 2048 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.

RS-485 1024 Configures the COM2 Port for RS-485 communication. RS-485 mode has precedence

over multidrop mode if both are enabled.

SECURITY 4 When enabled, the serial port requires a password before it will respond (see Section

8.4). The only command that is active is the help screen (? CR).

MULTIDROP

PROTOCOL 32 Multidrop protocol allows a multi-instrument configuration on a single communications

channel. Multidrop requires the use of instrument IDs.

ENABLE

MODEM 64 Enables to send a modem initialization string at power-up. Asserts certain lines in the

RS-232 port to enable the modem to communicate.

ERROR

CHECKING2 128 Fixes certain types of parity errors at certain Hessen protocol installations.

XON/XOFF

HANDSHAKE2 256 Disables XON/XOFF data flow control also known as software handshaking.

HARDWARE

HANDSHAKE 8 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

FIFO 512 Disables the HARDWARE FIFO (First In – First Out), When FIFO is enabled it improves

data transfer rate for that COM port.

COMMAND

PROMPT 4096 Enables a command prompt when in terminal mode.

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.

green (activity Flickers during any activity on the LAN.

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

be used. Section 6.3.2 details how to configure the instrument with a static IP

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

server(s). The Ethernet configuration properties (Table 6-3) are viewable via

the analyzer’s front panel display.

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Table 6-3: LAN/Internet Configuration Properties

PROPERTY DEFAULT STATE DESCRIPTION

DHCP ON

This displays whether the DHCP is turned ON or OFF.

Press EDIT and toggle ON for automatic configuration

after first consulting network administrator.

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.

GATEWAY IP

ADDRESS

0.0.0.0

Can only be edited when DHCP is set to OFF.

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.

SUBNET MASK 0.0.0.0

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.

TCP PORT1 3000

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.

HOST NAME T802

The name by which your analyzer will appear when

addressed from other computers on the LAN or via the

Internet. To change, see Section 6.3.2.1.

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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To view the above properties listed in Table 6-3, press:

(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).

ENTR accept

new settings

EXIT ignores

new settin

SETUP X.X PRIMARY SETUP MENU

CFG DAS RNGE PASS CL K MORE EXIT

SAMPLE ENTER SETUP PASS : 81

8 1 8 ENTR EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

< TST TST > CAL SETUP

SETUP X.X COMMUNICATIONS MENU

ID INET COM1 COM2 EXIT

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

SETUP X.X DHCP: ON

ON ENTR EXIT

SETUP X.X DHCP: ON

<SET SET> EDIT EXIT

SETUP X.X DHCP: OFF

OFF ENTR EXIT

(continues in next illustration)

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Internet Configuration Touchscreen Functions

BUTTON FUNCTION

[0] Press this key to cycle through the range of

numerals and avai lable character s (“0 – 9” & “ . ”)

<CH CH> Moves the cursor one character left or right.

DEL Deletes a char acter at the cursor location.

ENTR Accepts the new settin g an d returns to the pr evious

m enu .

EXIT Igno re s the new se ttin g and returns to the pr evio us

m enu .

Buttons ap pe ar only as applicable.

SETUP X.X DHCP: OFF

SET> EDIT EXIT

SETUP X.X INST IP: 000.000.000.000

<SET SET> EDIT EXIT

SETUP X.X GATEWAY IP: 000.000.000.000

<SET SET> EDIT EXIT

SETUP X.X INST IP: [0] 00.000.000

<CH CH> DEL [0] ENTR EXIT

SETUP X.X SUBNET MASK:255.255.255.0

<SET SET> EDIT EXIT

SETUP X.X SUBNET MASK:[2]55.255.255.0

<CH CH> DEL [?] ENTR EXIT

SETUP X.X TCP PORT 3000

<SET EDIT EXIT

The PORT number needs to re mai n at 3000.

Do not change this setting unless instructed to by

Teledyne API’s Customer Service personnel.

(Continued from preceding illustration)

SETUP X.X GATEWAY IP: [0] 00.000.000

<CH CH> DEL [?] ENTR EXIT

Cursor

location is

indicated by

brackets

SETUP X.X INITIALIZING INET 0%

…

INITIALIZING INET 100%

SETUP X.X INITIALIZATI0N SUCCEEDED

SETUP X.X INITIALIZATION FAILED

SETUP X.X

COMMUNICATIONS MENU

ID INET COM1 COM2 EXIT

Pre ssing EXIT from

any of the above

display menus

causes the Ethernet

card to reinitialize its

internal interface

firmware

Contact your IT

Network Administrator

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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 FUNCTION

<CH Moves the cursor one character to the left.

CH> Moves the cursor one character to the right.

INS Inserts a character before the cursor location.

DEL Deletes a character at the cursor location.

[?]

Press to cycle through the range of numerals

and characters available for insertion. 0-9, A-

Z, space ’ ~ !  # $ % ^ & * ( ) - _ = +[ ] { } <

>\ | ; : , . / ?

ENTR Accepts the new setting and returns to the

previous menu.

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 SECURITY MODE OFF

Computer Mode ON MULTIDROP MODE OFF

MODBUS RTU OFF ENABLE MODEM OFF

MODBUS ASCII OFF ERROR CHECKING ON

E,8,1 MODE OFF XON/XOFF HANDSHAKE OFF

E,7,1 MODE OFF HARDWARE HANDSHAKE OFF

RS-485 MODE 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.

Note  USB configuration requires that the baud rates of the instrument

and the PC match; check the PC baud rate and change if needed.

 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

Slave ID

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).

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

(examples used here are for

MODBUS Poll software)

1. Click Setup / [Read / Write Definition] /.

a. In the Read/Write Definition window (see example that follows) select a Function (what you

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

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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Example Read/Write Definition window:

Example Connection Setup window:

Example MODBUS Poll window:

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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

Baud Rate 300 – 115200 1200

Data Bits 8 7

Stop Bits 1 2

Parity None Even

Duplex Full Half

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

Section 6.2 and Table 6-1.

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

CMD 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.

BCC 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.

TEXT Responses from the instrument are always delimited with <CR> at the beginning and the end

of the string, regardless of the command encoding.

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:

RANGE1 or LOW and RANGE2 or HIGH (See Section 5.4.1).

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

added (see Section 6.5.2.6).

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

STATUS FLAG NAME DEFAULT BIT

ASSIGNMENT

WARNING FLAGS1

SAMPLE FLOW WARNING 0001

INVALID CONC

(The instrument’s front panel display will show the

concentration as “Warnings”)

0080

OPERATIONAL FLAGS1

In MANUAL Calibration Mode 0200

In O2 ZERO Calibration Mode3 0400

In CO2 ZERO Calibration Mode3 0400

In O2 SPAN Calibration Mode3 0800

In CO2 SPAN Calibration Mode3 0800

UNITS OF MEASURE FLAGS4

UGM 0000

MGM 2000

PPB 4000

PPM 6000

SPARE/UNUSED BITS 0001, 0002, 0004,

0008, 0010 0020, 0040,

0100, 1000, 8000

UNASSIGNED FLAGS (0000)

BOX TEMP WARNING O2 CONC ALARM 22

O2 CELL TEMP WARN ANALOG CAL WARNING

CO2 CELL TEMP WARN CAL MP O2

SAMPLE PRESS WARN CAL MP CO2

RELAY BOARD WARN REAR BOARD NOT DET

CANNOT DYN SPAN SYSTEM RESET

CANNOT DYN ZERO 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 Only applicable if the analyzer is equipped with an alarm option.

3 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

<TST TST> CAL SETUP

DEL deletes the

character currently

inside the cursor

brackets.

Press [?] repeatedly to cycle through

the available character set: 0-9

NOTE: Values of A-F can also be set

but are meaningless.

move the cursor

brackets “[ ]”

left and right along

the bit string.

SETUP X.X HESSEN STATUS FLAGS

<SET SET> EDIT EXIT

SETUP X.X COMMUNICATIONS MENU

ID HESN COM1 COM2 EXIT

SETUP X.X HESSEN VARIATION:TYPE1

SET> EDIT EXIT

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

Continue pressing SET> until ...

SETUP X.X BOX TEMP WARNING:0000

PREV NEXT EDIT PRNT EXIT

SETUP X.X O2 CELL TEMP WARNING:[0]000

<CH CH> INS DEL [0] ENTR EXIT

SETUP X.X O2 CELL TEMP WARN:0000

PREV NEXT EDIT PRNT EXIT

Continue pressing NEXT until desired

flag message is displayed

EXIT discards the

new setting

ENTR accepts the

new setting

INS Inserts a the

character at the

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

Section 5.7.1). The default ID code for the T802 analyzers is either “0” or 802.

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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.

Note The DAS can be disabled only by disabling or deleting its individual data

channels.

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

steady off

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.

blinking

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.

steady on Sampling normally.

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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

time a calibration is performed, etc.). See Section 7.1.4.2

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

PROPERTY DESCRIPTION

DEFAULT

SETTING SETTING RANGE

NAME The name of the data channel. “NONE” Up to 6 letters or digits 1

TRIGGERING

EVENT

The event that triggers the data channel to measure

and store the datum ATIMER Any available event

(see Appendix A-5).

NUMBER AND

LIST OF

PARAMETERS

A User-configurable list of data types to be

recorded in any given channel.

(PMTDET)

Any available parameter

(see Appendix A-5).

REPORT PERIOD The amount of time between each channel data

point.

000:01:00

(1 hour)

000:00:01 to

366:23:59

(Days:Hours:Minutes)

NUMBER OF

RECORDS

The number of reports that will be stored in the data

file. Once the limit is exceeded, the oldest data is

over-written.

100

1 to 30,000 (max), limited

by available storage

space. 2

RS-232 REPORT Enables the analyzer to automatically report

channel values to the RS-232 ports. OFF OFF or ON

CHANNEL

ENABLED

Enables or disables the channel. Allows a channel

to be temporarily turned off without deleting it. ON OFF or ON

CAL HOLD OFF Disables sampling of data parameters while

instrument is in calibration mode. 3 OFF OFF or ON

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

VARS menu (see Section 5.8.)

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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Triggering Events and Data Parameters/Functions for these default channels are:

Figure 7-1: Default DAS Channel Setup

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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.

Continue pressing NEXT to view remaining

DAS channels

SAMPLE RANGE=500.0 PPB NOX= XXXX

<TST TST> CAL SETUP

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X DATA ACQUISITION

VIEW EDIT EXIT

SETUP X.X CONC: DATA AVAILABLE

NEXT VIEW EXIT

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 %

PV10 PREV NX10 NEXT <PRM PRM> EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL MSG SETUP

SETUP X.X 102:04:55 STABIL=00.02

PV10 PREV NX10 NEXT <PRM PRM> EXIT

<PRM

PRM>

PV10

NX10

Button

Selects the previous parameter on the list

Selects the next parameter on the list

Moves the VIEW backward 1 record or channel

Moves the VIEW backward 10 records

Moves the VIEW forward 1 record or channel

Moves the VIEW forward 10 records

FUNCTION

Buttons only appear when when applicable.

DAS VIEW – Menu Button Functions

(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.

SETUP X.X

CFG ACAL RNGE PASS CLK MORE EXIT

SETUP X.X

VIEW EXIT

SETUP X.X

NEXT INS DEL PRNT

SETUP X.X

8 1 8 EXIT

Enters EDIT mode for the selected channel

<TST TST> CAL MSG

Exports the configuration of all data channels to the

RS-232 interface

Selects the previous data channel in the list

Inserts a new data channel into the list BEFORE the

selected channel

Selects the next data channel in the list

Deletes the currently selected data channel

Enters EDIT mode

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

4032 Event – number of data points this channel is set up to store

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

7.1.4 then press:

Starting at the EDIT CHANNEL MENU

SETUP X.X 0) CONC: ATIMER 2, 4032, RS232

NEXT INS DEL EDIT PRNT EXIT

SETUP X.X NAME: CONC

CONC——ENTREXIT 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 ’ ~ ! # $ % ^ &

* ( ) - _ = +[ ] { } < >\ | ; : , . / ?

SETUP X.X NAME: CONC

SET> EDIT EXIT

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.

SAMPLE MODE INST: Records instantaneous reading.

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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To define the REPORT PERIOD, follow the instruction shown in Section 7.1.4

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

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

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

Use the PREV and

NEXT buttons to

scroll to the DATA

CHANNEL to be

edited

SETUP X.X RS-232 REPORT: ON

OFF ENTR EXIT EXIT discards the new

setting

ENTR accepts the

new setting

Toggle to turn the

RS-232 REPORT

feature

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

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

Press PREV and

NEXT to scroll to the

DATA CHANNEL to

be edited

SETUP X.X CAL.HOLD OFF: OFF

OFF ENTR EXIT EXIT discards the new

setting

ENTR accepts the

new setting

Toggle to turn the

HOLDOFF feature

ON/OFF

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.

To set the length of the DAS_HOLD OFF period, see Section 11.1.3.

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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.

To disable a data channel, follow the instruction shown in Section 7.1.4 then

press:

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7.2. REMOTE DAS CONFIGURATION

The DAS can be configured and operated remotely via either the APICOM

interface or a terminal emulation program. (Refer to Section 8 of this manual for

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

HyperTerminal (see Figure 7-4 for example). It is best to start by downloading

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

troubleshooting. Figure 7-2 shows examples of APICOM’s main interface, which

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

listed in Table 8-1 and in Appendix A.

8.2.1.1. HELP COMMANDS IN INTERACTIVE MODE

Table 8-1: Terminal Mode Software Commands

COMMAND Function

Control-T 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).

(carriage return)

A carriage return is required after each command line is typed into the

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.

(backspace)

Erases one character to the left of the cursor location.

ESC

(escape)

Erases the entire command line.

?[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 is the command type (one letter; refer to Table 8-2) that defines the type of

command. Allowed designators are listed in Appendix A-6.

[ID] is the machine identification number (Section 5.7.1). Example: the

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

C Calibration

D Diagnostic

L Logon

T Test measurement

V Variable

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

(Section 6.2.1, Table 6-1).

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

<TST TST> CAL SETUP

If there is a problem initializing the

modem the message,

“MODEM NOT INITIALIZED”

will appear.

