Teledyne Tablet Accessory T803 Users Manual

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OPERATION MANUAL

MODEL T803
CO2/O2 ANALYZER

© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone:
Phone:
Fax:
Email:
Website:
Copyright 2011-2013
Teledyne Advanced Pollution Instrumentation

800-324-5190
858-657-9800
858-657-9816
api-sales@teledyne.com
http://www.teledyne-api.com/
07276B DCN 6418
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
© 2011-2013 Teledyne Advanced Pollution Instrumentation. All rights reserved.
TRADEMARKS
All trademarks, registered trademarks, brand names or product names appearing in this document are the
property of their respective owners and are used herein for identification purposes only.

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SAFETY MESSAGES
Important safety messages are provided throughout this manual for the purpose of avoiding personal
injury or instrument damage. Please read these messages carefully. Each safety message is associated
with a safety alert symbol, and are placed throughout this manual; the safety symbols are also located
inside the instrument. It is imperative that you pay close attention to these messages, the descriptions of
which are as follows:

WARNING: Electrical Shock Hazard

HAZARD: Strong oxidizer

GENERAL WARNING/CAUTION: Read the accompanying message for
specific information.

CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or the
instrument.
Technician Symbol: All operations marked with this symbol are to be
performed by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central
safety grounding point for the instrument.

CAUTION
This instrument should only be used for the purpose and in the manner
described in this manual. If you use this instrument in a manner other than
that for which it was intended, unpredictable behavior could ensue with
possible hazardous consequences.
NEVER use any gas analyzer to sample combustible gas(es)!
Note
For Technical Assistance regarding the use and maintenance of this instrument or any
other Teledyne API product, contact Teledyne API’s Technical Support Department:
Telephone: 800-324-5190
Email: sda_techsupport@teledyne.com
or access any of the service options on our website at http://www.teledyne-api.com/

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

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 :
complémentaire pour des renseignements spécifiques

Lire

consigne

MISE EN GARDE : Surface chaude

Ne pas toucher : Toucher à certaines parties de l’instrument sans protection ou
sans les outils appropriés pourrait entraîner des dommages aux pièces ou à
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!

07276B DCN6418

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

reviewed

CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and
packing instructions and Return Merchandise Authorization (RMA) procedures
when returning parts for repair or calibration may void your warranty. For antiESD handling and packing instructions please refer to “Packing Components for
Return to Teledyne API’s Technical Support” in the Primer on Electro-Static
Discharge section of this manual, and for RMA procedures please refer to our
Website at http://www.teledyne-api.com under Customer Support > Return
Authorization.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

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07276B DCN6418

ABOUT THIS MANUAL
This T803 Operation Manual, PN 07276, is comprised of multiple documents in PDF
format, as listed below.
Part No.

Rev

Name/Description

06759

T803 Operation Manual, top level assy

06763

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

07269

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

06532

Warranty / Repair Form, Appendix C
Documents included in Appendix D

06294

Interconnect Wire List

06407

Interconnect Diagram

05803

SCH, PCA 05802, MOTHERBOARD, GEN-5

06698

SCH, PCA 06697, INTRFC, LCD TCH SCRN,

06882

SCH, LVDS TRANSMITTER BOARD

06731

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 inoformation such as
version-specific software documentation, lists of spare parts* and recommended
stocking levels, and schematics.
*Part numbers do not reflect real-time updates – contact Sales or Technical
Support).

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

REVISION HISTORY
T803 Operation and Maintenance Manual, PN07276
Date
Rev
DCN
Description
2013 January 14
B
6418
Administrative updates and Specs corrections
2011 March 11
A
6006
Initial Release

viii

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TABLE OF CONTENTS
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI) ...................................................................... i
Safety Messages ...............................................................................................................................................iii
Warranty ............................................................................................................................................................ v
About This Manual............................................................................................................................................vii
Revision History...............................................................................................................................................viii

1. INTRODUCTION, FEATUERES, AND OPTIONS ..............................................................17
1.1. T803 Overview.............................................................................................................................................. 17
1.2. Features........................................................................................................................................................ 17
1.3. Options ......................................................................................................................................................... 18

2. SPECIFICATIONS, APPROVALS & COMPLIANCE................................................................21
2.1. Specifications................................................................................................................................................ 21
2.2. Approvals and Certifications......................................................................................................................... 22
2.2.1. Safety .................................................................................................................................................... 22
2.2.2. EMC....................................................................................................................................................... 22
2.2.3. Other Type Certifications....................................................................................................................... 22

3. GETTING STARTED...........................................................................................................23
3.1. Unpacking the T803 Analyzer ...................................................................................................................... 23
3.1.1. Ventilation Clearance ............................................................................................................................ 25
3.2. Instrument Layout ......................................................................................................................................... 25
3.2.1. Front Panel ............................................................................................................................................ 25
3.2.2. Rear Panel............................................................................................................................................. 29
3.2.3. Internal Chassis Layout......................................................................................................................... 31
3.3. Connections and Setup ................................................................................................................................ 32
3.3.1. Electrical Connections ........................................................................................................................... 32
3.3.2. Pneumatic Connections ........................................................................................................................ 46
3.4. Startup, Functional Checks, and Initial Calibration....................................................................................... 50
3.4.1. Startup ................................................................................................................................................... 50
3.4.2. Warm Up ............................................................................................................................................... 50
3.5. Warning Messages ....................................................................................................................................... 50
3.5.1. Functional Check................................................................................................................................... 52
3.5.2. Initial Calibration .................................................................................................................................... 53

4. BASIC OPERATION ...........................................................................................................57
4.1. Overview of Operating Modes ...................................................................................................................... 57
4.2. Sample Mode................................................................................................................................................ 58
4.3. Calibration Mode........................................................................................................................................... 60
4.4. Setup MODE................................................................................................................................................. 61

5. SETUP MENU ..................................................................................................................63
5.1. SETUP  CFG: Configuration Information .................................................................................................. 63
5.2. S ETUP  ACAL: [NOT USED] ................................................................................................................... 63
5.3. SETUP  DAS: Internal Data Acquisition System ...................................................................................... 63
5.4. SETUP  RNGE: Analog Output Reporting Range Configuration.............................................................. 64
5.4.1. Physical Range versus Analog Output Reporting Ranges.................................................................... 64
5.4.2. Analog Output Ranges for CO2 and O2 Concentration ......................................................................... 65
5.4.3. Reporting Range Modes ....................................................................................................................... 66
5.4.4. SETUP RNGE  DIL: Using the Optional Dilution Ratio Feature..................................................... 71
5.5. SETUP  PASS: Password Feature ........................................................................................................... 72
5.6. SETUP  CLK: Setting the T803 Analyzer’s Internal Clock........................................................................ 75
5.6.1. Setting the Internal Clock’s Time and Day ............................................................................................ 75
5.6.2. Adjusting the Internal Clock’s Speed..................................................................................................... 75
5.7. SETUP  MORE COMM ......................................................................................................................... 77

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.8. SETUP  MORE  VARS: Internal Variables (VARS)............................................................................... 77
5.9. SETUP  MORE  DIAG: Using the Diagnostics Functions .................................................................... 80
5.9.1. Accessing the Diagnostic Features ....................................................................................................... 81
5.10. Using the T803 Analyzer’s Analog Outputs................................................................................................ 82
5.10.1. Accessing the Analog Output Signal Configuration Submenu............................................................ 82
5.10.2. Analog Output Voltage / Current Range Selection.............................................................................. 84
5.10.3. Calibration of the Analog Outputs ....................................................................................................... 85
5.10.4. Turning an Analog Output Over-Range Feature ON/OFF .................................................................. 94
5.10.5. Adding a Recorder Offset to an Analog Output................................................................................... 95
5.10.6. Selecting a Test Channel Function for Output A4............................................................................... 96
5.10.7. AIN Calibration .................................................................................................................................... 98
5.10.8. Analog Inputs (XIN1…XIN8) Option Configuration ............................................................................. 99
5.11. SETUP MORE  ALRM: Using the Gas Concentration Alarms (Option 61)....................................... 100
5.11.1. Setting the T803 Option 61 Concentration Alarm Limits ................................................................... 101

6. COMMUNICATIONS SETUP AND OPERATION .............................................................103
6.1. Data Terminal/Communication Equipment (DTE DCE) .................................................................................... 103
6.2. Communication Modes, Baud Rate and Port Testing ................................................................................ 103
6.2.1. COM Port Communication Modes....................................................................................................... 103
6.2.2. COM Port Baud Rate .......................................................................................................................... 106
6.2.3. COM Port Testing................................................................................................................................ 107
6.2.4. Machine ID .......................................................................................................................................... 108
6.3. Remote Access via the Ethernet ................................................................................................................ 109
6.3.1. Configuring the Ethernet using DHCP................................................................................................. 109
6.3.2. Manually Configuring the Network IP Addresses................................................................................ 112
6.3.3. Changing the Analyzer’s HOSTNAME ................................................................................................ 114
6.4. USB Port for Remote Access ..................................................................................................................... 115
6.5. Communications Protocols......................................................................................................................... 117
6.5.1. MODBUS Setup .................................................................................................................................. 117
6.5.2. Hessen ................................................................................................................................................ 118
6.5.3. Setting Hessen Protocol Status Flags................................................................................................. 126
6.5.4. Instrument ID Code ............................................................................................................................. 128

7. DATA ACQUISITION SYSTEM (DAS & APICOM............................................................129
7.1. SETUP  DAS: Using the Data Acquisition System (DAS) ...................................................................... 129
7.1.1. DAS Status .......................................................................................................................................... 130
7.1.2. DAS Structure...................................................................................................................................... 130
7.1.3. Default DAS Channels......................................................................................................................... 131
7.1.4. SETUP DAS VIEW: Viewing DAS Channels and Individual Records......................................... 134
7.1.5. SETUP DAS EDIT: Accessing the DAS Edit Mode .................................................................... 135
7.1.6. Disabling/Enabling Data Channels...................................................................................................... 147
7.2. Remote DAS Configuration ........................................................................................................................ 148
7.2.1. DAS Configuration via APICOM.......................................................................................................... 148

8. REMOTE OPERATION.....................................................................................................151
8.1. Computer Mode .......................................................................................................................................... 151
8.1.1. Remote Control via APICOM .............................................................................................................. 151
8.2. Interactive Mode ......................................................................................................................................... 152
8.3. Remote Access by Modem......................................................................................................................... 155

9. CALIBRATION PROCEDURES .......................................................................................159
9.1. Before Calibration ....................................................................................................................................... 160
9.1.1. Required Equipment, Supplies, and Expendables.............................................................................. 160
9.1.2. Calibration Gases ................................................................................................................................ 160
9.1.3. Data Recording Devices...................................................................................................................... 161
9.2. Manual Calibration Checks and Calibration of the T803 Analyzer............................................................. 162
9.2.1. Setup for Calibration Checks and Calibration ..................................................................................... 162
9.2.2. Performing a Manual Calibration Check.............................................................................................. 163
9.2.3. Performing a Manual Calibration......................................................................................................... 163

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Table of Contents

9.3. Assessing Calibration Quality..................................................................................................................... 166
9.4. Calibration of the T803’s Electronic Subsystems ....................................................................................... 167
9.4.1. Pressure Calibration ............................................................................................................................ 167
9.4.2. Flow Calibration................................................................................................................................... 169

10. MAINTENANCE SCHEDULE & PROCEDURES ...........................................................173
10.1. Maintenance Schedule ............................................................................................................................. 173
10.2. Predictive Diagnostics .............................................................................................................................. 177
10.3. Maintenance Procedures.......................................................................................................................... 177
10.3.1. Replacing the Sample Particulate Filter ............................................................................................ 177
10.3.2. Rebuilding the Sample Pump............................................................................................................ 178
10.3.3. Performing Leak Checks ................................................................................................................... 179
10.3.4. Performing a Sample Flow Check..................................................................................................... 180
10.3.5. Cleaning Exterior Surfaces of the T803 ............................................................................................ 180