SETUP X.X COMMUNICATIONS MENU

ID INET COM1 COM2 EXIT

SETUP X.X COM1 MODE:0

<SET SET> EDIT EXIT

SETUP X.X COM1: INITIALIZE MODEM

<SET SET> INIT ENTR EXIT

SETUP X.X MODEM INITIALIZED

PREV NEXT OFF EXIT

Continue pressing <SET or SET> until ...

SETUP X.X INITIALIZING MODE

Test Runs

Automatically

SETUP X.X PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X SECONDARY SETUP MENU

COMM VARS DIAG EXIT

(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.

This is done by turning on the SECURITY MODE (Mode 4, Section 6.2.1).

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 940331 is the default password.

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.

SECTION 9.2 – Manual Calibration Checks and Calibration

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.

SECTION 9.3 – Assessing Calibration Quality

This section describes how to judge the effectiveness of a recently performed

calibration.

SECTION 9.4 – Calibration of the T802’s Electronic Subsystems

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

SECTION 9.5 – Calibration of the Optional CO2 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 Type Nominal Concentration

2657a O2 in N2 2%

2658a O2 in N2 10 %

2659a O2 in N2 21%

2619a1 CO2 in N2 0.5%

2620a1 CO2 in N2 1%

2622a1 CO2 in N2 2%

2624a1 CO2 in N2 3%

2744b1 CO2 in N2 7%

27451 CO2 in N2 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

IMPORTANT IMPACT ON READINGS OR DATA

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

calibration. See Section 11 for troubleshooting tips.

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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

Note When setting expected concentration values, consider impurities in your

span gas.

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

functions (Section 3.4.2 or Appendix A-3), all of which are automatically stored

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

different. If they are, refer to troubleshooting in Section 11.

Table 9-2: Calibration Data Quality Evaluation

FUNCTION MINIMUM VALUE OPTIMUM VALUE MAXIMUM VALUE

SLOPE 0.700 1.000 1.300

OFFSET -0.500 0.000 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.

If they are, refer to troubleshooting in Section 11.

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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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:

SETUP X.X PRIMARY SETUP MENU

CFG DAS ACAL RANG 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

DIAG SIGNAL I/O

PREV NEXT ENTR EXIT

Continue pressing NEXT until ...

DIAG FCAL ACTUAL FLOW: 120 CC/M

0120 ENTREXIT

Toggle to match the actual

flow as measured by the

external flow meter

EXIT discards the new

setting

ENTR accepts the

new setting

DIAG FLOW CALIBRATION

PREV NEXT ENTR EXIT

SAMPLE RANGE=100.00 % O2=XXX.XX

<TST TST> CAL SETUP

(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

when calibration the span point of your CO2 sensor option (Table 3-8).

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:

Press 3

times to return

SETUP X.X

CO2 O2 ENTR

<TST TST> SETUP

SETUP X.X

CFG DAS ACAL RANG PASS CLK EXIT

SETUP X.X

COMM DIAG ALRM EXIT

SETUP X.X 0) DAS_HOLD_OFF=15.0 Minutes

<PREV JUMP EDIT PRNT EXIT

SETUP X.X

<PREV NEXT> JUMP PRNT EXIT

SETUP X.X

O2 ENTR EXIT

SETUP X.X

EXIT

CO2and O2

options only

appear if

associated

sensors are

installed.

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

and troubleshooting are covered in Section 11 of this manual.

10.1. MAINTENANCE SCHEDULE

Table 10-1 shows a typical maintenance schedule for the analyzer. Please note

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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Table 10-1. T802 Maintenance Schedule

DATE PERFORMED

ITEM ACTION FREQ CAL

CHECK

REQ’D.

MANUAL

Particulate

Filter Replace Weekly or as

needed No 10.3.1

Verify Test

Functions

Record and

analyze

Weekly or after

any

Maintenance or

Repair

No 11.1.2

Pump

Diaphragm Replace Annually Yes 10.3.2

Perform Flow

Check Check Flow Annually No 10.3.4

Perform

Leak Check

Verify Leak

Tight

Annually or

after any

Maintenance or

Repair

No 10.3.3

Pneumatic

lines

Examine and

clean As needed Yes if

cleaned

Chassis Wipe down As needed

Only if

cover

removed

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Table 10-2: T802 Test Function Record

DATE RECORDED

FUNCTION OPERATING

MODE*

STABIL O2 ZERO CAL

PRES SAMPLE

O2SLOPE SPAN CAL

O2 OFFSET ZERO CAL

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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

performed on your instrument at the factory. Table 10-3 can be used as a basis

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 CONDITION BEHAVIOR INTERPRETATION

STABIL O2 Zero Cal Increasing  Pneumatic Leaks – instrument & sample system

Increasing > 1”  Pneumatic Leak between sample inlet and Sample Cell

 Change in sampling manifold

PRES Sample

Decreasing > 1”

 Dirty particulate filter

 Pneumatic obstruction between sample inlet and

sensor

 Obstruction in sampling manifold

Increasing  Pneumatic Leaks

 Contaminated zero gas

OFFSET Zero Cal

Decreasing  Contaminated zero gas

Increasing  Pneumatic Leaks – instrument & sample system

 Calibration system deteriorating

SLOPE Span Cal

Decreasing  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

presents a simple leak check procedure. Section 10.3.3.2 details a more thorough

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.

1. Attach the Flow Meter to the SAMPLE inlet port on the rear panel (Figure

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.

5. Follow the procedures defined in Section 11.6 to confirm that the analyzer’s

vital functions are working (power supplies, CPU, relay PCA, keyboard, etc.).

See Figure 3-5 for the general layout of components and sub-assemblies in the

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

message being displayed on the front panel. Table 11-1 lists warning messages,

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

recommended that proper operation of power supplies (See Section 11.6.2), the

relay board (See Section 11.6.5), and the A/D Board (See Section 11.6.9.1) be

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:

Suppresses the

warning messages

Press CLR to clear the current

message.

If more than one warning is

active, the next message will take

its place.

Once the last warning has

been cleared, the RANGE

function will be displayed in

the analyzer’s main

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 O2=XXX.XX

TEST CAL MSG CLR SETUP

SAMPLE RANGE=100 % O2=XXX.XX

<TST TST> CAL MSG SETUP

SAMPLE WARNING O2=XXX.XX

TEST CAL MSG CLR SETUP

SAMPLE SYSTEM RESET O2=XXX.XX

TEST CAL MSG CLR SETUP

MSG returns the active

warnings to the message

field.

SAMPLE RANGE=100.00 % O2=XXX.XX

<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

O2 CELL TEMP

WARN

The O2 cell temp is controlled at 50

 2 °C.

Bad heater

Bad temperature sensor

Bad relay controlling the heater

Entire relay board is malfunctioning

I2C bus malfunction

BOX TEMP

WARNING

Box Temp is

< 8 °C or > 50 °C.

NOTE: Box temperature typically runs ~7oc warmer than

ambient temperature.

Poor/blocked ventilation to the analyzer.

Stopped exhaust-fan

Ambient temperature outside of specified range

CANNOT DYN

SPAN Dynamic Span operation failed Measured concentration value is too high or low.

Concentration slope value to high or too low

CANNOT DYN

ZERO Dynamic Zero operation failed Measured concentration value is too high.

Concentration offset value to high.

CONFIG

INITIALIZED

Configuration and Calibration data

reset to original Factory state.

Failed disk on module

User erased data

DATA INITIALIZED Data Storage in DAS was erased Failed Disk on Module

User cleared data

REAR BOARD NOT

DET

Motherboard not detected on power

up.

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

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WARNING

MESSAGE FAULT CONDITION POSSIBLE CAUSES

RELAY BOARD

WARN

The CPU cannot communicate with

the Relay Board.

I2C bus failure

Failed relay board

Loose connectors/wiring

SAMPLE FLOW

WARN

Sample flow rate is < 80 cm3/min or

> 180 cm3/min

Failed sample pump

Blocked sample inlet/gas line

Dirty particulate filter

Leak downstream of critical flow orifice

Failed flow sensor/circuitry

SAMPLE PRES

WARN

Sample Pressure is <15 in-Hg or

> 35 in-Hg

Normally 29.92 in-Hg at sea level

decreasing at 1 in-Hg per 1000 ft of

altitude (with no flow – pump

disconnected).

If sample pressure is < 15in-Hg:

Blocked particulate filter

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

Bad pressure sensor/circuitry

SYSTEM RESET The computer has rebooted.

This message occurs at power on. If you have not cycled the

power on your instrument:

Failed +5 VDC power,

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

(As Displayed) INDICATED FAILURE(S)

TIME

Time of day clock is too fast or slow

To adjust See Section 5.6.

Battery in clock chip on CPU board may be dead.

RANGE

Incorrectly configured measurement range(s) could cause response problems with a

Data logger or chart recorder attached to one of the analog output.

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.

STABIL Indicates noise level of instrument or concentration of sample gas (See Section 11.3 for

causes).

PRES See Table 11-1 for SAMPLE PRES WARN

SAMPLE FL Check for gas flow problems (see Section 11.3).

O2 CELL TEMP Temperatures outside of the specified range or oscillating temperatures are cause for

concern

BOX TEMP If the box temperature is out of range, check fan in the power supply module. Areas to

the side and rear of instrument should allow adequate ventilation. See Table 11-1 for

BOX TEMP WARNING.

O2 SLOPE

Values outside range indicate

Contamination of the zero air or span gas supply

Instrument is miscalibrated

Blocked gas flow

Bad/incorrect span gas concentration due.

O2 OFFSET Values outside range indicate contamination of the zero air supply

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

Theory of Operation (found in Section 12), are useful for troubleshooting in three

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)

(Red)

I2C bus Health

(Watchdog Circuit)

Continuously ON

Continuously OFF

Failed/Halted CPU

Faulty Motherboard, Keyboard or Relay PCA

Faulty Connectors/Wiring between Motherboard,

Keyboard or Relay PCA

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

(

ellow

)

Sensor Heater

D5 (Yellow) – CO

Sensor Heater

(only with CO

option)

D1 (RED)

Watchdog Indicator

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

Table 11-4: Relay PCA Status LED Failure Indications

LED Color Function Status When LED Lit

(Energized State)

Status When LED Unlit

(Default State)

D1 Red Watchdog Circuit Cycles ON/OFF every 3 Seconds

under direct control of the analyzer’s CPU.

D2-D4 SPARE

D51 Yellow CO2 Sensor Cell heater Heating Not Heating

D6 Yellow O2 Sensor heater Heating Not Heating

D72 Green

D82 Green

D92 Green

D102 Green

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

described in Section 10.3.4. If this test shows the flow to be correct, check the

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

(See Section 10.3.2). Check the Spare Parts List for information on pump

rebuilding kits.

2. Check for leaks as described in Section 10.3.3. Repair the leaking fitting, line

and re-check.

3. Check for the sample filter and the orifice filter for dirt. Replace filters (See

10.3.1).

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.

1. Check for leaks in the pneumatic systems as described in Section 10.3.3.

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.

2. Check for leaks in the pneumatic systems as described in Section 10.3.3.

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.

2. Check for leaks in the pneumatic systems as described in 10.3.3.

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

the SIGNAL I/O function under the DIAG Menu (See Section 5.9). This

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

Section 10 discussed a variety of methods for identifying possible sources of

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: DC Power Test Point and Wiring Color Codes

NAME TEST POINT# TP AND WIRE COLOR

Dgnd 1 Black

+5V 2 Red

Agnd 3 Green

+15V 4 Blue

-15V 5 Yellow

+12V Ret (ground) 6 Purple

+12V 7 Orange

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

NAME # NAME #

MIN V MAX V

PS1 +5 Dgnd 1 +5 2 4.85 5.25

PS1 +15 Agnd 3 +15 4 13.5 16V

PS1 -15 Agnd 3 -15V 5 -13.5V -16V

PS1 Agnd Agnd 3 Dgnd 1 -0.05 0.05

PS1 Chassis Dgnd 1 Chassis N/A -0.05 0.05

PS2 +12 +12V Ret 6 +12V 7 11.75 12.5

PS2 Dgnd +12V Ret 6 Dgnd 1 -0.05 0.05

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.

1. Use the Signal I/O function (See Section 11.1.3 and Appendix A) to view the

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

voltmeter to measure the output as described in Section 5.9.3.6.

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 % CURRENT V(250 OHMS) CURRENT V(250 OHMS)

1 0 2 mA 0.5V 4 1

2 20 5.6 1.4 7.2 1.8

3 40 9.2 2.3 10.4 2.6

4 60 12.8 3.2 13.6 3.4

5 80 16.4 4.1 16.8 4.2

6 100 20 5 20 5

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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).

Under the DIAG SIGNAL I/O menu (See Section11.1.3), scroll through the

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

1 SYSTEM OK

2 CONC VALID

3 O2 ZERO CAL

4 O2 SPAN CAL

5 ZERO CAL RNG2

6 CO2 ZERO CAL

7 SPARE

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:

1. Incorrect cabling and connectors. See Section 3.3.1.8 for connector and pin-

out information.

2. The BAUD rate and protocol are incorrectly configured. See Section 6.2.2.

3. If a modem is being used, additional configuration and wiring rules must be

observed. See Section 8.3

4. Incorrect setting of the DTE – DCE switch is set correctly. See Section 6.1.

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.

3. Check to make sure the set up command is correct (See Section 8.3)

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.

2. Locate the assembly attached to the sample pump, see Figure 3-5.

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

ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY

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

void the instrument warranty. Refer to Section 13 for more

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

Why does the ENTR button

sometimes disappear on the

Front Panel Display?

During certain types of adjustments or configuration operations, the

ENTR button will disappear if you select a setting that is nonsensical

(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.

Why is the ZERO or SPAN

button not displayed during

calibration?

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%.

How do I enter or change the

value of my Span Gas?

Press the CONC button found under the CAL button of the main

SAMPLE display menus to enter the expected CO2 span

concentration. See Section 9.2.3.1 or for more information.

Why does the analyzer not

respond to span gas

Section 11.4 has some possible answers to this question.

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?

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

for either or both of these effects, see Section 5.9.5; - The analog

outputs are not calibrated, which can happen after a firmware

upgrade. - Both the electronic scale and offset of the analog outputs

can be adjusted (Section 5.9.3.2). Alternately, use the data logger

itself as the metering device during calibrations procedures.

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QUESTION ANSWER

How do I perform a leak check? See Section 10.3.3.

How do I measure the sample

flow?

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

cm3/min 10%. See Section 9.4.2.

What is the averaging time for

this instrument?

The default averaging time, optimized for ambient pollution

monitoring, is 60 seconds for stable concentrations and 10 seconds

for rapidly changing concentrations; See 12.5.9 for more information.

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: sda_techsupport@teledyne.com

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

Coil

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

Section 9.5 for more details.

 Stability of the CO2 sensor can be viewed via the front panel (see Section

9.5.3).

The CO2 concentration range is 0-20%. See Section 9.5.1 for information on

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.

SPRING O-RINGS

FILTER

CRITICAL

FLOW

ORIFICE

REA OF

LOW

PRESSURE

AREA OF

HIGH

PRESSURE

Sonic

Shockwave

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..

Flow/Pressure Sensor PCA

Optional CO2

Sensor Heater

Analog Outputs

Aout 1

Aout 4

Analog Outputs

(D/A) External Digital I/O

Power Up

Circuit

PC 104 Bus

PC 104

CPU Card

Disk on

Module

Flash

Chip

Aout 3

Aout 2

TEST CHANNEL OUTPUT

Status

Outputs

1 - 8

Control

Outputs

1 – 6

Optional

Current

Loop

Outputs

CPU

Status

LED

I2C Bus

O2Cell

Heater

Thermistor Interface

Box

Temperature

Sample Flow

Sensor

A/D

Converter

RELAY PCA

I2C

Status

LED

O2Range 2

O2Range 1

MOTHERBOARD

Sample Pressure

Sensor

Sensor Inputs

CO2(optional)

O2Sensor

Optional CO2

Sensor

Internal

Digital I/O

Concentration

O2Sensor

Temperature

CO2Sensor

Temperature

(Optionl)

BOX

Temperature

COM2

Female

RS232

Male Ethernet

USB COM

port

ANALOG

(

C Bus

)

COM1 (RS-232 only)

COM2 (RS-232 or RS-485)

or USB

Touchscreen

Dis

LVDS

transmitter

board

USB

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

system (DAS – Section 7). The LEDs on the DOM indicate power and

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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Power

Connection

for DC

Heaters

Status LED’s

(D2 through D16)

DC Power Supply

Test Points

Watchdog

Status LED (D1)

(JP5)

Thermocouple

Configuration

Jumpers

Thermocouple

Signal Output

I2C

Connector

alve Control

Drivers

Pump Power

Output

(JP7)

Pump AC

Configuration

Jumper

AC Power

DC Power

Distribution

Connectors

alve Control

Connector

(J2)

Connector for

AC Relays

K4 & K5

(J18)

Connector for AC Relays K4 & K5

Heater AC Power

Configuration

Jumpers

JP2

JP6

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

populated see Figure 12-11).

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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AC Relay Retainer

Plate

Retainer

Mounting

Screws

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

are described in Table 12-1, and their locations are illustrated in Figure 12-12.

Table 12-1: Relay PCA Status LEDs

LED Color Function Status When LED Lit

(Energized State)

Status When LED Unlit

(Default State)

D1 Red Watchdog Circuit Cycles ON/OFF every 3 Seconds

under direct control of the analyzer’s CPU.

D2-D4 SPARE

D51 Yellow CO2 Sensor Cell heater Heating Not Heating

D6 Yellow O2 Sensor heater Heating Not Heating

D72 Green

D82 Green

D92 Green

D102 Green

D11 - 16 SPARE

1 Only active when the optional CO2 sensor is installed

2 Not Used.

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(

ellow

)

Sensor Heater

D5 (Yellow) –CO

Sensor Heater (only with CO

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, 50C. 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.

See Section 5.9.3.2 for instructions on performing this calibration.

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

front panel display (See Section 11.1.2).

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

the user. (see Section 5.9.2). All four analog outputs are connected back to the

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

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).

CONTROL INPUTS

By applying +5VDC power supplied from an external source such as a PLC or

Data logger (See Section 3.3.1.6), Zero and Span calibrations can be initiated by

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

these five attributes. As illustrated in Figure 12-13, power enters the analyzer

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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RELAY PCA

SENSOR SUITES

LOGIC DEVICES

(e.g. CPU, I2C bus,

Touchscreen,

MotherBoard, etc.)

ON / OFF

SWITCH

PS 2

(+12 VDC)

COOLING

FAN(S)

PUMP

AC HEATERS

PS 1

ANALOG

SENSORS

(e.g. Temp Sensor,

Pressure Sensor,

Flow Sensor) Pre-Amplifiers

& Amplifiers

Solenoid

Drivers

AC POWER

DC POWER

POWER IN

+5 VDC

±15 VDC

CO2 SENSOR PCA

(when optional CO2

sensor installed)

O2Sensor

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

Analyzer Operations

Calibration Procedures

Configuration Procedures

Autonomic Systems

Diagnostic Routines

Memory Handling

DAS Records

Calibration Data

System Status Data

Interface Handling

Sensor Input Data

Display Messages

Touchscreen

Analog Output Data

RS232 & RS485

External Digital I/O

Measurement

Algorithm

ANALYZER

HARDWARE

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

PROTONS = 3

ELECTRONS = 3

NET CHARGE = 0

PROTONS = 3

ELECTRONS = 3

NET CHARGE = 0

Materials

Separate

PROTONS = 3

ELECTRONS = 2

NET CHARGE = -1

PROTONS = 3

ELECTRONS = 4

NET CHARGE = +1

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 10-25% RH

Walking across nylon carpet 1,500V 35,000V

Walking across vinyl tile 250V 12,000V

Worker at bench 100V 6,000V

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.

A quick comparison of the values in Table 13-1 with the those shown in Table

13-2, listing device susceptibility levels, shows why Semiconductor Reliability

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 10 100

VMOS 30 1800

NMOS 60 100

GaAsFET 60 2000

EPROM 100 100

JFET 140 7000

SAW 150 500

Op-AMP 190 2500

CMOS 200 3000

Schottky Diodes 300 2500

Film Resistors 300 3000

This Film Resistors 300 7000

ECL 500 500

SCR 500 1000

Schottky TTL 500 2500

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.

Wrist Str

Protective Mat

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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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

3. Follow steps 6 and 7 of Opening Shipments from Teledyne API’s Technical

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

(see Section 11.9 for contact information). Follow the instructions listed

above for working at the instrument rack and workstation.

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GLOSSARY

Note: Some terms in this glossary may not occur elsewhere in this manual.

Term Description/Definition

10BaseT an Ethernet standard that uses twisted (“T”) pairs of copper wires to transmit at

10 megabits per second (Mbps)

100BaseT same as 10BaseT except ten times faster (100 Mbps)

APICOM name of a remote control program offered by Teledyne-API to its customers

ASSY Assembly

CAS 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 carbon dioxide

C3H8 propane

CH4 methane

H2O water vapor

HC general abbreviation for hydrocarbon

HNO3 nitric acid

H2S hydrogen sulfide

NO nitric oxide

NO2 nitrogen dioxide

NOX nitrogen oxides, here defined as the sum of NO and NO2

NOy 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 ammonia

O2 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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Term Description/Definition

DAC Digital-to-Analog Converter

DAS Data Acquisition System

DCE Data Communication Equipment

DHCP 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 Diagnostics, the diagnostic settings of the analyzer.

DOM 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 Dynamic Random Access Memory

DR-DOS Digital Research DOS

DTE Data Terminal Equipment

EEPROM Electrically Erasable Programmable Read-Only Memory also referred to as a

FLASH chip or drive

ESD Electro-Static Discharge

ETEST Electrical Test

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 non-volatile, solid-state memory

FPI 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 a clocked, bi-directional, serial bus for communication between individual

analyzer components

IC 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 Internal Zero Span

LAN Local Area Network

LCD Liquid Crystal Display

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Term Description/Definition

LED Light Emitting Diode

LPM 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 Non-Dispersive Infrared

NIST-SRM National Institute of Standards and Technology - Standard Reference Material

PC Personal Computer

PCA Printed Circuit Assembly, the PCB with electronic components, ready to use

PC/AT Personal Computer / Advanced Technology

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 Programmable Logic Device

PLL Phase Lock Loop

PMT Photo Multiplier Tube, a vacuum tube of electrodes that multiply electrons

collected and charged to create a detectable current signal

P/N (or PN) Part Number

PSD 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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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 Storage and Retrieval of Aerometric Data

SLAMS State and Local Air Monitoring Network Plan

SLPM Standard Liters Per Minute of a gas at standard temperature and pressure

STP Standard Temperature and Pressure

TCP/IP Transfer Control Protocol / Internet Protocol, the standard communications

protocol for Ethernet devices

TEC Thermal Electric Cooler

TPC Temperature/Pressure Compensation

USB 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 Variables, the variable settings of the instrument

V-F Voltage-to-Frequency

Z/S Zero / Span

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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

A-1

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)

A-2 Error! Unknown document property name.Error! Unknown document property name.

This page intentionally left blank.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-3

APPENDIX A-1: Software Menu Trees, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)

PRIMARY SETUP

SAMPLE

MSG1CLR1SETUP

CALTEST1

CONCZERO SPAN

DASCFG ACAL CLKRNGE PASS MORE

1 Only appears when warning messages are active.

2Only appears if analyzer is equipped with CO2sensor option.

3Only appears on units with alarm option enabled.

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

ACAL is a special configuration; consult factory.

SECONDARY

SETUP MENU

Press to

cycle

through the

active

warning

messages.

Press to

clear an

active

warning

messages.

CO22

DIAGCOMM VARS ALAR3

RANGE=[Value] % 1

O2 RN1=[Value] %1

O2 RN2=[Value] %1

CO2 RNG=[Value]%2

STABIL=[Value] %

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

TIME=[HH:MM:SS]

LOW4HIGH4

O2 CO22

Figure A-1: Basic Sample Display Menu

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Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-4 Error! Unknown document property name.Error! Unknown document property name.

SETUP

PASS

DAS RNGE CLK MORE

ACALCFG

MODEL TYPE AND NUMBER

PART NUMBER

SERIAL NUMBER

SOFTWARE REVISION

LIBRARY REVISION

iCHIP SOFTWARE REVISION

HESSEN PROTOCOL

REVISION2

CPU TYPE & OS REVISION

DATE FACTORY

CONFIGURATION SAVED

Go to iDAS

Menu Tree

TIME DATE

OFF

DIL1

SAMPLE

Go to

SECONDARY SETUP

Menu Tree

1 Only appears if Dilution option is active.

2Only appears if Hessen protocol is active.

3CO2 mode only appears if analyzer is equipped

with the related sensor option.

4Only appears if the DUAL or AUTO range

modes are selected.

ACAL is a special configuration; consult factory.

SET

MODE

DUALSNGL AUTO O2 RANGE #14

O2 RANGE #24

CO2 RANGE3

Figure A-2: Primary Setup Menu (Except DAS)

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Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-5

SETUP

PASS

DAS RNGE CLK MOREACALCFG

SAMPLE

1 Editing an existing DAS channel will erase any

data stored on the channel options.

2Changing the event for an existing DAS channel

DOES NOT erase the data stored on the

channel.

ACAL is a special configuration; consult factory.

EDITVIEW

PREV NEXT

CONC

PNUMTC

CALDAT

FAST

DETAIL

Selects the data point to be viewed

Cycles through

parameters assigned

to this DAS channel

<PRM PRM>NX10NEXTPREVPV10

EDIT1PRNTDELINSNEXTPREV

ENTER PASSWORD: 818

NX10NEXTSET><SET

YES

NAME

EVENT

PARAMETERS

NUMBER OF RECORDS

REPORT PERIOD

RS-232 REPORT

CAL MODE

CHANNEL ENABLE

OFF NO

YES1

Sets the maximum number of

records recorded by this channel

Sets the time lapse between

each report

Create/edit the name of the channel

PREV NEXT

Cycles through list

of available trigger

events2

NOYES1

EDIT1PRNTDELINSNEXTPREV

PRNTEDITSET><SET

YES

Cycles through list of

currently active

parameters for this

channel

MAXMINAVGINST

PRECISIONSAMPLE MODEPARAMETER

Cycles through list of available &

currently active parameters for this

channel

NEXTPREV

VIEW

CONC

PNUMTC

CALDAT

FAST

DETAIL

Figure A-4: Primary Setup Menu (DAS)

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-6 Error! Unknown document property name.Error! Unknown document property name.

Go to Menu Tree

Go to

COMM / Hessen

Menu Tree

1E-Series: only appears if optional Ethernet PCA is

installed. When Ethernet PCA is present COM2

submenu disappears.

2Only appears if HESSEN PROTOCOL mode is ON

(See COM1 & COM2 – MODE submenu above).

3instrument IP, gateway ip & subnet mask are only

editable when DHCP is OFF.

4Although TCP PORT is editable regardless of the dhcp

state, do not change the setting for this property.

5HOST NAme is only editable when DHCP is ON.

6T-Series only.

ACAL is a special configuration; consult factory.

Figure A-5: Secondary Setup Menu (COMM & VARS)

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-7

SETUP

PASSDAS RNGE CLK MORE

ACAL

CFG

SAMPLE

COMM VARS DIAG

Go to DIAG Menu Tree

HESN2

INET1

ID ENTER PASSWORD: 818

ENTER PASSWORD: 818ENTER PASSWORD: 818

1E-Series: only appears if Ethernet Option is installed.

2Only appears if HESSEN PROTOCOL mode is ON.

ACAL is a special configuration; consult factory.

Go to COMM / VARS Menu

Tree Go to COMM / VARS Menu

Tree

COM1 COM2

EDITSET><SET

GAS LISTRESPONSE MODEVARIATION STATUS FLAGS

TYPE2TYPE1 CMDTEXTBCC

EDIT PRNTDELINSNEXTPREV

NOYES GAS TYPE

GAS ID

REPORTED

OFF

Set/create unique gas ID number

CO2

SET><SET

O2, 110, REPORTED

CO2, 111, REPORTED

Figure A-6: Secondary Setup Menu - HESSEN Submenu

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-8 Error! Unknown document property name.Error! Unknown document property name.