11. TROUBLESHOOTING AND SERVICE ..........................................................................181
11.1. General Troubleshooting .......................................................................................................................... 181
11.1.1. Fault Diagnosis with WARNING Messages ...................................................................................... 182
11.1.2. Fault Diagnosis with TEST Functions ............................................................................................... 185
11.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function ..................................................... 186
11.2. Using the Internal Electronic Status LEDs ............................................................................................... 188
11.2.1. CPU Status Indicator ......................................................................................................................... 188
11.2.2. Relay PCA Status Indicators ............................................................................................................. 188
11.3. Gas Flow Problems .................................................................................................................................. 190
11.3.1. T803 Internal Gas Flow Diagrams..................................................................................................... 190
11.3.2. Typical Sample Gas Flow Problems ................................................................................................. 191
11.4. Calibration Problems ................................................................................................................................ 192
11.4.1. Miscalibrated ..................................................................................................................................... 192
11.4.2. Non-Repeatable Zero and Span ....................................................................................................... 193
11.4.3. Inability to Span – No SPAN Button .................................................................................................. 193
11.4.4. Inability to Zero – No ZERO Button................................................................................................... 193
11.5. Other Performance Problems................................................................................................................... 193
11.5.1. Temperature Problems...................................................................................................................... 194
11.6. Subsystem Checkout................................................................................................................................ 194
11.6.1. AC Mains Configuration .................................................................................................................... 194
11.6.2. DC Power Supply .............................................................................................................................. 194
11.6.3. I2C Bus............................................................................................................................................... 195
11.6.4. Touchscreen Interface....................................................................................................................... 195
11.6.5. LCD Display Module.......................................................................................................................... 196
11.6.6. Relay Board....................................................................................................................................... 196
11.6.7. Sensor Assembly............................................................................................................................... 196
11.6.8. Pressure/Flow Sensor Assembly ...................................................................................................... 196
11.6.9. Motherboard ...................................................................................................................................... 198
11.6.10. CPU ................................................................................................................................................. 199
11.6.11. RS-232 Communications ................................................................................................................ 200
11.6.12. CO2 Sensor STATUS LED’s............................................................................................................ 201
11.7. Repair Procedures.................................................................................................................................... 201
11.7.1. Repairing Sample Flow Control Assembly........................................................................................ 201
11.7.2. Disk-On-Module Replacement Procedure ........................................................................................ 202
11.8. FRequently Asked Questions (FAQ’s)...................................................................................................... 203
11.9. Technical Assistance................................................................................................................................ 204

12. PRINCIPLES OF OPERATION ......................................................................................205
12.1. O2 Sensor ................................................................................................................................................. 205
12.1.1. Magnetic Properties of O2 Gas.......................................................................................................... 205
12.1.2. Paramagnetic Measurement of O2 .................................................................................................... 205
12.2. CO2 Sensor ............................................................................................................................................... 207
12.2.1. NDIR Measurement of CO2 ............................................................................................................... 207

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

12.3. Operation within the T803 Analyzer ......................................................................................................... 208
12.4. Pneumatic Operation ................................................................................................................................ 209
12.5. Flow Rate Control ..................................................................................................................................... 210
12.5.1. Critical Flow Orifice............................................................................................................................ 210
12.5.2. Particulate Filter................................................................................................................................. 211
12.5.3. Pneumatic Sensors ........................................................................................................................... 211
12.6. Electronic Operation ................................................................................................................................. 212
12.6.1. Overview............................................................................................................................................ 212
12.6.2. Central Processing Unit (CPU).......................................................................................................... 213
12.6.3. Relay Board....................................................................................................................................... 215
12.6.4. Heater Control ................................................................................................................................... 217
12.6.5. Motherboard ...................................................................................................................................... 218
12.6.6. I2C Data Bus...................................................................................................................................... 219
12.6.7. Power Supply / Circuit Breaker ......................................................................................................... 220
12.6.8. Front Panel Touchscreen/Display Interface ...................................................................................... 221
12.6.9. Software Operation............................................................................................................................ 222
12.6.10. Adaptive Filter.................................................................................................................................. 222
12.6.11. Calibration - Slope and Offset ......................................................................................................... 223
12.6.12. Temperature and Pressure Compensation ..................................................................................... 223
12.6.13. Internal Data Acquisition System (DAS) ......................................................................................... 223

13. A PRIMER ON ELECTRO-STATIC DISCHARGE .........................................................225
13.1. How Static Charges are Created.............................................................................................................. 225
13.2. How Electro-Static Charges Cause Damage ........................................................................................... 226
13.3. Common Myths About ESD Damage ....................................................................................................... 227
13.4. Basic Principles of Static Control.............................................................................................................. 228
13.4.1. General Rules.................................................................................................................................... 228
13.4.2. Basic Anti-ESD Procedures for Analyzer Repair and Maintenance.................................................. 229
INDEX............................................................................................................................................................ 237

LIST OF FIGURES
Figure 3-1:
Figure 3-2:
Figure 3-3:
Figure 3-4:
Figure 3-5:
Figure 3-6:
Figure 3-7:
Figure 3-8:
Figure 3-9:
Figure 3-10:
Figure 3-11:
Figure 3-12:
Figure 3-13:
Figure 3-14:
Figure 3-15:
Figure 3-16:
Figure 3-17:
Figure 3-18:
Figure 4-1:
Figure 4-2:
Figure 5-1:
Figure 5-2:
Figure 5-3:
Figure 5-4:

xii

Front Panel Layout ......................................................................................................... 25
Display Screen and Touch Control................................................................................. 26
Display/Touch Control Screen Mapped to Menu Charts................................................ 28
Rear Panel Layout.......................................................................................................... 29
Internal Layout................................................................................................................ 31
Analog In Connector....................................................................................................... 33
Analog Output Connector............................................................................................... 34
Current Loop Option Installed ........................................................................................ 35
Status Output Connector................................................................................................ 37
Control Input Connector ................................................................................................. 38
Concentration Alarm Relay ............................................................................................ 39
Default Pin Assignments, Rear Panel COM Port Connectors ....................................... 41
CPU Connector Pin-Outs for RS-232 Mode................................................................... 42
Jumper and Cables for Multidrop Mode ......................................................................... 44
RS-232-Multidrop PCA Host/Analyzer Interconnect Diagram........................................ 45
Pneumatic Connections, Using Bottled Span Gas......................................................... 48
T803 Internal Gas Flow .................................................................................................. 49
Viewing and Clearing T803 WARNING Messages ........................................................ 52
Front Panel Display ........................................................................................................ 58
Viewing T803 Test Functions ......................................................................................... 59
Analog Output Connector Pin Out.................................................................................. 65
Setup for Checking / Calibrating DCV Analog Output Signal Levels ............................. 89
Setup for Checking / Calibration Current Output Signal Levels Using an Ammeter ...... 91
Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ..... 93

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Figure 7-1:
Figure 7-2:
Figure 7-3:
Figure 9-1:
Figure 10-1:
Figure 11-1:
Figure 11-2:
Figure 11-3:
Figure 11-4:
Figure 11-5:
Figure 11-6:
Figure 11-7:
Figure 12-1:
Figure 12-2:
Figure 12-3.
Figure 12-4.
Figure 12-5:
Figure 12-6:
Figure 12-7:
Figure 12-8.
Figure 12-9:
Figure 12-10:
Figure 12-11:
Figure 12-12:
Figure 12-13:
Figure 12-14:
Figure 13-1:
Figure 13-2:

Table of Contents

Default DAS Channel Setup......................................................................................... 133
APICOM Remote Control Program Interface ............................................................... 148
APICOM User Interface for Configuring the DAS ........................................................ 149
Pneumatic Connections Using Bottled Span Gas........................................................ 162
Sample Particulate Filter Assembly.............................................................................. 178
Viewing and Clearing Warning Messages ................................................................... 184
Example of Signal I/O Function.................................................................................... 187
CPU Status Indicator .................................................................................................... 188
Relay PCA Status LEDs Used for Troubleshooting ..................................................... 189
T803 – Internal Gas Flow ............................................................................................. 190
Location of Diagnostic LEDs on CO2 Sensor PCA....................................................... 201
Critical Flow Restrictor Assembly / Disassembly ......................................................... 202
Paramagnetic O2 Sensor Design ................................................................................. 206
Paramagnetic O2 Sensor Block Diagram ..................................................................... 206
CO2 Sensor Theory of Operation ................................................................................. 207
CO2 Sensor PCA Layout and Electronic Connections ................................................. 208
Internal Pneumatic Flow............................................................................................... 209
Flow Control Assembly & Critical Flow Orifice ............................................................. 211
T803 Electronic Block Diagram .................................................................................... 213
CPU Card ..................................................................................................................... 214
Relay PCA Layout (PN 04135)..................................................................................... 215
Relay PCA with AC Relay Retainer in Place................................................................ 216
Status LED Locations – Relay PCA ............................................................................. 217
Power Distribution Block Diagram................................................................................ 220
Front Panel and Display Interface Block Diagram ....................................................... 221
Basic Software Operation............................................................................................. 222
Triboelectric Charging .................................................................................................. 225
Basic Anti-ESD Workbench.......................................................................................... 228

LIST OF TABLES
Table 1-1:
Table 2-1:
Table 3-1:
Table 3-2:
Table 3-3:
Table 3-4.
Table 3-5:
Table 3-6:
Table 3-7:
Table 3-8:
Table 3-9:
Table 4-1:
Table 4-2:
Table 6-4:
Table 6-5:
Table 5-6:
Table 5-1:
Table 5-2:
Table 5-3:
Table 5-4:
Table 5-5:
Table 5-6:

07276B DCN6418

Analyzer Options ............................................................................................................ 18
T803 Specifications ........................................................................................................ 21
Ventilation Clearance ..................................................................................................... 25
Display Screen and Touch Control Description ............................................................. 27
Rear Panel Component Descriptions ............................................................................. 30
Analog Input Pin Assignments ....................................................................................... 33
Analog Output Pin-Outs ................................................................................................. 34
Status Output Signals..................................................................................................... 37
Control Input Signals ...................................................................................................... 38
Front Panel Display during System Warm-Up ............................................................... 50
Warning Messages......................................................................................................... 51
Analyzer Operating Modes............................................................................................. 58
Test Functions Defined .................................................................................................. 60
Primary Setup Mode Features and Functions................................................................ 61
Secondary Setup Mode Features and Functions........................................................... 62
Password Levels ............................................................................................................ 73
Variable Names (VARS)................................................................................................. 78
Diagnostic Mode (DIAG) Functions................................................................................ 80
DIAG - Analog I/O Functions.......................................................................................... 82
Analog Output Voltage Range Min/Max......................................................................... 84
Voltage Tolerances for the TEST CHANNEL Calibration .............................................. 89
Current Loop Output Check ........................................................................................... 93

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Table 5-7:
Table 5-8:
Table 6-1:
Table 6-2:
Table 6-3:
Table 6-4:
Table 6-5:
Table 6-6:
Table 7-1:
Table 7-2:
Table 7-3:
Table 8-1:
Table 8-2:
Table 9-1:
Table 9-2:
Table 10-1:
Table 10-2:
Table 10-3:
Table 11-1:
Table 11-2:
Table 11-3:
Table 11-4:
Table 11-5:
Table 11-6:
Table 11-7:
Table 11-8:
Table 12-1:
Table 13-1:
Table 13-2:

Test Channels Functions available on the T803’s Analog Output ................................. 96
Concentration Alarm Default Settings .......................................................................... 100
COM Port Communication Modes................................................................................ 104
Ethernet Status Indicators ............................................................................................ 109
LAN/Internet Configuration Properties ......................................................................... 110
RS-232 Communication Parameters for Hessen Protocol........................................... 119
Teledyne API Hessen Protocol Response Modes ....................................................... 122
Default Hessen Status Flag Assignments.................................................................... 126
SAMPLE LED Status Indicators for DAS ..................................................................... 130
DAS Data Channel Properties...................................................................................... 131
DAS Data Parameter Functions ................................................................................... 138
Terminal Mode Software Commands........................................................................... 152
Teledyne API Serial I/O Command Types ................................................................... 153
NIST SRM's Available for Traceability of O2 Calibration Gases.................................... 161
Calibration Data Quality Evaluation.............................................................................. 166
T803 Maintenance Schedule........................................................................................ 175
T803 Test Function Record.......................................................................................... 176
Predictive uses for Test Functions ............................................................................... 177
Warning Messages - Indicated Failures ....................................................................... 184
Test Functions - Indicated Failures .............................................................................. 186
Relay PCA Watchdog LED Failure Indications ............................................................ 188
Relay PCA Status LED Failure Indications .................................................................. 189
DC Power Test Point and Wiring Color Codes ............................................................ 194
DC Power Supply Acceptable Levels........................................................................... 195
Analog Output Test Function - Nominal Values Current Outputs ................................ 198
Status Outputs Check .................................................................................................. 199
Relay PCA Status LEDs............................................................................................... 216
Static Generation Voltages for Typical Activities.......................................................... 225
Sensitivity of Electronic Devices to Damage by ESD................................................... 226

LIST OF APPENDICES
APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION v. A.4 (E-Series); 1.0.3 (T-Series)
A-1 - Software Menu Trees
A-2 - Setup Variables for Serial I/O
A-3 - Warnings and Test Functions
A-4 - Signal I/O Definitions
A-5 - DAS Functions
A-6 - Terminal Command Designators
A-7 - MODBUS® Register Map
APPENDIX B - SPARE PARTS LIST
APPENDIX C – REPAIR QUESTIONNAIRE
APPENDIX D – ELECTRONIC SCHEMATICS

xiv

07276B DCN6418

PART I
–
GENERAL INFORMATION AND SETUP

07276B DCN6418

Section 1 General Information

Teledyne API T803 CO2/O2 Analyzer Operation Manual

This page intentionally left blank.

07276B DCN6418

1. INTRODUCTION, FEATUERES, AND OPTIONS
1.1. T803 OVERVIEW
The Model T803 Carbon Dioxide/Oxygen Analyzer (T803 CO2/O2 Analyzer) is
a microprocessor-controlled analyzer that determines the concentration of
molecular carbon dioxide (CO2) and oxygen (O2) in the sample gas drawn
through the instrument. It uses infrared absorption to measure CO2 concentration
and paramagnetic technology to measure O2 concentration.
The Model T803 analyzer’s multi-tasking software gives the ability to track and
report a large number of operational parameters in real time. These readings are
compared to diagnostic limits kept in the analyzer’s memory where, should any
fall outside of those limits, the analyzer issues automatic warnings.
Built-in data acquisition capability using the analyzer's internal memory, allows
the logging of multiple parameters including averaged or instantaneous
concentration values, calibration data, and operating parameters such as pressure
and flow rate. Stored data are easily retrieved through the serial port or Ethernet
port via our APICOM software or from the front panel, allowing operators to
perform predictive diagnostics and enhanced data analysis by tracking parameter
trends. Multiple averaging periods of one minute to 365 days are available for
over a period of one year.

1.2. FEATURES
Some of the exceptional features of your T803 CO2 / O2 Analyzer are:


Non-depleting, CO2/O2 measurement technologies:
 Virtually no cross-sensitivities
 Rapid response times
 No consumable parts
 Consistent performance over time

07276B DCN6418



Microprocessor controlled for versatility



LCD Graphical User Interface with capacitive touch screen



Multi-tasking software for viewing of test variables during operation



Continuous self checking with alarms



Bi-directional USB, RS-232, and 10/100Base-T Ethernet (optional USB and
RS-485) ports for remote operation



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

Introduction, Featueres, and Options

Teledyne API T803 CO2/O2 Analyzer Operation Manual

HAZARD
OXYGEN IS A STRONG OXIDIZER.
This is a general purpose instrument designed for usage in nonhazardous areas.
Ensure that all safety precautions related combustible gases are followed.
Before working with the casing open, be sure to turn off power to the analyzer, and
perform air or N2 gas purging of not only the analyzer inside, but also the sample gas
line.
In addition, carefully prevent oil and grease from adhering to any tubing. Otherwise,
poisoning, fire or explosion may be caused due to gas leakage, etc.

1.3. OPTIONS
Table 1-1 presents the options available with this analyzer. For assistance with
ordering, please contact the Sales department of Teledyne API at:

Table 1-1:
Option

800-324-5190

FAX:

858-657-9816

PHONE (Direct):

858-657-9800

E-MAIL:

api-sales@teledyne.com

WEB SITE

www.teledyne-api.com

Analyzer Options
Option
Number

Description/Notes

Reference

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

Pumps
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

Internal Pump

N/A

High Voltage Internal Pump 240V @ 50Hz

N/A

Rack Mount
Kits

PHONE (toll free,
North America)

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

Rack mount brackets only (compatible with carrying strap, Option 29)

N/A

Rack mount for external pump pack (no slides)

N/A

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Option
Number

Option

Carrying Strap/Handle

Introduction, Featueres, and Options

Description/Notes

Reference

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 T803 WEIGHS ABOUT 28 POUNDS (12.7 KG). TAKE CARE TO
AVOID PERSONAL INJURY WHEN LIFTING/CARRYING THE
ANALYZER.
ALSO, DISCONNECT ALL CABLES AND TUBING FROM THE
ANALYZER BEFORE MOVING IT.
Analog Inputs w/USB port
64B
Current Loop Analog
Outputs
41
Parts Kits

Used for connecting external voltage signals from other instrumentation (such as
meteorological instruments).
Also can be used for logging these signals in the analyzer’s internal
DAS. (See Option 64A for USB port only).

Adds isolated voltage-to-current conversion circuitry to the analyzer’s analog
outputs.
Can be configured for 0-20 mA or 4-20 mA.
May be ordered separately for any of the analog outputs.
Can be installed at the factory or retrofitted in the field.

Section 3.3.1.4

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
Shielded, straight-through DB-9F to DB-25M cable, about
1.8 m long. Used to interface with older computers or
code activated switches with DB-25 serial connectors.

60A

RS-232

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.

Concentration Alarm Relay
61
RS-232 Multidrop
62

07276B DCN6418

Sections 3.3.1.2
and 5.10.8

Sections 3.3.1.8
and 6

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

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

Introduction, Featueres, and Options

Option

Option
Number

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Description/Notes

Reference

USB COM Port
64A
Special Features

N/A

Separate option if instrument not configured with Option 64B (analog
inputs). Disabled when using Multidrop or RS-485 communication.
Built in features, software activated
Maintenance Mode Switch, located inside the instrument, places the
analyzer in maintenance mode where it can continue sampling, yet
ignore calibration, diagnostic, and reset instrument commands. This
feature is of particular use for instruments connected to Multidrop or
Hessen protocol networks.

Sections 3.3.1.8 and
6.4

N/A

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.

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.

N/A

Section 5.4.4

Call Technical Support for activation.

07276B DCN6418

2. SPECIFICATIONS, APPROVALS & COMPLIANCE
2.1. SPECIFICATIONS
Table 2-1:

T803 Specifications

Parameter

Description

CO2
Ranges

Min: 0-1% Full scale
Max: 0-20% Full scale (user selectable, dual ranges and auto-ranging supported)

Zero Noise1

<0.02% (RMS)

Span Noise

< 0.1% of reading (RMS)

Lower Detectable Limit2

<0.04%

Zero Drift

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

Span Drift (7 days)

<± 0.1%

Accuracy

<± (1.5% of range + 2% of reading)

Temperature Coefficient

<± 0.01% /°C

Ranges

Min: 0-1% Full scale
Max: 0-100% Full scale (user selectable)

Zero Noise1
Lower Detectable Limit

<0.02% (RMS)
2

<0.04%

Zero Drift 3

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

Span Noise1

< 0.05% of reading (RMS)

Span Drift (7 days)

<± 0.1%

Accuracy

<± 0.1%

Linearity

<± 0.1 %

Temperature Coefficient

<± 0.01% /°C

Rise and Fall Time

<60 seconds to 95%

Sample Flow Rate

120ml ± 20ml/min

Humidity Range

0-95% RH, Non-Condensing

Pressure Range

25-31 in•Hg

Temperature Range

5 - 40C operating

Dimensions (HxWxD)

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

Weight

28 lb (12.7 kg)

AC Power

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

Analog Output Ranges

0.1 V, 1 V, 5 V or 10 V (selectable)
Three outputs convertible to 4-20 mA isolated current loop.
All Ranges with 5% under/over-range

Recorder Offset

± 10%

Analog Output Resolution

1 part in 4096 of selected full-scale voltage

07276B DCN6418

Specifications, Approvals & Compliance

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Parameter

Description

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

1
2

As defined by the USEPA

Defined as twice the zero noise level by the USEPA
3
Note: zero drift is typically <± 0.1% O2 during the first 24 hrs of operation

2.2. APPROVALS AND CERTIFICATIONS
The Teledyne API Model T803 Carbon Dioxide/Oxygen Analyzer was tested and
certified for Safety and Electromagnetic Compatibility (EMC). This section
presents the compliance statements for those requirements and directives.

2.2.1. SAFETY
IEC 61010-1:2001, Safety requirements for electrical equipment for
measurement, control, and laboratory use.
CE: 2006/95/EC, Low-Voltage Directive
North American:
cNEMKO (Canada): CAN/CSA-C22.2 No. 61010-1-04
NEMKO-CCL (US): UL No. 61010-1 (2nd Edition)

2.2.2. EMC
EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial Immunity
EN 55011 (CISPR 11), Group 1, Class A Emissions
FCC 47 CFR Part 15B, Class A Emissions
CE: 2004/108/EC, Electromagnetic Compatibility Directive

2.2.3. OTHER TYPE CERTIFICATIONS
For additional certifications, please contact Technical Support:
Toll-free Phone:

800-324-5190

Phone:

858-657-9800

Fax:

858-657-9816

Email:

sda_techsupport@teledyne.com

07276B DCN6418

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

3.1. UNPACKING THE T803 ANALYZER
CAUTION
GENERAL SAFETY HAZARD
To avoid personal injury, always use two persons to lift and carry the T803.

CAUTION – AVOID WARRANTY INVALIDATION
Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to
be felt by the human nervous system. Damage resulting from failure to use ESD
protection when working with electronic assemblies will void the instrument warranty.
See A Primer on Electro-Static Discharge in this manual for more information on preventing
ESD damage.

CAUTION!
Do not operate this instrument until removing dust plugs from SAMPLE and EXHAUST
ports on the rear panel!

Note

Teledyne API recommends that you store shipping containers/materials
for future use if/when the instrument should be returned to the factory
for repair and/or calibration service. See Warranty section in this manual
and shipping procedures on our Website at http://www.teledyne-api.com
under Customer Support > Return Authorization.

Verify that there is no apparent external shipping damage. If damage has
occurred, please advise the shipper first, then Teledyne API. Keep the shipping
container/packaging intact for the shipper’s examination.
Included with your analyzer is a printed record of the final performance
characterization performed on your instrument at the factory.

07276B DCN6418

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

This record, Final Test and Validation Data Sheet, PN 068360000 is an
important quality assurance and calibration record for this instrument. It
should be placed in the quality records file for this instrument.
1. Carefully remove the top cover of the analyzer and check for internal shipping
damage as follows:
a) Remove the locking screw located in the top, center of the Front panel;
b) Remove the two flat head, Phillips screws on the sides of the instrument
(one per side towards the rear);
c) Slide the cover backwards until it clears the analyzer’s front bezel;
d) Lift the cover straight up.
2. Inspect the interior of the instrument to make sure all circuit boards and other
components are in good shape and properly seated.
3. Check that the connectors of the various internal wiring harnesses and
pneumatic hoses are firmly and properly seated.
4. Verify that all of the optional hardware ordered with the unit has been
installed. These are listed on the paperwork accompanying the analyzer.