Figure A-7: Secondary Setup Menu (DIAG)

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-9

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 Duration of DAS hold off period.

STABIL_GAS — O2

CO2 4

O2 3,

CO2 1

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

ON enables contact closure

dynamic zero; OFF disables it.

DYN_SPAN — OFF OFF, ON

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.

CLOCK_ADJ Sec./Day 0 -60–60

Time-of-day clock speed

adjustment.

SERVICE_CLEAR8 — OFF OFF

ON resets the service interval

timer.

TIME_SINCE_SVC8 Hours 0 0–500000 Time since last service.

SVC_INTERVAL8 Hours 0 0–100000

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 Hours 2 0.1–100

Time until automatically

switching out of software-

controlled maintenance mode.

LATCH_WARNINGS8 — ON ON, OFF

ON enables latching warning

messages; OFF disables

latching.

CONV_TIME — 33 MS 33 MS, 66 MS,

133 MS,

266 MS,

533 MS,

1 SEC, 2 SEC

Conversion time for O2 and CO2

detector channels. Enclose value

in double quotes (“) when setting

from the RS-232 interface.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-10 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

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

Dwell time before taking each

sample.

O2_FILT_ADAPT3 — ON ON, OFF

ON enables O2 adaptive filter;

OFF disables it.

O2_FILT_SIZE3 Samples 60 1–500

O2 moving average filter size in

normal mode.

O2_FILT_ASIZE3 Samples 10 1–500

O2 moving average filter size in

adaptive mode.

O2_FILT_DELTA3 % 2 0.1–100

Absolute change in O2

concentration to shorten filter.

O2_FILT_PCT3 % 2 0.1–100

Relative change in O2

concentration to shorten filter.

O2_FILT_DELAY3 Seconds 20 0–300

Delay before leaving O2 adaptive

filter mode.

O2_DIL_FACTOR3 — 1 0.1–1000

Dilution factor for O2. Used only if

is dilution enabled with

FACTORY_OPT variable.

50 O2_CELL_SET3 ºC

Warnings:

45–55

30–70 O2 sensor cell temperature set

point and warning limits.

O2_CELL_CYCLE3 Seconds 10 0.5–30

O2 cell temperature control cycle

period.

O2_CELL_PROP3 — 1 0–10

O2 cell PID temperature control

proportional coefficient.

O2_CELL_INTEG3 — 0.1 0–10

O2 cell PID temperature control

integral coefficient.

O2_CELL_DERIV3 — 0 (disabled) 0–10

O2 cell PID temperature control

derivative coefficient.

O2_STD_CELL_TEMP3 ºK 323 1–500 Standard O2 cell temperature for

temperature compensation.

O2_STD_CELL_PRESS3 "Hg 28.50 1.00–50.00

Standard O2 cell pressure for

pressure compensation.

CO2_DWELL 1 Seconds 1 0.1–30

Dwell time before taking each

sample.

CO2_FILT_ADAPT 1 — ON ON, OFF

ON enables CO2 adaptive filter;

OFF disables it.

CO2_FILT_SIZE 1 Samples 48 1–300

CO2 moving average filter size in

normal mode.

CO2_FILT_ASIZE 1 Samples 12 1–300

CO2 moving average filter size in

adaptive mode.

CO2_FILT_DELTA 1 % 2 0.1–10

Absolute change in CO2

concentration to shorten filter.

CO2_FILT_PCT 1 % 10 0.1–100

Relative change in CO2

concentration to shorten filter.

CO2_FILT_DELAY 1 Seconds 90 0–300

Delay before leaving CO2

adaptive filter mode.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-11

Setup Variable Numeric

Units Default

Value Value Range Description

CO2_DIL_FACTOR 1 — 1 0.1–1000

Dilution factor for CO2. Used only

if is dilution enabled with

FACTORY_OPT variable.

50 CO2_CELL_SET 1 ºC

Warnings:

45–55

30–70 CO2 sensor cell temperature set

point and warning limits.

CO2_CELL_CYCLE 1 Seconds 10 0.5–30

CO2 cell temperature control

cycle period.

CO2_CELL_PROP 1 — 1 0–10

CO2 cell PID temperature control

proportional coefficient.

CO2_CELL_INTEG 1 — 0.1 0–10

CO2 cell PID temperature control

integral coefficient.

CO2_CELL_DERIV 1 — 0 (disabled) 0–10

CO2 cell PID temperature control

derivative coefficient.

CO2_STD_CELL_TEMP 1 ºK 323 1–500 Standard CO2 cell temperature

for temperature compensation.

CO2_STD_CELL_PRESS 1 "Hg 28.50 1.00–50.00

Standard CO2 cell pressure for

pressure compensation.

O2_TARG_SPAN13 % 20.95 0.1–100

Target O2 concentration during

span calibration of range 1.

O2_SLOPE13 — 1 0.5–2 O2 slope for range 1.

O2_OFFSET13 % 0 -10–10 O2 offset for range 1.

CO2_TARG_SPAN11 % 12 0.1–1000

Target CO2 concentration during

span calibration of range 1.

CO2_SLOPE11 — 1 0.5–5 CO2 slope for range 1.

CO2_OFFSET11 % 0 -10–10 CO2 offset for range 1.

O2_TARG_SPAN25 % 20.95 0.1–100

Target O2 concentration during

span calibration of range 2.

O2_SLOPE25 — 1 0.5–2 O2 slope for range 2.

O2_OFFSET25 % 0 -10–10 O2 offset for range 2.

CO2_TARG_SPAN24 % 12 0.1–1000

Target CO2 concentration during

span calibration of range 2.

CO2_SLOPE24 — 1 0.5–5 CO2 slope for range 2.

CO2_OFFSET24 % 0 -10–10 CO2 offset for range 2.

RANGE_MODE — SNGL SNGL,

DUAL,

AUTO

Range control mode. Enclose

value in double quotes (“) when

setting from the RS-232

interface.

CONC_RANGE1 % 100 0.1–500 D/A concentration range 1

CONC_RANGE2 % 100 0.1–500 D/A concentration range 2

CONC_RANGE3 2 % 15 0.1–500 D/A concentration range 3

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-12 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

Setup Variable Numeric

Units Default

Value Value Range Description

120 SAMP_FLOW_SET cc/m

Warnings:

80–180

0–6000 Sample flow set point for flow

calculation and warning limits.

SAMP_FLOW_SLOPE — 1 0.5–1.5

Sample flow slope correction

factor (adjusted flow = measured

flow x slope).

29.92 SAMP_PRESS_SET "Hg

Warnings:

15–35

0–100 Sample pressure set point for

pressure compensation and

warning limits.

30 BOX_SET ºC

Warnings:

8–50

5–60 Box temperature warning limits.

Set point is not used.

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,

1200,

2400,

4800,

9600,

19200,

38400,

57600,

115200

RS-232 COM1 baud rate.

Enclose value in double quotes

(“) when setting from the RS-232

interface.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-13

Setup Variable Numeric

Units Default

Value Value Range Description

MODEM_INIT —

“AT Y0 &D0

&H0 &I0 S0=2

&B0 &N6 &M0

E0 Q1 &W0”

Any character

in the allowed

character set.

Up to 100

characters

long.

RS-232 COM1 modem

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 BitFlag 0 0–65535 RS-232 COM2 mode flags.

(Same settings as

RS232_MODE.)

BAUD_RATE2 — 19200 300,

1200,

2400,

4800,

9600,

19200,

38400,

57600,

115200

RS-232 COM2 baud rate.

Enclose value in double quotes

(“) when setting from the RS-232

interface.

MODEM_INIT2 —

“AT Y0 &D0

&H0 &I0 S0=2

&B0 &N6 &M0

E0 Q1 &W0”

Any character

in the allowed

character set.

Up to 100

characters

long.

RS-232 COM2 modem

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 0–999999 RS-232 log on password.

MACHINE_ID ID 802 0–9999 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

NONE,

SAMPLE

PRESSURE

SAMPLE

FLOW,

O2 CELL

TEMP 3,

CO2 CELL

TEMP 1,

CHASSIS

TEMP

Diagnostic analog output ID.

Enclose value in double quotes

(“) when setting from the RS-232

interface.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-14 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

Setup Variable Numeric

Units Default

Value Value Range Description

REMOTE_CAL_MODE — O2 RANGE1

CO2 RANGE1

O2 RANGE1 3,

O2 RANGE2 5,

CO2 RANGE1

CO2 RANGE2

Range to calibrate during

contact-closure and Hessen

calibration. Enclose value in

double quotes (“) when setting

from the RS-232 interface.

PASS_ENABLE — OFF OFF, ON

ON enables passwords; OFF

disables them.

STABIL_FREQ Seconds 10 1–300

Stability measurement sampling

frequency.

STABIL_SAMPLES Samples 25 2–40

Number of samples in

concentration stability reading.

SERIAL_NUMBER —

“00000000 ” Any character

in the allowed

character set.

Up to 100

characters

long.

Unique serial number for

instrument. Enclose value in

double quotes (“) when setting

from the RS-232 interface.

DISP_INTENSITY — HIGH HIGH,

MED,

LOW,

DIM

Front panel display intensity.

Enclose value in double quotes

(“) when setting from the RS-232

interface.

I2C_RESET_ENABLE — ON OFF, ON I2C bus automatic reset enable.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-15

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

characters

long.

Time-of-day clock format flags.

Enclose value in double quotes

(“) when setting from the RS-232

interface.

“%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.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-16 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

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.

2 T-Series/E-Series: 802 with CO2 option or 803.

3 T-Series/E-Series: 802 or 803.

4 T-Series/E-Series: 801 or 803.

5 T-Series/E-Series: 802 only.

6 T-Series external analog input option.

7 E Series internet option.

8 T-Series only

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-17

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 Description

Warnings

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 O2 ALARM 1 WARN O2 concentration alarm limit #1 exceeded

WO2ALARM2 3 O2 ALARM 2 WARN O2 concentration alarm limit #2 exceeded

WCO2ALARM1 2 CO2 ALARM 1 WARN CO2 concentration alarm limit #1

exceeded

WCO2ALARM2 2 CO2 ALARM 2 WARN CO2 concentration alarm limit #2

exceeded

WSAMPFLOW SAMPLE FLOW WARN Sample flow outside of warning limits

specified by SAMP_FLOW_SET variable.

WSAMPPRESS SAMPLE PRESS WARN Sample pressure outside of warning limits

specified by SAMP_PRESS_SET

variable.

WBOXTEMP BOX TEMP WARNING

Chassis temperature outside of warning

limits specified by BOX_SET variable.

WO2CELLTEMP 3 O2 CELL TEMP WARN 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 Contact closure zero calibration failed

while DYN_ZERO was set to ON.

WDYNSPAN CANNOT DYN SPAN Contact closure span calibration failed

while DYN_SPAN was set to ON.

WREARBOARD REAR BOARD NOT DET Rear board was not detected during

power up.

WRELAYBOARD RELAY BOARD WARN Firmware is unable to communicate with

the relay board.

WFRONTPANEL FRONT PANEL WARN Firmware is unable to communicate with

the front panel.

WANALOGCAL ANALOG CAL WARNING 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”.

2 T-Series/E-Series: 801, 803 or 802 with CO2 option.

3 T-Series/E-Series: 802 or 803.

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.

8 T-Series/E-Series: 801 or 802 without CO2 option.

10 External analog input option.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-18 Error! Unknown document property name.Error! Unknown document property name.Error! Unknown do

Table A-3: Test Measurements

Name 1 Message Text Description

Test Measurements

O2RANGE 5

CO2RANGE 4

O2 RNG=500.0 %

CO2 RNG = 500.0 %

D/A range in single or auto-range modes.

O2RANGE1 5

CO2RANGE1 4

O2 RN1=500.0 %

CO2 RN1=500.0 %

D/A 1 range in independent range mode.

O2RANGE2 5

CO2RANGE2 4

O2 RN2=500.0 %

CO2 RN2=500.0 %

D/A 2 range in independent range mode.

O2RANGE 6

CO2RANGE 7

O2 RNG=100 %

CO2 RNG=100 %

D/A 3 range.

STABILITY STABIL=0.0 % 8

O2 STB=0.0 % 2 or

CO2 STB=0.0 % 2

Concentration stability.

SAMPPRESS PRES=29.9 IN-HG-A Sample pressure.

SAMPFLOW SAMP FL=100 CC/M Sample flow rate.

O2SLOPE 3 O2 SLOPE=0.980 O2 slope, computed during zero/span

calibration.

O2OFFSET 3 O2 OFST=1.79 % O2 offset, computed during zero/span

calibration.

CO2SLOPE 2 CO2 SLOPE=1.0000 CO2 slope, computed during zero/span

calibration.

CO2OFFSET 2 CO2 OFST=0.00 % CO2 offset, computed during zero/span

calibration.

O2CELLTEMP 3 O2 CELL TEMP=50.2 C O2 sensor cell temperature.

CO2CELLTEMP 2 CO2 CELL TEMP=50.2 C CO2 sensor cell temperature.

BOXTEMP BOX TEMP=35.5 C Internal chassis temperature.

O2 3 O2=0.00 % 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 AIN1=37.15 EU External analog input 1 value in

engineering units.

XIN2 10 AIN2=37.15 EU External analog input 2 value in

engineering units.

XIN3 10 AIN3=37.15 EU External analog input 3 value in

engineering units.

XIN4 10 AIN4=37.15 EU External analog input 4 value in

engineering units.

XIN5 10 AIN5=37.15 EU External analog input 5 value in

engineering units.

XIN6 10 AIN6=37.15 EU External analog input 6 value in

engineering units.

XIN7 10 AIN7=37.15 EU External analog input 7 value in

engineering units.

XIN8 10 AIN8=37.15 EU External analog input 8 value in

engineering units.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-19

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”.

2 T-Series/E-Series: 801, 803, or 802 with CO2 option.

3 T-Series/E-Series: 802 or 803.

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.

8 T-Series/E-Series: 801 or 802 without CO2 option.

10 External analog input option.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-20 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

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 Spare

I2C_RESET 6 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 0 0 = go into calibration mode

1 = exit calibration mode and go into measure mode

EXT_CAL_SPAN 1 0 = calibrate span

1 = calibrate zero

EXT_CAL_RANGE2 2 0 = calibrate range #2

1 = calibrate range #1

EXT_CAL_CO2 1 3 0 = calibrate CO2

1 = calibrate O2

4–5 Spare

6–7 Always 1

Control inputs, U14, J1006, pins 1–6 = bits 0–5, default I/O address 325 hex

0–5 Spare

6–7 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

1 = system OK

0 = any alarm condition or in diagnostics mode

ST_SYSTEM_OK2,

MB_RELAY_36 3

Controlled by MODBUS coil register

1 = conc. limit 1 exceeded

0 = conc. OK

ST_CONC_ALARM_1,

MB_RELAY_37 3

Controlled by MODBUS coil register

1 = conc. limit 2 exceeded

0 = conc. OK

ST_CONC_ALARM_2,

MB_RELAY_38 3

Controlled by MODBUS coil register

1 = auto-range 2 in use

0 = auto-range 1 in use

ST_AUTO_RANGE2,

MB_RELAY_39 3

Controlled by MODBUS coil register

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-21

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 0 0 = system OK

1 = any alarm condition

ST_CONC_VALID 1 0 = conc. valid

1 = warnings or other conditions that affect validity of

concentration

ST_CAL_MODE 2 0 = in calibration mode

1 = in measure mode

ST_CAL_SPAN 3 0 = calibrating span

1 = calibrating zero

ST_CAL_RANGE2 4 0 = calibrating range 2

1 = calibrating range 1

ST_CAL_CO2 1 5 0 = calibrating CO2

1 = calibrating O2

6–7 Spare

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 5 (input) 0 = maintenance mode

1 = normal mode

LANG2_SELECT 6 (input) 0 = select second language

1 = select first language (English)

SAMPLE_LED 8 (output) 0 = sample LED on

1 = off

CAL_LED 9 (output) 0 = cal. LED on

1 = off

FAULT_LED 10 (output) 0 = fault LED on

1 = off

AUDIBLE_BEEPER 14 (output) 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 Spare

CO2_CELL_HEATER 2 4 0 = CO2 sensor cell heater on

1 = off

O2_CELL_HEATER 4 5 0 = O2 sensor cell heater on

1 = off

CAL_VALVE 6 6 0 = let cal. gas in

1 = let sample gas in

O2_SPAN_VALVE 4, 6 7 0 = let O2 span gas in

1 = let zero gas in

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-22 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

Signal Name Bit or Channel

Number Description

CO2_SPAN_VALVE 2, 6 8 0 = let CO2 span gas in

1 = let zero gas in

VENT_VALVE 6 9 0 = open vent valve

1 = close vent valve

10–15 Spare

Rear board primary MUX analog inputs

0–3 Spare

4 Temperature MUX

5 Spare

O2_CONC_SENSOR 4 6 O2 concentration sensor

SAMPLE_PRESSURE 7 Sample pressure

8 Spare

REF_4096_MV 9 4.096V reference from MAX6241

SAMPLE_FLOW 10 Sample flow rate

CO2_CONC_SENSOR 2 11 CO2 concentration sensor

12–13 Spare (thermocouple input?)

14 DAC MUX

REF_GND 15 Ground reference

Rear board temperature MUX analog inputs

BOX_TEMP 0 Internal box temperature

1 Spare

CO2_CELL_TEMP 2 2 CO2 sensor cell temperature

3 Spare

O2_CELL_TEMP 4 4 O2 sensor cell temperature

5–7 Spare

Rear board DAC MUX analog inputs

DAC_CHAN_1 0 DAC channel 0 loopback

DAC_CHAN_2 1 DAC channel 1 loopback

DAC_CHAN_3 2 DAC channel 2 loopback

DAC_CHAN_4 3 DAC channel 3 loopback

Rear board analog outputs

CONC_OUT_1,

DATA_OUT_1

0 Concentration output #1,

Data output #1

CONC_OUT_2,

DATA_OUT_2

1 Concentration output #2,

Data output #2

CONC_OUT_3 1

DATA_OUT_3

2 Concentration output #3,

Data output #3

TEST_OUTPUT,

DATA_OUT_4

3 Test measurement output,

Data output #4

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-23

Signal Name Bit or Channel

Number Description

External analog input board, default I2C address 5C hex

XIN1 7 0 External analog input 1

XIN2 7 1 External analog input 2

XIN3 7 2 External analog input 3

XIN4 7 3 External analog input 4

XIN5 7 4 External analog input 5

XIN6 7 5 External analog input 6

XIN7 7 6 External analog input 7

XIN8 7 7 External analog input 8

1 T-Series/E-Series: 803 or 802 with CO2 option.

2 T-Series/E-Series: 801 or 803.

3 MODBUS option.

4 T-Series/E-Series: 802 or 803.

5 future

6 Future valve option.

7 T-Series: External analog input option.

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-24 Error! Unknown document property name.Error! Unknown document property name.Error! Unknown doc

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 Exit O2 zero calibration mode

EXO2SP 3 Exit O2 span calibration mode

EXO2MP 3 Exit O2 multi-point calibration mode

O2SLPC 3 O

2 slope and offset recalculated

EXCO2Z 1 Exit CO2 zero calibration mode

EXCO2S 1 Exit CO2 span calibration mode

EXCO2M 1 Exit CO2 multi-point calibration mode

CO2SLC 1 CO2 slope and offset recalculated

EXITDG Exit diagnostic mode

CONC1W Concentration limit 1 exceeded

CONC2W Concentration limit 2 exceeded

O2TMPW 3 O

2 sensor cell temperature warning

CO2TMW 1 CO2 sensor cell temperature warning

SFLOWW Sample flow warning

SPRESW Sample pressure warning

BTEMPW Box temperature warning

1 T-Series/E-Series: 801, 803 or 802 with CO2 option.

2 future.

3 T-Series/E-Series: 802 or 803.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-25

Table A-6: DAS Parameters

Name Description Units

O2SLP1 2 O

2 slope for range #1 —

O2SLP2 4 O

2 slope for range #2 —

O2OFS1 2 O

2 offset for range #1 %

O2OFS2 4 O

2 offset for range #2 %

CO2SL1 1 CO2 slope for range #1 —

CO2SL2 3 CO2 slope for range #2 —

CO2OF1 1 CO2 offset for range #1 %

CO2OF2 3 CO2 offset for range #2 %

O2ZSC1 2 O2 concentration for range #1 during zero/span calibration, just

before computing new slope and offset %

O2ZSC2 4 O2 concentration for range #2 during zero/span calibration, just

before computing new slope and offset %

CO2ZS1 1 CO2 concentration for range #1 during zero/span calibration, just

before computing new slope and offset %

CO2ZS2 3 CO2 concentration for range #2 during zero/span calibration, just

before computing new slope and offset %

O2CNC1 2 O

2 concentration for range #1 %

O2CNC2 4 O

2 concentration for range #2 %

CO2CN1 1 CO2 concentration for range #1 %

CO2CN2 3 CO2 concentration for range #2 %

STABIL Concentration stability #1 %

O2TEMP 2 O

2 sensor cell temperature C

O2DUTY 2 O

2 sensor cell temperature controller duty cycle Fraction

(0.0 = off,

1.0 = on full)

CO2TMP 1 CO2 sensor cell temperature C

CO2DTY 1 CO2 sensor cell temperature controller duty cycle Fraction

(0.0 = off,

1.0 = on full)

SMPFLW Sample flow cc/m

SMPPRS Sample pressure “Hg

BOXTMP Internal box temperature C

REFGND Ground reference (REF_GND) mV

RF4096 4096 mV reference (REF_4096_MV) mV

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-26 Error! Unknown document property name.Error! Unknown document property name.Error! Unknown doc

Name Description Units

XIN1 5 External analog input 1 value Volts

XIN1SLPE 5 External analog input 1 slope eng unit / V

XIN1OFST 5 External analog input 1 value eng unit

XIN2 5 External analog input 2 value Volts

XIN2SLPE 5 External analog input 2 slope eng unit / V

XIN2OFST 5 External analog input 2 value eng unit

XIN3 5 External analog input 3 value Volts

XIN3SLPE 5 External analog input 3 slope eng unit / V

XIN3OFST 5 External analog input 3 value eng unit

XIN4 5 External analog input 4 value Volts

XIN4SLPE 5 External analog input 4 slope eng unit / V

XIN4OFST 5 External analog input 4 value eng unit

XIN5 5 External analog input 5 value Volts

XIN5SLPE 5 External analog input 5 slope eng unit / V

XIN5OFST 5 External analog input 5 value eng unit

XIN6 5 External analog input 6 value Volts

XIN6SLPE 5 External analog input 6 slope eng unit / V

XIN6OFST 5 External analog input 6 value eng unit

XIN7 5 External analog input 7 value Volts

XIN7SLPE 5 External analog input 7 slope eng unit / V

XIN7OFST 5 External analog input 7 value eng unit

XIN8 5 External analog input 8 value Volts

XIN8SLPE 5 External analog input 8 slope eng unit / V

XIN8OFST 5 External analog input 8 value eng unit

1 T-Series/E-Series: 801, 803 or 802 with CO2 option.

2 T-Series/E-Series: 802 or 803.

3 T-Series/E-Series: 801 or 803.

4 T-Series/E-Series: 802 only.

5 T-Series: External analog input option.

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-27

APPENDIX A-6: Terminal Command Designators, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)

Table A-7: Terminal Command Designators

COMMAND ADDITIONAL COMMAND SYNTAX DESCRIPTION

? [ID] Display help screen and commands list

LOGON [ID] password Establish connection to instrument

LOGOFF [ID] Terminate connection to instrument

SET ALL|name|hexmask Display test(s)

LIST [ALL|name|hexmask] [NAMES|HEX] Print test(s) to screen

name Print single test

T [ID]

CLEAR ALL|name|hexmask Disable test(s)

SET ALL|name|hexmask Display warning(s)

LIST [ALL|name|hexmask] [NAMES|HEX] Print warning(s)

name Clear single warning

W [ID]

CLEAR ALL|name|hexmask Clear warning(s)

ZERO|LOWSPAN|SPAN [1|2] Enter calibration mode

ASEQ number Execute automatic sequence

COMPUTE ZERO|SPAN Compute new slope/offset

EXIT Exit calibration mode

C [ID]

ABORT Abort calibration sequence

LIST Print all I/O signals

name[=value] Examine or set I/O signal

LIST NAMES Print names of all diagnostic tests

ENTER name Execute diagnostic test

EXIT Exit diagnostic test

RESET [DATA] [CONFIG] [exitcode] Reset instrument

PRINT ["name"] [SCRIPT] Print DAS configuration

RECORDS ["name"] 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

D [ID]

CANCEL Halt printing DAS records

LIST Print setup variables

name[=value [warn_low [warn_high]]] Modify variable

name="value" Modify enumerated variable

CONFIG Print instrument configuration

MAINT ON|OFF Enter/exit maintenance mode

V [ID]

MODE Print current instrument mode

DASBEGIN [<data channel definitions>] DASEND Upload DAS configuration

CHANNELBEGIN propertylist CHANNELEND Upload single DAS channel

CHANNELDELETE ["name"] Delete DAS channels

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 DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-28 Error! Unknown document property name.Error! Unknown document property name.Error! Unknown doc

Table A-8: Terminal Key Assignments

TERMINAL KEY ASSIGNMENTS

ESC Abort line

CR (ENTER) Execute command

Ctrl-C Switch to computer mode

COMPUTER MODE KEY ASSIGNMENTS

LF (line feed) Execute command

Ctrl-T Switch to terminal mode

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-29

APPENDIX A-7: MODBUS® Register Map, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)

MODBUS Register

Address

(dec., 0-based)

Description Units

MODBUS Floating Point Input Registers

(32-bit IEEE 754 format; read in high-word, low-word order; read-only)

0 4 O

2 slope for range 1 —

2 6 O

2 slope for range 2 —

4 4 O

2 offset for range 1 %

6 6 O

2 offset for range 2 %

8 4 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 O

2 concentration for range 1 %

14 6 O

2 concentration for range 2 %

16 4 O

2 sensor cell temperature C

18 4 O

2 sensor cell temperature control duty cycle Fraction

20 Concentration stability %

22 Sample flow cc/m

24 Sample pressure “Hg

26 Internal box temperature C

28 Ground reference (REF_GND) mV

30 4096 mV reference (REF_4096_MV) mV

100 1 CO2 slope for range 1 —

102 5 CO2 slope for range 2 —

104 1 CO2 offset for range 1 %

106 5 CO2 offset for range 2 %

108 1 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 CO2 concentration for range 1 %

114 5 CO2 concentration for range 2 %

116 1 CO2 sensor cell temperature C

118 1 CO2 sensor cell temperature control duty cycle Fraction

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-30 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

MODBUS Register

Address

(dec., 0-based)

Description Units

130 7 External analog input 1 value Volts

132 7 External analog input 1 slope eng unit /V

134 7 External analog input 1 offset eng unit

136 7 External analog input 2 value Volts

138 7 External analog input 2 slope eng unit /V

140 7 External analog input 2 offset eng unit

142 7 External analog input 3 value Volts

144 7 External analog input 3 slope eng unit /V

146 7 External analog input 3 offset eng unit

148 7 External analog input 4 value Volts

150 7 External analog input 4 slope eng unit /V

152 7 External analog input 4 offset eng unit

154 7 External analog input 5 value Volts

156 7 External analog input 5 slope eng unit /V

158 7 External analog input 5 offset eng unit

160 7 External analog input 6 value Volts

162 7 External analog input 6 slope eng unit /V

164 7 External analog input 6 offset eng unit

166 7 External analog input 7 value Volts

168 7 External analog input 7 slope eng unit /V

170 7 External analog input 7 offset eng unit

172 7 External analog input 8 value Volts

174 7 External analog input 8 slope eng unit /V

176 7 External analog input 8 offset eng unit

MODBUS Floating Point Holding Registers

(32-bit IEEE 754 format; read/write in high-word, low-word order; read/write)

0 4 Maps to O2_TARG_SPAN1 variable; target conc. for range 1 %

2 6 Maps to O2_TARG_SPAN2 variable; target conc. for range 2 %

100 1 Maps to CO2_TARG_SPAN1 variable; target conc. for range 1 %

102 5 Maps to CO2_TARG_SPAN2 variable; target conc. for range 2 %

07275B DCN6418

Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418) Appendix A

Error! Unknown document property name.Error! Unknown document property name. A-31

MODBUS Register

Address

(dec., 0-based)

Description Units

MODBUS Discrete Input Registers

(single-bit; read-only)

0 Box temperature warning

1 4 O

2 cell temperature warning

2 Sample flow warning

3 Sample pressure warning

4 System reset warning

5 Rear board communication warning

6 Relay board communication warning

7 Front panel communication warning

8 Analog calibration warning

9 Dynamic zero warning

10 Dynamic span warning

11 Invalid concentration

12 4 In O2 zero calibration mode

13 4 In O2 span calibration mode

14 4 In O2 multi-point calibration mode

15 System is OK (same meaning as SYSTEM_OK I/O signal)

16 O2 concentration alarm limit #1 exceeded

17 O2 concentration alarm limit #2 exceeded

18 In Hessen manual mode

100 1 CO2 cell temperature warning

101 1 In CO2 zero calibration mode

102 1 In CO2 span calibration mode

103 1 In CO2 multi-point calibration mode

104 1 CO2 concentration alarm limit #1 exceeded

105 1 CO2 concentration alarm limit #2 exceeded

07275B DCN6418

Appendix A Models T802, 802E Appendix A Menu Trees (Reference: 06530C DCN6418)

A-32 Error! Unknown document property name.Error! Unknown document property name. Error!