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Getting Started

3.1.1. VENTILATION CLEARANCE
Whether the analyzer is set up on a bench or installed into an instrument rack, be
sure to leave sufficient ventilation clearance.
Table 3-1:

Ventilation Clearance

AREA

MINIMUM REQUIRED CLEARANCE

Back of the instrument

4 in.

Sides of the instrument

1 in.

Above and below the instrument

1 in.

3.2. INSTRUMENT LAYOUT
Instrument layout shows front panel and display, rear panel connectors, and
internal chassis layout.

3.2.1. FRONT PANEL

Figure 3-1:

07276B DCN6418

Front Panel Layout

Getting Started

Teledyne API T803 CO2/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.

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Table 3-2:

Display Screen and Touch Control Description

Field
Status

Getting Started

Description/Function
LEDs indicating the states of Sample, Calibration and Fault, as follows:
Name

Color

SAMPLE

Green

State
Off
On
Blinking

Definition
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
On
Blinking

Auto Cal disabled
Auto Cal enabled
Unit is in calibration mode

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.

07276B DCN6418

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Figure 3-3:

Display/Touch Control Screen Mapped to Menu Charts

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Getting Started

3.2.2. REAR PANEL

Figure 3-4:

07276B DCN6418

Rear Panel Layout

Getting Started

Teledyne API T803 CO2/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.
Connector for three-prong cord to apply AC power to the analyzer.

AC Power CAUTION! The cord’s power specifications (specs) MUST comply with the power
Connector specs on the analyzer’s rear panel Model number/Volt/Freq information label
Model/specs label Identifies analyzer’s model number, and provides voltage and frequency specifications

SAMPLE

Inlet connection to be used for any one of the following:

Sample gas

Span gas

Calibration gas

Zero air
Connect an exhaust gas line of not more than 10 meters long here that leads outside

EXHAUST 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.
Switch to select either data terminal equipment or data communication equipment

DCE DTE during RS-232 communication.

STATUS For ouputs 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
Option for external voltage signals from other instrumentation and for logging these

ANALOG IN signals

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

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Getting Started

3.2.3. INTERNAL CHASSIS LAYOUT

Figure 3-5:

07276B DCN6418

Internal Layout

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

3.3. CONNECTIONS AND SETUP
This section presents the electrical (Section 3.3.1) and pneumatic (Section 0)
connections for setup and preparing for instrument operation.

3.3.1. ELECTRICAL CONNECTIONS
CAUTION
ELECTRICAL SHOCK HAZARD
Never disconnect PCAs, wiring harnesses or electronic subassemblies while the
analyzer is under power.

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

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Getting Started

CAUTION
GENERAL SAFETY HAZARD
The T803 analyzer can be configured for both 100-130 V and 210-240 V at either
47 or 63 Hz.
To avoid damage to your analyzer, make sure that the AC power voltage
matches the voltage indicated on the Analyzer’s serial number label tag (See
Figure 3-4) before plugging the T803 into line power.

3.3.1.2. ANALOG INPUTS (OPTION 64) CONNECTIONS
The Analog In connector is used for connecting external voltage signals from
other instrumentation (such as meteorological instruments) and for logging these
signals in the analyzer’s internal DAS. The input voltage range for each analog
input is 0-10 VDC, and the input impedance is nominally 20kΩ in parallel with
0.1µF.

Figure 3-6:

Analog In Connector

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

DAS
PARAMETER1

Analog input # 1

AIN 1

Analog input # 2

AIN 2

Analog input # 3

AIN 3

Analog input # 4

AIN 4

Analog input # 5

AIN 5

Analog input # 6

AIN 6

Analog input # 7

AIN 7

07276B DCN6418

DESCRIPTION

GND
1

Analog Input Pin Assignments

Analog input # 8

AIN 8

Analog input Ground

N/A

See Section 7.1 for details on setting up the DAS.

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

3.3.1.3. ANALOG OUTPUT CONNECTIONS
The T803 is equipped with several analog output channels accessible through the
ANALOG OUT connector on the rear panel of the instrument. The standard
configuration for these outputs is VDC. An optional current loop output is
available for each (Section 3.3.1.4).
When the instrument is in its default configuration, channel A1 outputs a signal
that is proportional to the CO2 concentration of the sample gas. If Dual or Auto
range is configured, channels A1 and A2 each output a signal proportional to the
CO2 concentration of the sample gas. Please refer to Section 5.4.3 for details.
Channel A3 outputs a signal proportional to the O2 concentration of the sample
gas.
Channel A4 is special. It can be set by the user (see Section 5.10.6) to output any
one of the parameters accessible through the buttons of the unit’s
front panel menu.
To access these signals attach a strip chart recorder and/or data-logger to the
appropriate analog output connections on the rear panel of the analyzer.
ANALOG OUT

A1
+

A2
-

Figure 3-7:
Table 3-5:
PIN
1
2
3
4
5
6
7
8

A3
-

A4
-

Analog Output Connector

Analog Output Pin-Outs
ANALOG OUTPUT
A1
A2
A3
A4

VOLTAGE SIGNAL

CURRENT SIGNAL

V Out

I Out +

Ground

I Out -

V Out

I Out +

Ground

I Out -

V Out

I Out +

Ground

I Out -

V Out

Ground

3.3.1.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41) SETUP
This option adds isolated, voltage-to-current conversion circuitry to the
analyzer’s analog outputs. This option may be ordered separately for any of the
analog outputs; it can be installed at the factory or added later. Call TELEDYNE
API Sales for pricing and availability.

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Figure 3-8:

Getting Started

Current Loop Option Installed

CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD
VOLTAGE OUTPUTS
CAUTION
Servicing or handling of circuit components requires electrostatic discharge
(ESD) protection, i.e. ESD grounding straps, mats and containers. Failure to
use ESD protection when working with electronic assemblies will void the
instrument warranty. See Section 12 for more information on preventing ESD
damage.

To convert an output configured for current loop operation to the standard 0 to 5
VDC output operation:
1. Turn off power to the analyzer.
2. If a recording device was connected to the output being modified, disconnect
it.
3. Remove the top cover:

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a) Remove the set screw located at the top center of the rear panel
b) Remove the screws fastening the top cover to the unit (two per side).
c) Slide cover back.
d) Lift the cover straight up.
4. Remove the screw holding the current loop option to the motherboard.
5. Disconnect the current loop option PCA from the appropriate connector on
the motherboard (see Figure 3-8).
Each connector, J19, J21 and J23, requires two shunts. Place one shunt on
the two left most pins and the second shunt on the two pins next to it (refer to
Figure 3-8 for an example).
6. 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

Figure 3-9:

CO2 CAL

5
CAL MODE – RANGE 2

4
SPAN CAL / ZERO MODE

3
CAL MODE / MEAS MODE

2
CONC VALID

SYSTEM OK

Status Output Connector

Table 3-6: Status Output Signals
Rear Panel Label

Status Definition

Condition
ON if no faults are present.
OFF if alarm condition

SYSTEM
OK/ALARM

CONC
VALID/CONC
INVALID

ON if concentration measurement is valid.
OFF any time the HOLD OFF feature is active, such as during calibration or when
any faults exist invalidating the measurement.

CAL MODE/
MEAS MODE

ON whenever the instrument is in Calibration Mode
OFF when instrument in Measure Mode

SPAN/ZERO
CAL

ON whenever the instrument’s SPAN point is being calibrated.
OFF whenever the instrument’s ZERO point is being calibrated.

RANGE2 CAL
RANGE1 CAL

ON if unit is in high range of either the DUAL or AUTO range modes.
OFF if unit is in default low, single range mode

CO2/O2 Sensor CAL

7&8

ON when CO2 sensor is in calibration mode.
OFF when O2 sensor is in calibration mode.

SPARE

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,

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

CONTROL IN

+
CAL/MEAS MODE

Figure 3-10:
Table 3-7:
Status Definition

CALIBRATION MODE or
MEASURE MODE

REMOTE SPAN or
REMOTE ZERO
CALIBRATION

RANGE2 or RANGE1
CALIBRATION

O2 SENSOR or CO2
SENSOR CALIBRATION

E&F

5 VDC
Power Supply

Control Input Connector
Control Input Signals

Open/Closed Condition Description
Open: initiates Calibration mode. The mode field of the front panel display
will read CO2 CAL R, CO2 CAL ZR, O2 CAL R or O2 CAL ZR
Closed: initiates Measure mode. The mode field of the front panel display
will read CO2 R, CO2 ZR, O2 R, or O2 ZR
Open: initiates remote SPAN calibration mode as part of performing a low
span calibration. The mode field of the front panel display will read CO2 CAL
SR or O2 CAL SR.
Closed: initiates remote ZERO calibration mode. The mode field of the front
panel display will read ZERO MODE.
Open: selects Range 2 for calibration.
Closed: selects Range 1, default range in single range mode.
Open: initiates calibration of the O2 sensor. The mode field of the front panel
display will read O2 CAL R or O2 CAL ZR.
Closed: Initiates calibration of the CO2 sensor. The mode field of the front
panel display will read CO2 CAL R or CO2 CAL ZR

SPARE
Digital Ground

External Power input

5 VDC output

External Power Connections

Local Power Connections

Input #

O2/CO2 CAL

RANGE SELECTION

SPAN/ZERO CAL

D
O2/CO2 CAL

C
RANGE SELECTION

B
SPAN/ZERO CAL

CAL/MEAS MODE

The ground level from the analyzer’s internal DC power supplies (same as
chassis ground)
Input pin for +5 VDC required to activate Pins A – F.
Internally generated 5V DC power. To activate inputs A – F, place a jumper
between this pin and the “U” pin. The maximum amperage through this port
is 300 mA (combined with the analog output supply, if used).

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3.3.1.7. CONCENTRATION ALARM RELAY (OPTION 61)
The Teledyne API T-Series analyzers have an option for four (4) “dry contact”
relays on the rear panel of the instrument. This relay option is different from and
in addition to the “Contact Closures” that come standard on all TAPI instruments.
The relays have three pins that have connections on the rear panel (refer Figure
3-11). They are a Common (C), a Normally Open (NO), and a Normally Closed
(NC) pin.

Figure 3-11:
Alarm 1
Alarm 2
Alarm 3
Alarm 4

Concentration Alarm Relay

“System OK 2”
“Conc 1”
“Conc 2”
“Range Bit”

“ALARM 1” RELAY

Alarm 1 which is “System OK 2” (system OK 1, is the status bit) is in the
energized state when the instrument is “OK” & there are no warnings. If there is
a warning active or if the instrument is put into the “DIAG” mode, Alarm 1 will
change states. This alarm has “reverse logic” meaning that if you put a meter
across the Common & Normally Closed pins on the connector you will find that
it is OPEN when the instrument is OK. This is so that if the instrument should
turn off or lose power, it will change states & you can record this with a data
logger or other recording device.
“ALARM 2” RELAY & “ALARM 3” RELAY

The “Alarm 2 Relay” on the rear panel, is associated with the “Concentration
Alarm 1” set point in the software & the “Alarm 3 Relay” on the rear panel is
associated with the “Concentration Alarm 2” set point in the software.
Alarm 2 Relay
CO2 Alarm 1 = xxx %
Alarm 3 Relay
CO2 Alarm 2 = xxx %
Alarm 2 Relay O2 Alarm 1 = xxx %
Alarm 3 Relay
O2 Alarm 2 = xxx %

The Alarm 2 Relay will be turned on any time the concentration set-point is
exceeded & will return to its normal state when the concentration value goes back
below the concentration set-point.
Even though the relay on the rear panel is a NON-Latching alarm & resets when
the concentration goes back below the alarm set point, the warning on the front
panel of the instrument will remain latched until it is cleared. You can clear the
warning on the front panel by either pushing the CLR button on the front panel or
through the serial port.