Unknown document property name.Error! Unknown document property name.

MODBUS Register

Address

(dec., 0-based)

Description Units

MODBUS Coil Registers

(single-bit; read/write)

0 Maps to relay output signal 36 (MB_RELAY_36 in signal I/O list)

1 Maps to relay output signal 37 (MB_RELAY_37 in signal I/O list)

2 Maps to relay output signal 38 (MB_RELAY_38 in signal I/O list)

3 Maps to relay output signal 39 (MB_RELAY_39 in signal I/O list)

20 3,4 Triggers O2 zero calibration of range 1 (on enters cal.; off exits cal.)

21 3,4 Triggers O2 span calibration of range 1 (on enters cal.; off exits cal.)

22 6,4 Triggers O2 zero calibration of range 2 (on enters cal.; off exits cal.)

23 6,4 Triggers O2 span calibration of range 2 (on enters cal.; off exits cal.)

24 1,3 Triggers CO2 zero calibration of range 1 (on enters cal.; off exits cal.)

25 1,3 Triggers CO2 span calibration of range 1 (on enters cal.; off exits cal.)

26 5,3 Triggers CO2 zero calibration of range 2 (on enters cal.; off exits cal.)

27 5,3 Triggers CO2 span calibration of range 2 (on enters cal.; off exits cal.)

1 T-Series/E-Series: 801, 803 or 802 with CO2 option.

2 future.

3 Set DYN_ZERO or DYN_SPAN variables to ON to enable calculating new slope or offset. Otherwise a calibration check

is performed.

4 T-Series/E-Series: 802 or 803.

5 T-Series/E-Series: 801 or 803.

6 T-Series/E-Series: 802 only.

7 T-Series: External analog input option.

07275B DCN6418

APPENDIX B - Spare Parts

Note

Use of replacement parts other than those supplied by Teledyne Advanced

Pollution Instrumentation (TAPI) may result in non-compliance with European

standard EN 61010-1.

Note

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.

07275B DCN6418

B-1

This page intentionally left blank.

B-2

07275B DCN6418

T80XSparePartsList

(Ref:072690000ADCN6431,2012April12)

PARTNUMBER DESCRIPTION

000940700 CD,ORIFICE,.005YELLOW

001763500 ASSY,FLOWCTL,110CC,1/4"ELBOW‐B

003290000 THERMISTOR,BASIC(VENDORASSY)(KB)

009690200 AKIT,TFEFLTRELEM(FL19,100=1)47mm

009690300 AKIT,TFEFLTRELEM(FL19,30=1)47mm

016290000 WINDOW,SAMPLEFILTER,47MM(KB)

016300800 ASSY,SAMPLEFILTER,47MM,ANGBKT,1UM

037860000 ORING,TEFLON,RETAININGRING,47MM(KB)

040010000 ASSY,FANREARPANEL(B/F)

040030100 PCA,PRESSSENSORS(1X),w/FM4

042410500 ASSY,PUMP,INT

043420000 ASSY,HEATER/THERM,O2SEN

045230200 PCA,RELAYCARD

055100200 ASSY,OPTION,PUMP,240V*

058021100 PCA,MOTHERBD,GEN5‐ICOP

066970000 PCA,INTRF.LCDTOUCHSCRN,F/P

067240000 CPU,PC‐104,VSX‐6154E,ICOP*(KB)

067300000 PCA,AUX‐I/OBD,ETHERNET,ANALOG&USB

067300100 PCA,AUX‐I/OBOARD,ETHERNET

067300200 PCA,AUX‐I/OBOARD,ETHERNET&USB

067900000 LCDMODULE,W/TOUCHSCREEN(KB)

068810000 PCA,LVDSTRANSMITTERBOARD

069500000 PCA,SERIAL&VIDEOINTERFACEBOARD

072150000 ASSY.TOUCHSCREENCONTROLMODULE

072740000 MANUAL,T801,OPERATORS

072750000 MANUAL,T802,OPERATORS

072760000 MANUAL,T803,OPERATORS

073770100 DOM,w/SOFTWARE,STD,T801*

073780100 DOM,w/SOFTWARE,STD,T802*

073790100 DOM,w/SOFTWARE,STD,T803*

CN0000073 POWERENTRY,120/60(KB)

CN0000458 PLUG,12,MC1.5/12‐ST‐3.81(KB)

CN0000520 PLUG,10,MC1.5/10‐ST‐3.81(KB)

FL0000001 FILTER,SS(KB)

FM0000004 FLOWMETER(KB)

HE0000017 HTR,12W/120V(50W/240V),CEAP(KB)

HW0000005 FOOT

HW0000020 SPRING

HW0000036 TFETAPE,1/4"(48FT/ROLL)

HW0000101 ISOLATOR

HW0000453 SUPPORT,CIRCUITBD,3/16"ICOP

HW0000685 LATCH,MAGNETIC,FRONTPANEL

KIT000219 AKIT,4‐20MACURRENTOUTPUT

KIT000253 ASSY&TEST,SPAREPS37

KIT000254 ASSY&TEST,SPAREPS38

OP0000030 OXYGENTRANSDUCER,PARAMAGNETIC

07275B DCN6418

B-3

T80XSparePartsList

(Ref:072690000ADCN6431,2012April12)

OR0000001 ORING,2‐006VT*(KB)

OR0000094 ORING,2‐228V,50DUROVITON(KB)

PU0000022 REBUILDKIT,FORPU20&04241(KB)

RL0000015 RELAY,DPDT,(KB)

SW0000006 SWITCH,THERMAL,60C(KB)

SW0000025 SWITCH,POWER,CIRCBREAK,VDE/CE*(KB)

SW0000059 PRESSURESENSOR,0‐15PSIA,ALLSEN

WR0000008 POWERCORD,10A(KB)

B-4

07275B DCN6418

M802E without a pump Expendables Ki

Part Number Description

006190600 AKIT, EXP, 802E W/O PUMP, 1UM

009690300 AKIT, TFE FLTR ELEMENT, 47MM, 1UM (30)

FL0000001 FILTER, SS

HW0000020 SPRING

OR0000001 ORING, SAMPLE FLOW

M802E with a pump Expendables Kit

Part Number Description

006190500 AKIT, EXP, 802E W/ PUMP, 1UM

009690300 AKIT, TFE FLTR ELEMENT, 47MM, 1UM (30)

FL0000001 FILTER, SS

HW0000020 SPRING

NOTE01-23 SERVICE NOTE, HOW TO REBUILD KNF PUMP

OR0000001 ORING, SAMPLE FLOW

PU0000022 REBUILD KIT, FOR PU20 & 04241 (KB)

This kit contains the following items (labor incl.)

M802E Expendables Kit, PN06535A (DCN5390)

07275B DCN6418

B-5

This page intentionally left blank.

B-6

07275B DCN6418

Appendix C

Warranty/Repair Questionnaire

T80X, M80XE

(06532C DCN 5798)

TELEDYNE API CUSTOMER SERVICE

EMAIL: api-customerservice@teledyne.com

PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816

C-1

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

O2 RANGE1 % 0-100%

O2 CELL TEMP1 ºC 50 ± 5

O2 SLOPE1 1.0 ± 0.3

O2 OFFSET1 -10 to 10%

CO2 RANGE1 % 0 to 20%

CO2 CELL TEMP1 ºC 50 ± 5

CO2 SLOPE1 1.0 ± 0.3

CO2 OFFSET1 -10 to 10%

STABIL %  0.2% with zero air

PRESS in-Hg-A ambient ± 1

SAMPLE FLOW cm3/min 120 ± 20

BOX TEMP ºC ambient ± 5ºC

following values are under the signal i/o submenu

REF_4096_MV mV 4096mV ±2 mV and Must be Stable

REF_GND mV 0± 0.5 and Must be Stable

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? ________________________________________

____________________________________________________________________________________

07275B DCN6418

Appendix C

Warranty/Repair Questionnaire

T80X, M80XE

(06532C DCN 5798)

TELEDYNE API CUSTOMER SERVICE

EMAIL: api-customerservice@teledyne.com

PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816

C-2

____________________________________________________________________________________

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.

07275B DCN6418

APPENDIX D – Wire List and Electronic Schematics

07275B DCN6418

D-1

This page intentionally left blank.

D-2

07275B DCN6418

T80X Interconnect List

(Reference: 073800100A DCN6418)

Cable PN Signal Assembly PN J/P Pin Assembly PN J/P Pin

036490100 CBL ASSY, AC POWER

AC Line Power Switch SW0000025 L

AC Neutral Power Switch SW0000025 N

Power Grnd Power Entry CN0000073 Shield

Power Grnd Power Entry CN0000073 Chassis

AC Line Switched Power Switch SW0000025 L PS2 (+12) PS0000038 SK2 1

AC Neu Switched Power Switch SW0000025 N PS2 (+12) PS0000038 SK2 3

Power Grnd Power Entry CN0000073 PS2 (+12) PS0000038 SK2 2

AC Line Switched PS2 (+12) PS0000038 SK2 1 PS1 (+5, ±15) PS0000037 SK2 1

AC Neu Switched PS2 (+12) PS0000038 SK2 3 PS1 (+5, ±15) PS0000037 SK2 3

Power Grnd PS2 (+12) PS0000038 SK2 2 PS1 (+5, ±15) PS0000037 SK2 2

AC Line Switched PS1 (+5, ±15) PS0000037 SK2 1 Relay Board 045230100 J1 1

AC Neu Switched PS1 (+5, ±15) PS0000037 SK2 3 Relay Board 045230100 J1 3

Power Grnd PS1 (+5, ±15) PS0000037 SK2 2 Relay Board 045230100 J1 2

038290000 CBL ASSY, DC POWER TO MOTHERBOARD

DGND Relay Board 045230100 J7 1 Motherboard 058021100 J15 1

+5V Relay Board 045230100 J7 2 Motherboard 058021100 J15 2

AGND Relay Board 045230100 J7 3 Motherboard 058021100 J15 3

+15V Relay Board 045230100 J7 4 Motherboard 058021100 J15 4

AGND Relay Board 045230100 J7 5 Motherboard 058021100 J15 5

-15V Relay Board 045230100 J7 6 Motherboard 058021100 J15 6

+12V RET Relay Board 045230100 J7 7 Motherboard 058021100 J15 7

+12V Relay Board 045230100 J7 8 Motherboard 058021100 J15 8

Chassis Gnd Relay Board 045230100 J7 10 Motherboard 058021100 J15 9

040230000 CBL, I2C, RELAY BOARD TO MOTHERBOARD

I2C Serial Clock Motherboard 058021100 P107 3 Relay Board 045230100 P3 1

I2C Serial Data Motherboard 058021100 P107 5 Relay Board 045230100 P3 2

I2C Reset Motherboard 058021100 P107 2 Relay Board 045230100 P3 4

I2C Shield Motherboard 058021100 P107 6 Relay Board 045230100 P3 5

041050000 CBL, INTERFACE BOARD TO MOTHERBOARD

Kbd Interupt LCD Interface PCA 066970000 J2 7 Motherboard 058021100 J106 1

DGND LCD Interface PCA 066970000 J2 2 Motherboard 058021100 J106 8

SDA LCD Interface PCA 066970000 J2 5 Motherboard 058021100 J106 2

SCL LCD Interface PCA 066970000 J2 6 Motherboard 058021100 J106 6

Shld LCD Interface PCA 066970000 J2 10 Motherboard 058021100 J106 5

041760000 CBL, DC POWER TO RELAY BOARD

DGND Relay Board 045230100 P8 1 Power Supply Triple PS0000037 J1 3

+5V Relay Board 045230100 P8 2 Power Supply Triple PS0000037 J1 1

+15V Relay Board 045230100 P8 4 Power Supply Triple PS0000037 J1 6

AGND Relay Board 045230100 P8 5 Power Supply Triple PS0000037 J1 4

-15V Relay Board 045230100 P8 6 Power Supply Triple PS0000037 J1 5

+12V RET Relay Board 045230100 P8 7 Power Supply Single PS0000038 J1 3

+12V Relay Board 045230100 P8 8 Power Supply Single PS0000038 J1 1

046710000 CBL, MOTHERBOARD TO XMITTER BD (MULTIDROP OPTION)

GND Motherboard 058021100 P12 2 Xmitter bd w/Multidrop 069500000 J4 2

RX0 Motherboard 058021100 P12 14 Xmitter bd w/Multidrop 069500000 J4 14

RTS0 Motherboard 058021100 P12 13 Xmitter bd w/Multidrop 069500000 J4 13

TX0 Motherboard 058021100 P12 12 Xmitter bd w/Multidrop 069500000 J4 12

CTS0 Motherboard 058021100 P12 11 Xmitter bd w/Multidrop 069500000 J4 11

RS-GND0 Motherboard 058021100 P12 10 Xmitter bd w/Multidrop 069500000 J4 10

RTS1 Motherboard 058021100 P12 8 Xmitter bd w/Multidrop 069500000 J4 8

CTS1/485- Motherboard 058021100 P12 6 Xmitter bd w/Multidrop 069500000 J4 6

RX1 Motherboard 058021100 P12 9 Xmitter bd w/Multidrop 069500000 J4 9

TX1/485+ Motherboard 058021100 P12 7 Xmitter bd w/Multidrop 069500000 J4 7

RS-GND1 Motherboard 058021100 P12 5 Xmitter bd w/Multidrop 069500000 J4 5

RX1 Motherboard 058021100 P12 9 Xmitter bd w/Multidrop 069500000 J4 9

TX1/485+ Motherboard 058021100 P12 7 Xmitter bd w/Multidrop 069500000 J4 7

RS-GND1 Motherboard 058021100 P12 5 Xmitter bd w/Multidrop 069500000 J4 5

063750000 CBL, CO2, O2 SENSOR THERM/HTR

O2-L Relay Board 045230100 P18 9 O2 sensor therm./htr 043420000 P1 4

O2-N Relay Board 045230100 P18 10 O2 sensor therm./htr 043420000 P1 2

Shield Relay Board 045230100 P18 12 O2 sensor therm./htr 043420000 P1

O2TA O2 sensor therm./htr 043420000 P1 3 Motherboard 058021100 P27 4

O2TB O2 sensor therm./htr 043420000 P1 1 Motherboard 058021100 P27 11

CO2THA CO2 sensor therm./htr 041920000 P1 2 Motherboard 058021100 P27 6

CO2THB CO2 sensor therm./htr 041920000 P1 1 Motherboard 058021100 P27 13

CO2-11B Relay Board 045230100 P18 1 CO2 Cell Heater 040400000 P1 4

CO2-12B Relay Board 045230100 P18 1 CO2 Cell Heater 040400000 P2 6

CO2-11A Relay Board 045230100 P18 2 CO2 Cell Heater 040400000 P3 3

CO2TS1 Relay Board 045230100 P18 3 CO2 Cell Heater 040400000 P4 1

CO2TS2 Relay Board 045230100 P18 4 CO2 Cell Heater 040400000 P5 2

CO2-12A Relay Board 045230100 P18 5 CO2 Cell Heater 040400000 P6 5

FROM TO

07275B DCN6418

D-3

T80X Interconnect List

(Reference: 073800100A DCN6418)

Cable PN Signal Assembly PN J/P Pin Assembly PN J/P Pin

FROM TO

066470000 CBL, CO2 & O2 SENSORS DC PWR

O2 SIGNAL - Motherboard 058021100 P109 7 O2 Sensor OP0000030 P1 9

O2 SIGNAL + Motherboard 058021100 P109 1 O2 Sensor OP0000030 P1 10

Shield Motherboard 058021100 P109 9

DGND O2 Sensor OP0000030 P1 5 Relay Board 045230100 P5 1

+5V O2 Sensor OP0000030 P1 6 Relay Board 045230100 P5 2

+12V RET CO2 Sensor OP0000033 P1 GND Relay Board 045230100 P5 7

+12V CO2 Sensor OP0000033 P1 L Relay Board 045230100 P5 8

066830000 CBL, FLOW MODULE

DGND LCD Interface PCA 066970000 P14 8 Relay Board 045230100 P10 1

+5V LCD Interface PCA 066970000 P14 1 Relay Board 045230100 P10 2

DGND LCD Interface PCA 066970000 P14 2 Relay Board 045230100 P11 1

+5V LCD Interface PCA 066970000 P14 3 Relay Board 045230100 P11 2

+12V RET Relay Board 045230100 P11 7 Chassis fan 040010000 P1 1

+12V Relay Board 045230100 P11 8 Chassis fan 040010000 P1 2

P/Flow Sensor AGND Relay Board 045230100 P11 3 P/Flow Sensor board 040030100 P1 3

P/Flow Sensor +15V Relay Board 045230100 P11 4 P/Flow Sensor board 040030100 P1 6

Pressure signal 1 P/Flow Sensor board 040030100 P1 2 Motherboard 058021100 P110 6

Pressure signal 2 P/Flow Sensor board 040030100 P1 4 Motherboard 058021100 P110 5

Flow signal 1 P/Flow Sensor board 040030100 P1 5 Motherboard 058021100 P110 4

Shield P/Flow Sensor board 040030100 P1 S Motherboard 058021100 P110 12

CO2+ CO2 Sensor OP0000033 P1 V Motherboard 058021100 P110 3

CO2- CO2 Sensor OP0000033 P1 O Motherboard 058021100 P110 9

06737 CBL, I2C to AUX I/O (ANALOG IN OPTION)

ATX- Motherboard 058021100 J106 1 Aux I/O PCA 067300000 J2 1

ATX+ Motherboard 058021100 J106 2 Aux I/O PCA 067300000 J2 2

LED0 Motherboard 058021100 J106 3 Aux I/O PCA 067300000 J2 3

ARX+ Motherboard 058021100 J106 4 Aux I/O PCA 067300000 J2 4

ARX- Motherboard 058021100 J106 5 Aux I/O PCA 067300000 J2 5

LED0+ Motherboard 058021100 J106 6 Aux I/O PCA 067300000 J2 6

LED1+ Motherboard 058021100 J106 8 Aux I/O PCA 067300000 J2 8

06738 CBL, CPU COM to AUX I/O (MULTIDROP OPTION)

RXD CPU PCA 067240000 COM1 1 Xmitter bd w/Multidrop 069500000 J3 1

DCD CPU PCA 067240000 COM1 2 Xmitter bd w/Multidrop 069500000 J3 2

DTR CPU PCA 067240000 COM1 3 Xmitter bd w/Multidrop 069500000 J3 3

TXD CPU PCA 067240000 COM1 4 Xmitter bd w/Multidrop 069500000 J3 4

DSR CPU PCA 067240000 COM1 5 Xmitter bd w/Multidrop 069500000 J3 5

GND CPU PCA 067240000 COM1 6 Xmitter bd w/Multidrop 069500000 J3 6

CTS CPU PCA 067240000 COM1 7 Xmitter bd w/Multidrop 069500000 J3 7

RTS CPU PCA 067240000 COM1 8 Xmitter bd w/Multidrop 069500000 J3 8

RI CPU PCA 067240000 COM1 10 Xmitter bd w/Multidrop 069500000 J3 10

06738 CBL, CPU COM to AUX I/O (USB OPTION)

RXD CPU PCA 067240000 COM1 1 Aux I/O PCA 0673000 or -02 J3 1

DCD CPU PCA 067240000 COM1 2 Aux I/O PCA 0673000 or -02 J3 2

DTR CPU PCA 067240000 COM1 3 Aux I/O PCA 0673000 or -02 J3 3

TXD CPU PCA 067240000 COM1 4 Aux I/O PCA 0673000 or -02 J3 4

DSR CPU PCA 067240000 COM1 5 Aux I/O PCA 0673000 or -02 J3 5

GND CPU PCA 067240000 COM1 6 Aux I/O PCA 0673000 or -02 J3 6

CTS CPU PCA 067240000 COM1 7 Aux I/O PCA 0673000 or -02 J3 7

RTS CPU PCA 067240000 COM1 8 Aux I/O PCA 0673000 or -02 J3 8

RI CPU PCA 067240000 COM1 10 Aux I/O PCA 0673000 or -02 J3 10

06739 CBL, CPU ETHERNET TO AUX I/O

ATX- CPU PCA 067240000 LAN 1 Aux I/O PCA 06730XXXX J2 1

ATX+ CPU PCA 067240000 LAN 2 Aux I/O PCA 06730XXXX J2 2

LED0 CPU PCA 067240000 LAN 3 Aux I/O PCA 06730XXXX J2 3

ARX+ CPU PCA 067240000 LAN 4 Aux I/O PCA 06730XXXX J2 4

ARX- CPU PCA 067240000 LAN 5 Aux I/O PCA 06730XXXX J2 5

LED0+ CPU PCA 067240000 LAN 6 Aux I/O PCA 06730XXXX J2 6

LED1 CPU PCA 067240000 LAN 7 Aux I/O PCA 06730XXXX J2 7

LED1+ CPU PCA 067240000 LAN 8 Aux I/O PCA 06730XXXX J2 8

06741 CBL, CPU USB TO FRONT PANEL

GND CPU PCA 067240000 USB 8 LCD Interface PCA 066970000 J9

LUSBD3+ CPU PCA 067240000 USB 6 LCD Interface PCA 066970000 J9

LUSBD3- CPU PCA 067240000 USB 4 LCD Interface PCA 066970000 J9

VCC CPU PCA 067240000 USB 2 LCD Interface PCA 066970000 J9

07482 CBL, HDMI, T-SERIES LCD Interface PCA 066970000 J15 Transmitter PCA 068810000 J1

D-4

07275B DCN6418

Advanced Pollution Instrumentation

A Teledyne Technologies Company

TELEDYNE





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SURSHUDXWKRUL]DWLRQ







PS1 (+5, 15)

PS2 (+12)

RELAY BOARD

AC POWER

ENTRANCE

AC POWER

SWITCH

0452301

J11

J106

03829

SK2

PS37

PS38

SK1

036490100

04176

J15

Press/Flow

0400301

J110

06683

J107

04023

PCA

O2 Sensor

OP30

06647

Fan

04001

O2 Sensor

04342

Therm/Htr

J18

J27

J109

06375

Int Pump

0424105

J20

Htr Config Plug

04030XXXX

JP6

Pump Config Plug

04289XXXX

JP7

TC Prog Plug

04976XXXX

JP5

CO2 Sensor

04342

Therm

CO2 Sensor

OP33

802-Option

803-Standard

801-Standard

802-Standard

803-Standard

801-N/A

CN3

CN5

CPU 06724

Analog

Out J1020 Out J1017

Status Control

In J1004

RS-232

J1013 J1010 & 1011

RS-485

CN4 Motherboard

058021100

AUX I/O 06730

06738

USB OPT

06739

J12

06746

DOM

Xmitter

06881

W/MD

06950

04671

MD OPT

06738

MD OPT

CP34

LCD w/Touchscreen

06790

07215

LCD Interface

06697

J10

J14

J15 J2

Cntrl Mod

KEY:

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.

04105

06741

07482

06737

ANALOG IN OPT

06760

CO2 Sensor

04040

Heater

J10

07275B DCN6418

D-5

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07275B DCN6418

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07275B DCN6418

D D

C C

B B

A A

Title

Number RevisionSize

Date: 6/24/2010 Sheet of

File: N:\PCBMGR\..\06696.P1.R3.schdoc Drawn By:

GUI Interface

06698 D

GM800480X-70-TTX2NLW

CL586-0529-2

Mode

aVsync

aHSync

3.3V

100K

L/R

U/D

aReset

DithB

L/RU/DDithB

10K

22uF/6.3V

JMK316BJ226KL 0.0022

CA_112

Mode

aVsync

aHSync

i BackLightDrive

aB7aB6

aB5aB4

aB3aB2

aG7aG6

aG5aG4

aG3aG2

aR6

aR5aR4

aR3aR2

aR7

aDCLK

3.3V

1.0

GMK107BJ105KA

B5B4

B3B2

B1B0

G5G4

G3G2

G1G0

R3R2

R1R0

DEN

CL586-0527-7

DEN

DCLK

L/R

U/D

Mode

3.3V +5V

+5V

5V-GND

12 11

JP3

4X3 Jumper

12 11

15 14

18 17

JP2

6X3 Jumper

Bklght+

Bklght-

Vcom

Vgh

AVdd

Vcom

aG1

aG0

aR1

aR0

aB1

aB0

CHASSIS CHASSIS CHASSIS CHASSIS

MT1

TP1

0039300100

1 2

3 4

5 6

7 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

B30B-PHDSS (LF)(SN)

1 2

3 4

5 6

7 8

9 10

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

B30B-PHDSS (LF)(SN)

FBMH3216HM501NT

FB1

CHASSIS CHASSIS CHASSIS CHASSIS CHASSIS

Vgl

M ake M odel JP

FEM A

800

,4-5,7-

Dat a Image F

G01 3

-5,

,5-

United Radiant Tech. UM

H-

MD-

/8/9

16/ 1

/18

,5-

Internal Dithering

0 = Enable

1 = Disable

Scan Direction

U/D L/R Scan Dir.

0 1 UD, LR

1 0 DU, RL

0 0 UD, RL

1 1 DU, LR

(1 = H, 0 = L)

22uF/6.3V

JMK316BJ226KL

22uF/6.3V

JMK316BJ226KL

10K

FBMH3216HM501NT

FB2

FBMH3216HM501NT

FB3

FBMH3216HM501NT

FB4

0.0022

CA_112

0.0022

CA_112

TP3 TP4

R280

MT2 MT3 MT4 MT5 MT6 MT7 MT8 MT9

5V-GND

TP2

BACKL

R21

jumper

bDCLK

CLK

R48

R47

R46

aB6

aB5

aB4

aB3

aB2

aG7

aG6

aG5

aG4

aG3

aG2

aR7

aR6

aR5

aR4

aR3

SCL

SDA

aB7

aR2

aData Enable

aB7

aB6

aB5

aB4

aB3

aB2

aG7

aG6

aG5

aG4

aG3

aG2

aR7

aR6

aR5

aR4

aR3

aR2

aData Enable

Default:R21B

+5V

5V-GND

J14

0039300100

FBMH3216HM501NT

FB16

FBMH3216HM501NT

FB17

SCL

SDA

07275B DCN6418

D-15

D D

C C

B B

A A

Title

Number RevisionSize

Date: 6/24/2010 Sheet of

File: N:\PCBMGR\..\06696.P2.R3.schdoc Drawn By:

06698 D

22uH

Vin

SHDN

SW 1

GND

FB 3

CAT4139TD-GT3

4.7uF/16V

R12

2.0

R14

5V-GND

+5V

9.76

R13

3.9uH

487K

309K

80.6K

R18

66.5K

R19

464K

R16

806K

R11

2K1

MBRM120LT1G

0.001C8

24pf

C13

0.33

C16

0.220

C20

470pf

C21

22uf/25V

C12

TMK325BJ226MM

0.1

C26

3.3V

33K

R23

43pf

C23

BAT54S

3.3V

Bklght+

Bklght-

Vcom

Vgh

AVdd

3.3V

FDV305N

5V-GND

+5V

Default: NI

R22 jumper

AVdd: +10.4V

TP5

SCL

SDA

INT 13

P0 4

P1 5

P2 6

P3 7

P4 9

P5 10

P6 11

P7 12

Vdd 16

Vss

PCF8574

SW_46

Maint_SW

Lang_Select

5V-GND

+5V

FDLY

PGND

DRVP 17

PGND

DRVN

VCOM 10

SUP 9

COMP

IN 11

VGH 15

REF

GND

SW 6

DLY2

SW 5

FB 1

DLY1

FBP 12

FBN

ADJ

GD 23

CTRL

CPI 16

VIN 4

TPS65150PWP

HTSNK 25

CD214A-B140LF

SW_46

Opt. Lang. Sw.