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The software for this instrument is flexible enough to allow you to configure the
alarms so that you can have 2 alarm levels for each gas.
CO2 Alarm 1 = 20 %
CO2 Alarm 2 = 100 %
O2 Alarm 1 = 20 %
O2 Alarm 2 = 100 %

In this example, O2 Alarm 1 & CO2 Alarm 1 will both be associated with the
“Alarm 2” relay on the rear panel. This allows you to have multiple alarm levels
for individual gases.
A more likely configuration for this would be to put one gas on the “Alarm 1”
relay and the other gas on the “Alarm 2” relay.
CO2 Alarm 1 = 20 %
CO2 Alarm 2 = Disabled
O2 Alarm 1 = Disabled
O2 Alarm 2 = 80 %
“ALARM 4” RELAY

This relay is connected to the “range bit”. If the instrument is configured for
“Auto Range”, and the instrument goes up into the high range, it will turn this
relay on.
3.3.1.8. COMMUNICATION CONNECTIONS
The T-Series analyzers are equipped with connectors for remote communications
interfaces: Ethernet, USB, RS-232, optional RS-232 Multidrop, and optional RS485. 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.
ETHERNET CONNECTION

For network or Internet communication with the analyzer, connect an Ethernet
cable from the analyzer’s rear panel Ethernet interface connector to an Ethernet
port. Please refer to Section 6.3 for a description of the default configuration and
setup instructions.
USB OPTION CONNECTION

For direct communication between the analyzer and a personal computer (PC),
connect a USB cable between the analyzer and desktop or laptop USB ports. (If
this option is installed, the COM2 port can only be used for RS232 multidrop
communication). USB download is required (Section 6.4).
RS-232 CONNECTION

For RS-232 communications with data terminal equipment (DTE) or with data
communication equipment (DCE) connect the applicable cable option (Table 1-1:
either a DB9-female-to-DB25-male cable, Option 60A, or a DB9-female-to-DB9female cable, Option 60B) from the analyzer’s rear panel RS-232 port to the
device. Adjust the DCE-DTE switch located on the rear panel (Figure 3-4) to
select DTE or DCE as appropriate (Section 6.1).

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IMPORTANT

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IMPACT ON READINGS OR DATA
Cables that appear to be compatible because of matching
connectors may incorporate internal wiring that makes the link
inoperable. Check cables acquired from sources other than
Teledyne API for pin assignments before using.
Received from the factory, the analyzer is set up to emulate a DCE or modem,
with Pin 3 of the DB-9 connector designated for receiving data and Pin 2
designated for sending data..


COM1: RS-232 (fixed) DB-9 male connector
 Baud rate: 115200 bits per second (baud)
 Data Bits: 8 data bits with 1 stop bit
 Parity: None



COM2: RS-232 (configurable to RS 485), DB-9 female connector
 Baud rate:19200 bits per second (baud)
 Data Bits: 8 data bits with 1 stop bit
 Parity: None

Figure 3-12:

Default Pin Assignments, Rear Panel COM Port Connectors

The signals from these two connectors are routed from the motherboard via a
wiring harness to two 10-pin connectors on the CPU card, J11 and J12.

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Figure 3-13:

CPU Connector Pin-Outs for RS-232 Mode

To assist in properly connecting the serial ports to either a computer or a modem,
there are activity indicators just above the RS-232 port. Once a cable is
connected between the analyzer and a computer or modem, both the red and
green LEDs should be on.


If the lights are not lit, use the small switch on the rear panel to switch it
between DTE and DCE modes

If both LEDs are still not illuminated, make sure the cable is properly
constructed.
RS-232 MULTIDROP OPTION CONNECTION

When the RS-232 Multidrop option is installed, connection adjustments and
configuration through the menu system are required. This section provides
instructions for the internal connection adjustments, then for external
connections, and ends with instructions for menu-driven configuration.
Note

Because the RS-232 Multidrop option uses both the RS232 and
COM2 DB9 connectors on the analyzer’s rear panel to connect the
chain of instruments, COM2 port is no longer available for separate
RS-232 or RS-485 operation.

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ATTENTION

Getting Started

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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Female DB9

Host

Male DB9

RS-232 port

Analyzer

Last Analyzer

COM2

RS-232

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 6.2.4).
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
CAUTION
GENERAL SAFETY HAZARD: CO2
While CO2 itself is not toxic, in sufficient concentrations it can be an irritant and
an asphyxiant.
Obtain a Material Safety Data Sheet for CO2 and any other hazardous components
of sample and calibration gases, and follow the prescribed safety guidelines.
Do not vent sample gases into the immediate vicinity of the analyzer nor into any
enclosed areas.

CAUTION
GENERAL SAFETY HAZARD: O2
While O2 is itself not toxic, the sample gas measured by, and in some cases the
calibration gases used with the T803 can contain other components that are
hazardous (e.g. NO, NO2, SO2, CO, etc).
Obtain a Material Safety Data Sheet (MSDS) for each such gas.
rigorously follow the safety guidelines described there.

Read and

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

3.3.2.1. CALIBRATION GASES
3.3.2.2. ZERO GAS
Zero gas is similar in chemical composition to the earth’s atmosphere but
scrubbed of all components that might affect the analyzer’s readings. Teledyne
API recommends using pure N2 when calibrating the zero point of your O2 and
CO2 sensors.

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CAUTION
GENERAL SAFETY HAZARD
Rapid release of pure N2 gas into an enclosed space can displace oxygen, and
therefore represents an asphyxiation hazard. This may happen with few
warning symptoms.
Do not vent calibration gases into enclosed areas.

3.3.2.3. 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. Teledyne
API recommends the following when calibrating the span point of each sensor:


O2 sensor: 21% O2 in N2



CO2 sensor: 16% CO2 in N2

Cylinders of calibrated gas traceable to NIST-Standard Reference Material
specifications (also referred to as SRMs or EPA protocol calibration gases) are
commercially available.
3.3.2.4. INTERFERENTS
Some gases, if present in the sample stream in high concentrations, could
potentially interfere with the analyzer. For example, if the Sample Gas to be
measured contains high levels of nitrogen dioxide (NO2) and/or nitrous oxide
(NO), the gases used for both the zero point calibration and the span calibration
should contain the same components in the same proportion in order to cancel
any interference effects.
3.3.2.5. BASIC PNEUMATIC CONNECTIONS
See Figure 3-4 and Table 3-3 for the location and descriptions of the various
pneumatic inlets/outlets referred to in this section.

CAUTION
GENERAL SAFETY HAZARD
Sample and calibration gases should only come into contact with Stainless Steel,
PTFE (Teflon) tubing, glass or electroless nickel.
The exhaust from the analyzer’s internal or customer supplied external pump
MUST be vented outside the immediate area or shelter surrounding the instrument.

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(O2 at 20.95% or
CO2 at 16%
Span Concentration)

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Calibrated gas

100%
Concentration

Calibrated N2

Getting Started

Figure 3-16:

Pneumatic Connections, Using Bottled Span Gas

3.3.2.6. SAMPLE GAS SOURCE
Attach a sample inlet line to the SAMPLE inlet port. The SAMPLE input line
should not be more than two (2) meters long.


Maximum pressure of any gas at the SAMPLE inlet should not exceed 1.5 inHg above ambient pressure and ideally should equal ambient atmospheric
pressure.



In applications where the sample gas is received from a pressurized
manifold, a vent must be placed on the sample gas before it enters the
analyzer. Please refer to Figure 3-16.

3.3.2.7. CALIBRATION GAS SOURCES
The source of calibration gas is also attached to the SAMPLE inlet, but only
when a calibration operation is actually being performed.
Note

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

3.3.2.8. INPUT GAS VENTING
The span gas, zero air supply and sample gas (if pressurized) line MUST be
vented (Figure 3-16) for two reasons: in order to ensure that the gases input do
not exceed the 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 at least into a well-ventilated area and away
from the immediate area surrounding the instrument

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3.3.2.9. EXHAUST OUTLET
Attach an exhaust line to the analyzer’s EXHAUST outlet fitting. The exhaust
line should be:


PTEF tubing; minimum O.D ¼”



A maximum of 10 meters long.



Vented outside the T803 analyzer’s enclosure, preferably outside the shelter
or at least into a well-ventilated area.

Figure 3-17:

IMPORTANT

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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.

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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, turn on the instrument.
The pump and exhaust fan should start immediately. The analyzer should
automatically switch to Sample Mode after completing the boot-up sequence and
start monitoring CO2 and O2 gases.

3.4.2. WARM UP
The T803 requires about 60 minutes warm-up time before reliable measurements
can be taken. During that time, various portions of the instrument’s front panel
will behave as follows. See Figure 3-1 for locations.
Table 3-8:
FIELD

COLOR

Front Panel Display during System Warm-Up

BEHAVIOR

SIGNIFICANCE

Conc
(Concentration)

N/A

Displays current,
compensated
CO2/O2
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

Unit is operating in sample mode; front panel display is being
updated.

Cal

Yellow

Off

The instrument’s calibration is not enabled.

Red

Blinking

Fault

The analyzer is warming up and hence out of specification for a
fault-free reading. various warning messages appear in the
Param field.

3.5. WARNING MESSAGES
Because internal temperatures and other conditions may be outside the specified
limits during the analyzer’s warm-up period, the software will suppress most
warning conditions for 30 minutes after power up. If warning messages persist

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Getting Started

after the 60-minute warm up period is over, investigate their cause using the
troubleshooting guidelines in Section 11.
Table 3-9:

Warning Messages

MESSAGE
ANALOG CAL WARNING

The temperature inside the T803 chassis is outside the specified limits.

CANNOT DYN SPAN2

Remote span calibration failed while the dynamic span feature was set to ON

CANNOT DYN ZERO3

Remote zero calibration failed while the dynamic zero feature was set to ON

CONFIG INITIALIZED

Configuration was reset to factory defaults or was erased.

CO2 ALRM1 WARNING4

CO2 concentration alarm limit 1 exceeded

CO2 ALRM2 WARNING4

CO2 concentration alarm limit 2 exceeded

CO2 CELL TEMP WARN

CO2 sensor cell temperature outside of warning limits specified by
CO2_CELL_SET variable.

3
4

DAS data storage was erased.

O2 ALRM1 WARNING4

O2 concentration alarm limit 1 exceeded

O2 ALRM2 WARNING4

O2 concentration alarm limit 2 exceeded

O2 CELL TEMP WARN

O2 sensor cell temperature outside of warning limits specified by
O2_CELL_SET variable.

REAR BOARD NOT DET

CPU unable to communicate with the motherboard.

RELAY BOARD WARN

CPU is unable to communicate with the relay PCA.

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 RESET1
2

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

BOX TEMP WARNING

DATA INITIALIZED

DEFINITION

The analyzer was rebooted or the CPU was reset.

Does not clear after power up.
Clears the next time successful zero calibration is performed.
Clears the next time successful span calibration is performed.
Only active if the Concentration Alarm Option is installed

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To view and clear warning messages:
SAMPLE

Suppresses the
warning messages

TEST

SAMPLE
TEST

NOTE:
If a warning message persists after
several attempts to clear it, the message
may indicate a real problem and not an
artifact of the warm-up period

SAMPLE
TEST

SYSTEM

Once the last warning has
been cleared, the RANGE
function will be displayed in
the analyzer’s main
MESSAGE FIELD.

Figure 3-18:

SYSTEM RESET
CAL

MSG CLR SETUP

SYSTEM RESET
CAL

MSG CLR SETUP

MSG returns the active
warnings to the message
field.

SYSTEM RESET
CAL

MSG CLR SETUP

SYSTEM RESET

TEST

Press CLR to clear the current
message.
If more than one warning is
active, the next message will take
its place.

CLR SETUP

SAMPLE

CO2 RNG=20.00 %

CAL

CO2=XXX.XX
SETUP

Viewing and Clearing T803 WARNING Messages

3.5.1. FUNCTIONAL CHECK
After the analyzer’s components have warmed up for at least 60 minutes, verify
that the software properly supports any hardware options that were installed. For
information on navigating through the analyzer’s software menus, see the menu
trees described in Appendix A.1.
Check to make sure that the analyzer is functioning within allowable operating
parameters. Appendix C includes a list of test functions, viewable from the
analyzer’s front panel, and their expected values. (These functions are also useful
tools for diagnosing performance problems (Section 11.1.2) with your analyzer).
The enclosed Final Test and Validation Data Sheet (PN 068360000) lists these
values before the instrument left the factory. To view the current values of these
parameters, press the front panel button sequence for TEST functions as shown in
Figure 6.2 in Section 6.2. Remember until the unit has completed its warm up
these parameters may not have stabilized.
If your local area network is running a dynamic host configuration protocol
(DHCP) software package, the Ethernet will automatically configure its interface
with your LAN.



However, it is a good idea to check these settings to make sure that the
DHCP has successfully downloaded the appropriate network settings from
your network server (see Section 6.3.1).
If your network is not running DHCP, you will have to configure the analyzer’s
interface manually (see Section 6.3.2).

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Getting Started

3.5.2. INITIAL CALIBRATION
To perform the calibration you must have sources for zero air and span gas
available for input into the SAMPLE port on the back of the analyzer. See
Section 0 for instructions for connecting these gas sources.
The initial calibration should be carried out using the same reporting range set up
as used during the analyzer’s factory calibration. This will allow you to compare
your calibration results to the factory calibration as listed on the Final Test and
Validation Data Sheet.
If both available DAS parameters for a specific gas type are being reported via
the instrument’s analog outputs e.g. CONC1 and CONC2 when the DUAL
range mode is activated, separate calibrations should be carried out for each
parameter.


Use the RNG1 button when calibrating for CONC1 (equivalent to LOW
RANGE).



Use the RNG2 button when calibrating for CONC2 (equivalent to HIGH
RANGE).

The calibration procedures assume:


that the zero point and span gases have been adjusted for known interferents
(Section 3.3.2.4)



that the Calibration gas will be supplied through the SAMPLE port



that the pneumatic setup matches that described in Section 0.

Perform the following outline of procedures for each sensor:
1. Verify the Reporting Range settings as presented in Section 5.4.3. We
recommend that you perform this initial checkout using the following reporting
range settings:
 Mode Setting: SNGL
 Analog Output Reporting Range: 16% for CO2 and 20.95% for O2
2. If the Dilution Ratio Option is enabled on your T803, perform the Dilution
Ratio set up as presented in Section 5.4.4
3. Set the expected Span Gas Concentration for CO2 and for O2, as presented
in Section 9.2.3.1. 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 9.2.3.2

The analyzer is now ready for operation.
Note

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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.

Getting Started

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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PART II
–
OPERATING INSTRUCTIONS

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Section II Operating Instructions

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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4. BASIC OPERATION
The T803 analyzer is a computer-controlled analyzer with a dynamic menu
interface that allows all major operations to be controlled from the front panel
touchscreen through user-friendly menus (A complete set of menu trees is located
in Appendix A of this manual)
This section includes step-by-step instructions for using the display/touchscreen
to set up and operate the analyzer's basic CO2 and O2 measurement features and
functional modes.

4.1. OVERVIEW OF OPERATING MODES
The T803 software has several operating modes (Table 6-1), and most commonly
operates in SAMPLE mode. In this mode a continuous read-out of the gas
concentration is displayed on the front panel. SAMPLE mode is used to:


perform calibrations



run test functions



read and clear warning messages



output analog data (when enabled)

The next most commonly used operating mode is SETUP mode, which is used
to;

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

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

Basic Operation

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Figure 4-1:

Front Panel Display

The mode field of the front panel display indicates to the user which operating
mode the unit is currently running.
In addition to SAMPLE and SETUP, other modes the analyzer can be operated
in are:
Table 4-1:

MODE

Analyzer Operating Modes

DESCRIPTION

SAMPLE

Sampling normally, flashing text indicates adaptive filter is on.

SAMPLE A

Indicates that unit is in Sample Mode while AUTOCAL feature is active.

CO2 M-P CAL

This is the basic calibration mode of the instrument and is activated by pressing the CAL button.

SETUP [X.X]

SETUP mode is being used to configure the analyzer. The gas measurement will continue during this
process. The revision of the T803 firmware being run will appear after the word “SETUP”

CAL CO2 Z[type]

2&3

CAL CO2 S[type]

2&3

CAL O2 Z[type]

2&3

CAL O2 S[type]

2&3

DIAG Mode

Unit is performing CO2 ZERO calibration procedure.
Unit is performing CO2 SPAN calibration procedure.
Unit is performing O2 ZERO calibration procedure.
Unit is performing O2 SPAN calibration procedure.
One of the analyzer’s diagnostic modes is active (Section 5.9).

[type:]
2
M: initiated manually by the user via the front panel touchscreen.
3
R: initiated remotely through the COM ports or digital control inputs.

4.2. SAMPLE MODE
This is the analyzer’s standard operating mode. In this mode the instrument is
analyzing the gas in the sample chamber, calculating CO2 and O2 concentrations
and reporting this information to the user via the front panel display, the analog
outputs and, if set up properly, the RS-232/485/Ethernet ports.
58

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Basic Operation

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 T803 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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Basic Operation

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Table 4-2:

Test Functions Defined

PARAMETER

DISPLAY TITLE

UNITS

Range

RNG
RN1
RN2

DEFINITION

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.

Stability

STB

Standard deviation of CO2 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.

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

SAMP FL

3
cm /min

Sample mass flow rate as measured by the flow rate sensor in the
sample gas stream.

CO2 Sensor
Slope
CO2 Sensor
Offset

CO2 SLOPE

CO2 slope, computed during zero/span calibration.

CO2 OFST

CO2 offset, computed during zero/span calibration.

Box Temperature

BOX TEMP

C

The temperature inside the analyzer chassis.

CO2 Cell
Temperature

CO2 CELL
TEMP

C

The current temperature of the CO2 sensor measurement cell.

O2 Cell
Temperature

O2 CELL TEMP

C

The current temperature of the O2 sensor measurement cell.

O2 Sensor Slope

O2 SLOPE

O2 slope, computed during zero/span calibration.

O2 Sensor Offset

O2 OFST

O2 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.

4.3. CALIBRATION MODE
The T803 will switch into calibration mode when the user presses the CAL
button. In this mode the user can, in conjunction with introducing zero or span
gases of known concentrations into the analyzer, cause it to adjust and recalculate
the slope (gain) and offset of the its measurement range. This mode is also used
to check the current calibration status of the instrument.
Section 9 provides more information about setting up and performing standard
calibration operations or checks.
Note

It is recommended that span calibration be performed at 80% of full scale of
the analyzer’s currently selected reporting range.
EXAMPLES:
If the reporting range is set for 0 to 50%, an appropriate span point would
be 40%.
If the of the reporting range is set for 0 to 100%, an appropriate span point
would be 80%.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Basic Operation

4.4. SETUP MODE
The SETUP mode is used to configure the analyzer’s hardware and software
features, perform diagnostic procedures, gather information on the instrument’s
performance and configure or access data from the internal data acquisition
system (DAS).
Note

Any changes made to a variable during one of the SETUP procedures are not
acknowledged by the instrument until the ENTR button is pressed. If the EXIT
button is pressed before the ENTR button, the analyzer will beep to notify the
user that the newly entered value has been lost.

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

Analyzer Configuration

CFG

Auto Cal Feature

ACAL

Internal Data Acquisition
(DAS)
Analog Output Reporting
Range Configuration
Calibration Password
Security
Internal Clock Configuration

CLK

Advanced SETUP features

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DAS

DESCRIPTION
Lists key hardware and software configuration information

MANUAL
SECTION
5.1

(Special configuration; consult factory).
Used to set up the DAS system and view recorded data

7.1

RNGE

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

5.2

PASS

Turns the calibration password feature ON/OFF

5.5

Used to Set or adjust the instrument’s internal clock

5.6

This button accesses the instrument’s secondary setup
menu

See
Table 6-5

Basic Operation

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Table 6-5:
MODE OR FEATURE

Secondary Setup Mode Features and Functions

MENU
ITEM

External Communication
Channel Configuration

COM

System Status Variables

VARS

System Diagnostic
Features
and
Analog Output
Configuration

DIAG

Alarm Limit Configuration1

ALRM

MANUAL
SECTION

DESCRIPTION
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.
Used to view various variables related to the instruments
current operational status
 Changes made to any variable will not be recorded in
the instrument’s memory until the ENTR button is
pressed.
 Pressing the EXIT button ignores the new setting.
Used to access a variety of functions that configure, test or
diagnose problems with a variety of the analyzer’s basic
systems.
Most notably, the menus to configure the output signals
generated by the instruments Analog outputs are located
here.
Used to turn the instrument’s two alarms on and off as well
as set the trigger limits for each.

5.7

5.5

5.9

5.11

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 button displays the instrument’s configuration information.
This display lists the analyzer model, serial number, firmware revision, software
library revision, CPU type and other information.


Special instrument or software features or installed options may also be listed
here.



Use this information to identify the software and hardware installed in your
T803 analyzer when contacting Technical Support.

To access the configuration table, press:
SAMPLE
CAL

SETUP X.X

MODEL TYPE, NUMBER AND NAME
PART NUMBER
SERIAL NUMBER
SOFTWARE REVISION
LIBRARY REVISION
OS REVISION

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK

Press NEXT or PREV to scroll through the
following list of Configuration information:

CO2=XXX.XX

EXIT

SUPPORT: TELEDYNE-API.COM

PREV NEXT

EXIT

Press EXIT at
any time to
return to the
SETUP menu

5.2. S ETUP  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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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.4. SETUP  RNGE: ANALOG OUTPUT REPORTING
RANGE CONFIGURATION
5.4.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING
RANGES
Functionally, the T803 analyzers have one hardware PHYSICAL RANGE that is
capable of determining concentrations from 0.00% to 100.00% for O2; CO2 is
variable depending on the exact CO2 sensor.
This architecture improves reliability and accuracy by avoiding the need for
extra, switchable, gain-amplification circuitry. Once properly calibrated, the
analyzer’s front panel will accurately report concentrations along the entire span
of its physical range.
Because many applications use only a small part of the analyzer’s full physical
range, data resolution problems can occur for most analog recording devices. For
example, in a typical application where a T803 is being used to measure
atmospheric 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 T803 analyzers solve this problem by allowing the user to select a scaled
reporting range for the analog outputs that only includes that portion of the
physical range relevant to the specific application.
Only this REPORTING RANGE of the analog outputs is scaled, the physical
range of the analyzer and the readings displayed on the front panel remain
unaltered.
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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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

5.4.2. ANALOG OUTPUT RANGES FOR CO2 AND O2
CONCENTRATION
The analyzer has several active analog output signals accessible through a
connector on the rear panel (see Figure 3-4).
ANALOG OUT
O2 concentration output

CO2 concentration outputs

Test Channel
A1
+

LOW range when DUAL
or AUTO mode is selected

Figure 5-1:

A2
-

A3
-

A4
-

HIGH range when DUAL
or AUTO mode is selected

Analog Output Connector Pin Out

All three outputs can be configured either at the factory or by the user for full
scale outputs of 0.1 VDC, 1VDC, 5VDC or 10VDC.
Additionally A1, A2 and A3 may be equipped with optional 0-20 mA current
loop drivers and configured for any current output within that range (e.g. 0-20, 220, 4-20, etc.). The user may also adjust the signal level and scaling of the actual
output voltage or current to match the input requirements of the recorder or
datalogger (See Section 5.10.5).
When the instrument is in its default configuration, channels A1 and A2 (Dual or
Auto range) output a signal proportional to the CO2 concentration of the sample
gas.(See Section 5.4.3).
Channel A3 outputs a signal proportional to the O2 concentration of the sample
gas.
EXAMPLE:
A1 OUTPUT: Output Signal = 0-5 VDC representing 0- 20 % CO2
concentration values
A3 OUTPUT: Output Signal = 0 – 10 VDC representing 0-100 % O2concentration
values.

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

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.4.3. REPORTING RANGE MODES
The T803 provides three analog output range modes to choose from.