Opt. Main Sw

Vgl

22uF/6.3V

C11

JMK316BJ226KL

1.0

C14

GMK107BJ105KA

1.0

C15

GMK107BJ105KA

1.0

C27

GMK107BJ105KA

24pf

C22

43pf

C24

43pf

C25

10K

R10

10K

R24

10K

R25

10K

R26

100K

R15

806K

R17

0.33

C17

0.33

C18

0.33

C19

BAT54S

4.7uF/16V

C10

Vgh: +16V

TP9

Vcom: +4V

TP10

Vgl: -7V

TP7

TP6

TP8

GUI Interface

C35

0.1

5V-GND AB

R31

10K

3.3V

R27

jumper

BACKL

SCL

SDA

Default:R27B

Default:R31B

Backlight Brightness Control

Control Mode R22 R27 R31

Remote – Video Port NO A NO

Remote – I2C YES B NO

Fixed Bright (default) NO B B

D-16

07275B DCN6418

D D

C C

B B

A A

Title

Number RevisionSize

Date: 6/24/2010 Sheet of

File: N:\PCBMGR\..\06696.P3.R3.schdoc Drawn By:

06698 D

To old TScreen

70553-004

J11

+5V

CHASSIS

J12

BUS +5

To new TScreen

70553-004

J10

LT 1

RT 2

SHLD 3

RL 4

LL 5

GND

D+

D-

CHS A

CHS B

TSHARC-12C

VBUS

D-

D+

GND

USB-B-MINI

VBUS

CHASSIS

5V-GND

USB3.3V

SDA

SCL

USB3.3V

R36

12K

-V 2

OUT

24MHZ

DS2

GRN

DS1

YEL

SCL

SDA

R37

100K

5V-GND

5V-GND 5V-GND

5V-GND

+5V

5V-GND

C28

1uF

USB3.3V

SHTDN

GND

OUT 1

BP 4

3.3V-REG

R38

0.5A/6V

D1-

D1+

D2-

D2+

+3.3V

D3-

D3+

D4-

D4+

+3.3V 10

TEST 11

PWR1 12

OCS1 13

+1.8V 14

3.3VCR 15

PWR2 16

OCS2 17

PWR3 18

OCS3 19

PWR4 20

OCS4 21

SDA/R1 22

+3.3V 23

SCL/S0 24

HS-IND/S1 25

RESET 26

VBUS-DET 27

SUS/R0

+3.3V

USB-

USB+

XTL2

CLK-IN

1.8VPLL

RBIAS

+3.3PLL

GND

USB2514-AEZG

C32

1uF

C44

1uF

5V-GND

+5V

1D-

2D+

3GND

USB-A_R/A

5V-GND

CHASSIS

FBMH3216HM501NT

FB5

C34

0.1

C36

0.1uF

C33

0.1uF

C31

0.1uF

R30

100K

R29

0.5A/6V

D+

D-

GND

+5V J5

USB-A_VERT

C29

470pf

C30

1uF

C37 0.01uF

JP4

3.3V

GND

FB7

R20

49.9

FB8

FB9

FB10

FB11

FB12

FB13

GUI Interface

1 8

U11

C40

0.1uF

C42

0.1uF

C45

0.1uF

C390.1

C43

0.1uF

C41

0.1

R33

100K

R45

R32

R34

100K

R35

100K

C38

1uF

R39

100K

JP5

C60

0.1uF

C59

0.1

D+

D-

GND

+5V J6

USB-A_VERT

+5V

D1_N

D1_P D4_P

D4_N

D3_P

D3_N

D2_P

D2_N

D_P

D_N

Configuration Select

Mode R32 R45

Default A A

MBUS B B

Install 100K for A, 0 Ohm for B

+5V

5V-GND

07275B DCN6418

D-17

D D

C C

B B

A A

Title

Number RevisionSize

Date: 6/24/2010 Sheet of

File: N:\PCBMGR\..\06696.P4.R3.schdoc Drawn By:

06698 D

TOUCH SCREEN INTERFACE CIRCUITRY ( TBD)

GUI Interface

R40

10K

Option

CLKOUT_P

CLKOUT_N

3.3V

C49

0.1

R41

100

FB6

FB14

Vcc PIN 28

C47

0.01

22uF/6.3V

C46

JMK316BJ226KL

C50

0.1

C51

0.1

C52

0.1 C55

0.1

C57

0.1

bDCLK

BACKL

NOTE:

To receive backlight control (BACKL) from CPU board

when using ICOP_0096 LVDS Transmitter.

The connection from pin 42 on the TTL video connector

(VSYNC) to U1-23 must be broken and connected to

pin 43.

aB6

aB5

aB4

aB3

aB2

aG7

aG6

aG5

aG4

aG3

aG2

aR7

aR6

aR5

aR4

aR3

aB7

aR2

aData Enable

R42

100

R43

100

R44

100

Vcc PIN 36

C48

0.01

Vcc PIN 42

C53

0.01

Vcc PIN 48

C54

0.01 C56

0.01

C58

0.01

FBMH3216HM501NT

FB15 C61

0.1

J13

HEADER-7X2

Y0M

8Y0P

Y1M

10 Y1P

Y2M

Y2P

CLKOUT

CLKINM

CLKINP

SHTDN

VCC

LVDS/VCC

PLLVCC

LVDSGND

PLLGND

D0 24

D1 26

D2 27

D3 29

D4 30

D5 31

D6 33

D7 34

D8 35

D9 37

D10 39

D11 40

D12 41

D13 43

D14 45

D15 46

D16 47

D17 1

D18 2

D19 4

D20 5

GND 3

GND 25

GND 32

GND 38

GND 44

SN75LVDS86A

3.3V

Y0_P

Y0_N

Y1_P

Y1_N

Y2_N

Y2_P

MH3

MH4

7MH1

MH2

J15

G3168-05000202-00

CHASSIS

R490

R500

R510

R520

R530

R540

R550

R560

FBMH3216HM501NT

FB18

C62

0.1

3.3V

Y0_P1

Y0_N1

Y1_P1

Y1_N1

Y2_N1

Y2_P1

CLKOUT_N1

CLKOUT_P1

D-18

07275B DCN6418

D D

C C

B B

A A

Title

Number RevisionSize

Date: 5/7/2010 Sheet of

File: N:\PCBMGR\..\06882-P1-R0.SchDoc Drawn By:

LVDS, Transmitter Board

06882

VAD6

VAD7

VAD8

VAD9

VAD10

VAD11

VBD10

VBD11

VAD0

VAD1

VAD2

VAD3

VBD2

VBD3

VBD4

VBD5

VBD6

VBD7

VBDE

Y0_N

Y0_P

Y1_N

Y1_P

Y2_N

Y2_P

CLKOUT_N

CLKOUT_P

22.1

From ICOP CPU To LCD Display

D10

D11

D12

D13

D14

D15

D16

D17

D18

D19

D20

GND

Y2P 34

Y2M 35

Y1P 38

Y1M 39

Y0P 40

Y0M 41

CLKOUTP 32

CLKOUTM 33

CLKIN 26

SHTDN 27

NC 14

NC 43

VCC 2

VCC 8

VCC 21

LVDSVCC 37

PLLVCC 29

VLDSGND 42

VLDSGND 36

VLDSGND 31

PLLGND 30

PLLGND 28

SN75LVDS84A

CHASSIS-0 CHASSIS

1 2

3 4

5 6

7 8

910

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

31 32

33 34

35 36

37 38

39 40

41 42

43 44

J2 Header 22X2

MH3

MH4

1MH1

MH2

G3168-05000101-00

CHASSIS

+3.3V

VAD0 VAD1

VAD2 VAD3

VAD6 VAD7

VAD8 VAD9

VAD10 VAD11

VBD2 VBD3

VBD4 VBD5

VBD6 VBD7

VBD10 VBD11

VBDE

VBGCLK

+3.3V

CLKIN

Y0_N

Y0_P

Y1_N

Y1_P

Y2_N

Y2_P

CLKOUT_N

CLKOUT_P

10K

BACKL

0.1

0.01

22uF/6.3V

JMK316BJ226KL

0.1

0.01

+3.3V

0.1

0.01

C10

0.1

C11

0.01

1 2

3 4

5 6

7 8

910

11 12

13 14

Header 7X2

+3.3V

Y0_P Y0_N

Y1_P Y1_N

CLKOUT_P

Y2_N

CLKOUT_N

Y2_P

MT1 MT2

07275B DCN6418

D-19

D D

C C

B B

A A

Title

Number RevisionSize

Date: 5/6/2011 Sheet of

File: N:\PCBMGR\..\06731-1_ETHERNET.SchDocDrawn By:

Auxiliary I/O Board (PWR-ETHERNET)

06731

STRAIGHT THROUGH ETHERNET

GND

+5V

SCL

SDA +5V-ISO

+C17

100uF

GND

DS3

GRN

Header 8

3 4

SP3050

R10

2.2k

47uH

TP1

TP3

TP2

DF11-8DP-2DS(24)

SDA

SCL

10 9

12 11

CONN_RJ45_LED

+5V-OUT

ISO-GND

C28

4.7uF

R16

ATX+

ATX-

ARX+

ARX-

LED0-

LED0+

LED1+

LED1-

VDD2 5

GND2 7

VDD1

GND1

LME0505

Header 8

R19

C18

.01/2KV R13

R20

CHASSIS

PRINTED DOCUMENTS ARE UNCONTROLLED

DCN:6092

D-20

07275B DCN6418

D D

C C

B B

A A

Title

Number RevisionSize

Date: 5/6/2011 Sheet of

File: N:\PCBMGR\..\06731-2_USB.SchDoc Drawn By:

Auxiliary I/O Board (USB)

06731

TXD-A

RTS-A

DTR-A

RXD-A

CTS-A

DSR-A

DCD-A

RI-A

V-BUS

VBUS 1

D- 2

D+ 3

GND 4

USB

GND

V-BUS

CHASSIS

GND

C1+

C1-

C2+

C2-

TI1

TI2

TI3

RI3 6

RI2 5

RI1 4

TO3 11

TO2 10

TO1 9

RO2 20

V- 3

V+ 27

VCC 26

STAT

SHTDN

RI4 7

RI5 8

ONLINE 23

GND 25

RO1

RO2

RO3

RO4

RO5

SP3243EU

GND

R12

4.75k

GND

3nc 4

U11

NUP2202W1

TXD-B

RXD-B

CTS-B

RTS-B

DSR-B

DTR-B

RI-B

DCD-B

MT1

MT-HOLE

C24

4.7uF

C26

1uF

C25

0.1uF

C22

0.1uF

C23

0.1uF

C19

0.1uF

C20

0.1uF

C21

0.1uF

DS4

GRN

R11

2.2k

CHASSIS

MT2

MT-HOLE

R14

R15

DCD

RXD

TXD

DTR

GND

DSR

RTS

CTS

N/C

DF11-10DP-2DS(24)

V-BUS

DCD 1

RI 2

DTR 28

DSR 27

TXD 26

RXD 25

RTS 24

CTS 23

GND 3

14 20

VBUS

8VREG-I

7D-

RST

SUSPEND

VDD

D+

4U10

CP2102

3.3V

D+

D-

CHASSIS

PRINTED DOCUMENTS ARE UNCONTROLLED

DCN:6092

07275B DCN6418

D-21

D D

C C

B B

A A

Title

Number RevisionSize

Date: 5/6/2011 Sheet of

File: N:\PCBMGR\..\06731-3_ADC.SchDoc Drawn By:

Auxiliary I/O Board (ADC)

06731

ANALOG INPUT

+5V-ISO

CH0

CH1

CH2

CH3

CH4

CH5

CH6

CH7

SHTDN 13

VDD 2

VDD 1

SDA 9

SCL 5

A2 10

A1 12

A0 6

REF 27

AGND

REF-AJ 26

DGND 3

24 NC 28

NC 25

MAX1270BCAI+

+5V

GND

+5V-ISO

SCL

SDA

AGND

ISO-GND

+5V-ISO

1 6

U4A

NC7WZ17P6X

ISO-GND

+5V-ISO

ISO-GND

SMS12

C13

0.1uF

C14

0.1uF

C12

0.1uF

C11

0.01uF

BLU

DS1

SDA

0.1uF

C10

4.7uF

AN-CH0

AN-CH1

AN-CH2

AN-CH3

AN-CH4

AN-CH5

AN-CH6

AN-CH7

4.99

C27

4.7uF

+5V-ADC

ISO-GND

2.2k

SMS12

3 4

U4B

NC7WZ17P6X

BLU

DS2

SCL

C15

.01/2KV

GND1 1

NC 2

VDD1 3

NC 4

SDA1 5

SCL1 6

GND1 7

NC 8

GND2

15 VDD2

13 SDA2

SCL2

GND2

ADuM2250

R17

49.9

ISO-GND

TP7

TP8

TP5

TP6

C29

1nF

R18

49.9

C30

1nF

AGND

0.1uF

TP4 AGND

ISO-GND

CHASSIS

PRINTED DOCUMENTS ARE UNCONTROLLED

DCN:6092

D-22

07275B DCN6418

Teledyne Respiratory Product T802 Users Manual

T802 to the manual f9501067-d4dc-491b-b6a7-ab398195e9ce

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