Single range (SNGL) mode sets a single maximum range for the analog
output. If single range is selected all three outputs are slaved together and
will represent the same measurement span (e.g. 0-20 %), however their
electronic signal levels may be configured for different ranges (e.g. 0-10
VDC vs. 0-0.1 VDC).



Dual range (DUAL) allows the A1 and A2 outputs to be configured with
different measurement spans as well as separate electronic signal levels.



Auto range (AUTO) mode gives the analyzer the ability to output data via a
low range and high range. When this mode is selected the analyzer will
automatically switch between the two ranges dynamically as the
concentration value fluctuates.

Range status is also output via the external digital I/O status outputs (See Section
3.3.1.4).
To select the Analog Output Range Type press:

Upper span limit setting for the individual range modes are shared. Resetting the
span limit in one mode also resets the span limit for the corresponding range in
the other modes as follows:
SNGL
Range



DUAL
Range1
Range2




AUTO
Low Range
High Range

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

5.4.3.1. RNGE  MODE  SNGL: CONFIGURING THE T803 ANALYZER FOR SINGLE
RANGE MODE
When the single range mode is selected (SNGL), all concentration outputs (A1,
A2 and A3) are slaved together and set to the same reporting range limits (e.g. 022.00 %). The span limit of this reporting range can be set to any value within the
physical range of the analyzer.
Although the outputs share the same concentration reporting range, the electronic
signal ranges of the analog outputs may still be configured for different values
(e.g. 0-5 VDC, 0-10 VDC, etc; see Section 5.10.2)
To select SNGL range 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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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.4.3.2. RNGE  MODE  DUAL: CONFIGURING THE T803 ANALYZER FOR DUAL
RANGE MODE
Selecting the DUAL range mode allows the A1 and A2 outputs to be configured
with different reporting ranges. The analyzer software calls these two ranges
RNG1 (low) and RNG2 (high).


The C2L RANGE 1 setting corresponds with the analog output labeled A1 on the rear panel of
the instrument.



The C2H RANGE 2 setting corresponds with the A2 output.

In DUAL range mode the RANGE test function displayed on the front panel will
be replaced by two separate functions:


CO2 RN1: The range setting for the A1 output.



CO2 RN2: The range setting for the A2 output.

To select the DUAL range mode press following touchscreen button sequence
SAMPLE
CAL

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

RANGE CONTROL MENU

MODE SET

SETUP X.X

EXIT

RANGE MODE:SNGL

SNGL DUAL AUTO

SETUP X.X

RANGE MODE:DUAL

SNGL DUAL AUTO

SETUP X.X
MODE SET

ENTR EXIT

RANGE CONTROL MENU
EXIT

When the instrument’s range mode is set to Dual the concentration field in the
upper right hand corner of the display alternates between displaying the low
range value and the high range value. The concentration that would be displayed,
is identified as follows: ”C2L” = LOW (or A1) and ”C2H” = HIGH (or A2).
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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Setup Menu

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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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.4.3.3. RNGE  MODE  AUTO: CONFIGURING THE T803 ANALYZER FOR AUTO
RANGE MODE
In AUTO range mode, the analyzer automatically switches the reporting range
between two user-defined ranges (low and high).


The unit will switch from low range to high range when the CO2 concentration
exceeds 98% of the low range span.



The unit will return from high range back to low range once the CO2
concentration falls below 75% of the low range span.

In AUTO Range mode the instrument reports the same data in the same range on
both the A1 and A2 outputs and automatically switches both outputs between
ranges as described above.
Also the RANGE test function displayed on the front panel will be replaced by
two separate functions:


CO2 RNG1: The LOW range setting for all analog outputs.



CO2 RNG2: The HIGH range setting for all analog outputs.

The high/low range status is also reported through the external, digital status bits
(See Section 3.3.1.4).
To set individual ranges press the following touchscreen button sequence:

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

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

5.4.4. SETUP RNGE  DIL: USING THE OPTIONAL DILUTION RATIO
FEATURE
This feature is an optional software utility that is used to compensate for any
dilution of the sample gas that may occur before it enters the sample inlet.
Typically this occurs in continuous emission monitoring (CEM) applications
where the sampling method used to remove the gas from the stack, dilutes the
sample.
Using the dilution ratio option is a 3-step process:
1. Select the reporting range mode and set the reporting range upper limit (see
Section 5.4.3).
Ensure that the upper span limit entered for the reporting range is the
maximum expected concentration of the non-diluted gas.

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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

3. Calibrate the analyzer.


Make sure that the calibration span gas is either supplied through the
same dilution system as the sample gas or has an appropriately lower
actual concentration.

EXAMPLE: If the reporting range limit is set for 100 % and the dilution ratio of the
sample gas is 20, either:


a span gas with the concentration of 100 % can be used if the span gas
passes through the same dilution steps as the sample gas, or;



a 5 % span gas must be used if the span gas IS NOT routed through the
dilution system.

5.5. SETUP  PASS: PASSWORD FEATURE
The menu system provides password protection of the calibration and setup
functions to prevent unauthorized adjustments. When the passwords have been
enabled in the PASS menu item, the system will prompt the user for a password
anytime a password-protected function (e.g., SETUP) is selected. This allows
normal operation of the instrument, but requires the password (101) to access to
the menus under SETUP. When PASSWORD is disabled (SETUP>PASS>OFF),
any operator can enter the Primary Setup (SETUP) and Secondary Setup
(SETUP>MORE) menus. Whether PASSWORD is enabled or disabled, a
password (default 818) is required to enter the VARS or DIAG menus in the
SETUP>MORE menu.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Table 5-6:

Setup Menu

Password Levels

PASSWORD

LEVEL

Null (000)

Operation

101

Configuration/Maintenance

818

Configuration/Maintenance Access to Secondary SETUP Submenus VARS and DIAG whether
PASSWORD is enabled or disabled.

IMPORTANT

MENU ACCESS ALLOWED
All functions of the main menu (top level, or Primary, menu).
Access to Primary and Secondary SETUP Menus when PASSWORD
is enabled.

IMPACT ON READINGS OR DATA
There are more VARS available when using the password, 929, for
configuration. Use caution when pressing any buttons while in this
setup. Any changes made may alter the performance of the
instrument or cause the instrument to not function properly. To
discard an accidental change to a setup parameter, press EXIT.
To enable or disable passwords, press:
SAMPLE
CAL

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG DAS RNGE PASS CLK MORE

SYSTEM

Toggle this
button to
enable, disable
password
feasture

OFF

SETUP X.X
ON

EXIT

PASSWORD ENABLE: OFF
ENTR EXIT

PASSWORD ENABLE: ON
ENTR EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Example: If all passwords are enabled, the following touchscreen button sequence
would be required to enter the SETUP menu:
SAMPLE
CAL

SYSTEM
0

SETUP

ENTER PASSWORD:0
0

SYSTEM
1

CO2=XXX.XX

ENTR EXIT

ENTER PASSWORD:101
0

ENTR EXIT

Analyzer enters selected menu
Note

When PASSWORD ENABLE is set to OFF, the instrument still prompts for a
password when entering the VARS and DIAG menus, but it displays the
default password (818). Press ENTR to continue.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

5.6. SETUP  CLK: SETTING THE T803 ANALYZER’S
INTERNAL CLOCK
5.6.1. SETTING THE INTERNAL CLOCK’S TIME AND DAY
The T803 has a time of day clock that supports the time of day TEST function,
the time stamps for the DAS feature and most COM port messages.
To set the clock’s time and day, press:

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

5.6.2. ADJUSTING THE INTERNAL CLOCK’S SPEED
In order to compensate for CPU clocks that run faster or slower, you can adjust a
variable called CLOCK_ADJ to speed up or slow down the clock by a fixed
amount every day.
The CLOCK_ADJUST variable is accessed via the VARS submenu: To change
the value of this variable, press:

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

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

5.8. SETUP  MORE  VARS: INTERNAL VARIABLES
(VARS)
The T803 has several user-adjustable software variables, which define certain
operational parameters. Usually, these variables are automatically set by the
instrument’s firmware, but can be manually redefined through the VARS menu.
The following table lists all variables that are available within the 818 password
protected level. See Appendix A2 for a detailed listing of all of the T803
variables that are accessible through the remote interface.

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Setup Menu

Table 5-1:
NO.

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Variable Names (VARS)
ALLOWED
SETTINGS

VARS

VARIABLE

DESCRIPTION

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.

STABIL_GAS

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

CO2; O2

CO2

TPC_ENABLE

NOTE: It is strongly recommended that this variable
NOT be changed.
ON enables, OFF disables temperature and pressure
compensation

ON, OFF

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]

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]

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

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. Toggle buttons to change the number of seconds.

-60 to +60
s/day

0 Sec/Day

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

TIME_SINCE_SVC

Displays time in hours since last service (restarted by the
SERVICE_CLEAR Variable).

0-50,000

SVC_INTERVAL

Sets the interval in hours between service reminders.

0-100,000

DYN_ZERO

DYN_SPAN

May be set for
intervals
between
0.5 – 20 min

Default
settings

15 min.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

To access and navigate the VARS menu, use the following button sequence.
SAMPLE
CAL

SETUP X.X

CO2=XXX.XX
MSG

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

SECONDARY SETUP MENU

COMM VARS

SETUP X.X
8
Toggle to enter
the correct
PASSWORD

SETUP X.X

DIAG

In all cases:
EXIT discards the new
setting

EXIT

ENTR accepts the
new setting

ENTER PASSWORD:818
8

ENTR EXIT

0) DAS_HOLD_OFF=15.0 Minutes

PREV NEXT JUMP

EDIT PRNT EXIT
SETUP X.X
1

SETUP X.X

ENTR EXIT
Toggle these keys to set
the iDAS HOLDOFF time
period in minutes
(MAX = 20 minutes).

1) STABIL_GAS=CO2

PREV NEXT JUMP

EDIT PRNT EXIT
SETUP X.X
O2

SETUP X.X

DAS_HOLD_OFF=15.0 Minutes

STABIL_GAS=O2

CO2

ENTR EXIT
Press to select which gas
will be reported by the
STABIL test function

2) TPC_ENABLE=ON

PREV NEXT JUMP

EDIT PRNT EXIT
SETUP X.X

TPC_ENABLE:ON

ON
SETUP X.X

3) DYN_ZERO=OFF

PREV NEXT JUMP

SETUP X.X

Toggle to turn ON or OFF
temperature pressure
compensation.

EDIT PRNT EXIT

4) DYN_SPAN=OFF

PREV NEXT JUMP

SETUP X.X

ENTR EXIT

EDIT PRNT EXIT

5) CONC_PRECISION=AUTO

PREV NEXT JUMP

EDIT PRNT EXIT
SETUP X.X
AUTO

SETUP X.X

CONC_PRECISION=AUTO
2

ENTR EXIT
Press to select the
precision of the gas
concentration display

6) CLOCK_ADJUST=0 Sec/Day

PREV NEXT JUMP

EDIT ENTR EXIT

SETUP X.X
+

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CLOCK_ADJUST=0 Sec/Day
0

ENTR EXIT

Enter sign and number of
seconds per day the clock
gains (-) or loses(+)

Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.9. SETUP  MORE  DIAG: USING THE DIAGNOSTICS
FUNCTIONS
A series of diagnostic tools is grouped together under the
SETUPMOREDIAG menu. These tools can be used in a variety of
troubleshooting and diagnostic procedures and are referred to in many places of
the maintenance and trouble-shooting sections of this manual.
The various operating modes available under the DIAG menu are:
Table 5-2:

Diagnostic Mode (DIAG) Functions

DIAG SUBMENU

SUBMENU FUNCTION

SIGNAL I/O

Allows observation of all digital and analog signals in
the instrument. Allows certain digital signals such as
These
heaters to be toggled ON and OFF.

Front Panel Mode
Indicator

MANUAL
SECTION

DIAG I/O

11.1.3

parameters are dependent on firmware revision, (see
Appendix A).

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

5.10.1

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

5.10.6

These settings are retained after exiting DIAG mode.

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Setup Menu

5.9.1. ACCESSING THE DIAGNOSTIC FEATURES
To access the DIAG functions press the following buttons:

CAL

MSG

SETUP X.X
CFG DAS ACAL RNGE PASS CLK

EXIT

SETUP X.X
COMM VARS

EXIT

SETUP X.X
EXIT

returns to the

Activates the
selected
submenu

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

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.10. USING THE T803 ANALYZER’S ANALOG OUTPUTS
The T803 analyzer comes equipped with four analog outputs.


The first two analog output (A1 & A2) signals represent the currently
measured CO2 concentration (see Section 5.4.2).



The third analog output (A3) measures the current O2 concentration.



The fourth output (A4) outputs a signal that can be set to represent the
current value of one of several test functions (see Table 5-7).

5.10.1. ACCESSING THE ANALOG OUTPUT SIGNAL CONFIGURATION
SUBMENU
The following lists the analog I/O functions that are available in the T803
analyzer.
Table 5-3:

DIAG - Analog I/O Functions

SUB MENU

FUNCTION

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 (CO2 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 and only if Auto or Dual
range is selected (CO2 high range, RNG2)

CONC_OUT_3

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

TEST OUTPUT

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

AIN
CALIBRATED
XIN1
.
.
.

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

For each of 8 external analog inputs channels, shows the gain, offset,
engineering units, and whether the channel is to show up as a Test function.

XIN8
1

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

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

To access the ANALOG I/O CONFIGURATION sub menu, press:
SAMPLE
CAL

SETUP X.X

CO2=XXX.XX
MSG

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

SECONDARY SETUP MENU

COMM VARS

SETUP X.X
8
Toggle
to enter the
correct
PASSWORD

DIAG

EXIT

ENTER PASSWORD:818

DIAG

ENTR EXIT

SIGNAL I/O
NEXT

ENTR

EXIT

Continue pressing NEXT until ...
AIO Configuration Submenu

DIAG

ANALOG I/O CONFIGURATION

PREV NEXT

DIAG AIO

ENTR

AOUTS CALIBRATED: NO

SET> CAL

DIAG AIO

EXIT

Adjusts the signal output
for Analog Output A1

EXIT

Adjusts the signal output
for Analog Output A2

CONC_OUT_2: 5V, OVR, CAL

EDIT

DIAG AIO

EXIT

CONC_OUT_1: 5V, OVR, CAL

EDIT

DIAG AIO

EXIT

CONC_OUT_3: 5V, OVR, CAL

EDIT

EXIT

Adjusts the signal output
for Analog Output A3
(O2 Sensor Only)

DIAG AIO

TEST_OUTPUT: 5V,OVR, CAL

EDIT

DIAG AIO
CAL

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

SECONDARY SETUP MENU

COMM VARS

SETUP X.X
8
Toggle to enter
the correct
PASSWORD

DIAG

EXIT

ENTER PASSWORD:818

DIAG

ENTR EXIT

SIGNAL I/O

PREV NEXT

ENTR

EXIT

Continue pressing NEXT until ...

DIAG
PREV NEXT

DIAG
PREV NEXT
Toggle to choose a
TEST channel
parameter

DIAG
PREV NEXT

TEST CHAN OUTPUT
ENTR

EXIT

TEST CHAN:NONE
ENTR

EXIT

TEST CHANNEL:SAMPLE PRESSURE
ENTR

EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

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

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Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.10.7. AIN CALIBRATION
This is the sub-menu to conduct a calibration of the T803 analyzer’s analog
inputs. This calibration should only be necessary after major repair such as a
replacement of CPU, motherboard or power supplies.
To perform an analog input calibration, select the ANALOG
CONFIGURATION submenu (see Section 5.10.1) then press:

I/O

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Setup Menu

5.10.8. 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
PREV

ANALOG I / O CONFIGURATION
NEXT

DIAG AIO
< SET SET>

ENTR
AOUTS CALIBRATED: NO
CAL

XIN1:1.00,0.00,V,OFF
EDIT

DIAG AIO
< SET

XIN1 OFFSET:0.00V

SET>

EDIT

XIN1 GAIN:1.00V/V
EDIT

EXIT

DIAG AIO
EXIT

XIN1 GAIN:1.00V/V
0

ENTR EXIT

XIN1 UNITS:V

SET>

DIAG AIO

Press EDIT at any channel
to to change Gain, Offset,
Units and whether to display
the channel in the Test
functions (OFF/ON).

EXIT

SET>

< SET

Press SET> to scroll to the first
channel. Continue pressing SET>
to view each of 8 channels.

EXIT

DIAG AIO

EXIT

EDIT

EXIT

XIN1 DISPLAY:OFF

< SET

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EDIT

EXIT

Press to change
Gain value

Pressing ENTR records the new setting
and returns to the previous menu.
Pressing EXIT ignores the new setting and
returns to the previous menu.

Setup Menu

Teledyne API T803 CO2/O2 Analyzer Operation Manual

5.11. SETUP MORE  ALRM: USING THE GAS
CONCENTRATION ALARMS (OPTION 61)
The T803 includes two 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 3.3.1.4). If the
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 5-8:

Note

100

Concentration Alarm Default Settings

ALARM

STATUS

LIMIT SET POINT

O2 ALARM1

Disabled

10.00 %

O2 ALARM2

Disabled

30.0 %

CO2 ALARM1

Disabled

5.000 %

CO2 ALARM2

Disabled

10.00 %

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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Teledyne API T803 CO2/O2 Analyzer Operation Manual

Setup Menu

5.11.1. SETTING THE T803 OPTION 61 CONCENTRATION ALARM
LIMITS
To enable 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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101

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6. COMMUNICATIONS SETUP AND OPERATION
The T803 is equipped with an Ethernet port, a USB port and two serial
communication (COM) ports (RS232 and COM2) located on the rear panel (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.
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 downloading the
USB driver and configuring per Section 6.4.

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-

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Enabled mode (32) are selected, the analyzer would display a combined MODE
ID of 35.
Table 6-1:
MODE1

COM Port Communication Modes

DESCRIPTION

QUIET

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

Computer mode inhibits echoing of typed characters and is used when the port is
communicating with a computer operated control program.

HESSEN
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

When enabled, the serial port requires a password before it will respond (see Section
8.2.1.6). The only command that is active is the help screen (? CR).

MULTIDROP
PROTOCOL

Multidrop protocol allows a multi-instrument configuration on a single communications
channel. Multidrop requires the use of instrument IDs.

ENABLE
MODEM

Enables to send a modem initialization string at power-up. Asserts certain lines in the
RS-232 port to enable the modem to communicate.

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

HARDWARE
FIFO

512

COMMAND
PROMPT

4096

The Hessen communications protocol is used in some European countries. TELEDYNE
API PN 02252 contains more information on this protocol.

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.
Disables the HARDWARE FIFO (First In – First Out), When FIFO is enabled it improves
data transfer rate for that COM port.
Enables a command prompt when in terminal mode.

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

104

Communication
independently.

Modes

for

each

COM

port

must

configured

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Communications Setup and Operation

Press the following buttons to select communication modes for one of the COM
Ports, such as the following example where RS-485 mode 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 one of the COM Ports, press:

106

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Communications Setup and Operation

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 button sequence.

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Teledyne API T803 CO2/O2 Analyzer Operation Manual

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

6.2.4. MACHINE ID
Each type of Teledyne API’s analyzer is configured with a default ID code. The
default ID code for the T803 analyzers is 803.
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 (see Section 6.3);



in a RS-232 multidrop chain (see Section 3.3.1.8) or;



operating over a RS-485 network (see Section 3.3.1.8).

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.
To edit the instrument’s ID code, press:

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.

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Communications Setup and Operation

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:
LED

Ethernet Status Indicators
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 USING DHCP
The Ethernet for your T803 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

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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.

109

Communications Setup and Operation

Table 6-3:
PROPERTY
DHCP

SUBNET MASK

TCP PORT1

HOST NAME
1

LAN/Internet Configuration Properties

DEFAULT STATE
ON

DESCRIPTION
This displays whether the DHCP is turned ON or OFF.
Press EDIT and toggle ON for automatic configuration
after first consulting network administrator.
This string of four packets of 1 to 3 numbers each (e.g.
192.168.76.55.) is the address of the analyzer itself.

INSTRUMENT
IP ADDRESS
GATEWAY IP
ADDRESS

Teledyne API T803 CO2/O2 Analyzer Operation Manual

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.
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.

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.

T803

The name by which your analyzer will appear when
addressed from other computers on the LAN or via the
Internet. To change, see Section 6.3.3.

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.

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 your network
server(s). The Ethernet configuration propertis (Table 6-3) are viewable via
the analyzer’s front panel display.

110

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Communications Setup and Operation

To view the above properties list 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:

SAMPLE



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)

Connect a cable from the analyzer’s Ethernet port to a Local Area Network
(LAN) or Internet port.

Access Ethernet configuration through: SETUP>MORE>COMM>INET.

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).

CO2 RNG=20.00 %

CO2=XXX.XX

< TST TST > CAL

SAMPLE
8

SETUP

ENTER SETUP PASS : 818
1

SETUP X.X

ENTR

PRIMARY SETUP MENU

CFG DAS RNGE PASS CLK MORE

SETUP X.X

EXIT

COM1 COM2

SETUP X.X

DHCP: ON

EDIT

OFF

(continues in next illustration)

EXIT

DHCP: ON

SETUP X.X
EXIT

COMMUNICATIONS MENU

INET

SETUP X.X

SECONDARY SETUP MENU

COMM VARS DIAG

SETUP X.X

ENTR EXIT

DHCP: OFF
ENTR EXIT

ENTR accept
new settings
EXIT ignores
new settings

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Communications Setup and Operation

Internet Configuration Touchscreen Functions
(Continued from preceding illustration)

SETUP X.X

DHCP: OFF

SET> EDIT

SETUP X.X

EXIT

BUTTON

FUNCTION

[0]

Press this key to cycle through the range of
numerals and available characters (“0 – 9” & “ . ”)

Moves the cursor one character left or right.

DEL

Deletes a character at the cursor location.

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.

INST IP: 000.000.000.000

EDIT

EXIT

SETUP X.X

Cursor
location is
indicated by
brackets

INST IP: [0] 00.000.000

DEL [0]

ENTR EXIT

SETUP X.X GATEWAY IP: 000.000.000.000
EDIT

EXIT

SETUP X.X

GATEWAY IP: [0] 00.000.000

DEL [?]

ENTR EXIT

SETUP X.X SUBNET MASK:255.255.255.0
EDIT

EXIT

SETUP X.X SUBNET MASK:[2]55.255.255.0
SETUP X.X TCP PORT 3000

EDIT

ENTR EXIT

The PORT number needs to remain at 3000.
Do not change this setting unless instructed to by
Teledyne API’s Customer Service personnel.

SETUP X.X

INITIALIZING INET 0%
…
INITIALIZING INET 100%

INITIALIZATI0N SUCCEEDED

SETUP X.X
ID

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DEL [?]

EXIT

INET

SETUP X.X

INITIALIZATION FAILED

Contact your IT
Network Administrator

COMMUNICATIONS MENU
COM1 COM2

EXIT

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6.3.3. 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 T803 analyzers is T803.

To change this name (particularly if you have more than one T803 analyzer on
your network), press:

BUTTON

FUNCTION

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, AZ, 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
Computer Mode
MODBUS RTU
MODBUS ASCII
E,8,1 MODE
E,7,1 MODE
RS-485 MODE

ON
ON
OFF
OFF
OFF
OFF
OFF

SECURITY MODE
MULTIDROP MODE
ENABLE MODEM
ERROR CHECKING
XON/XOFF HANDSHAKE
HARDWARE HANDSHAKE
HARDWARE FIFO
COMMAND PROMPT

OFF
OFF
OFF
ON
OFF
OFF
ON
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

116



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 informtion.

6.5.1. MODBUS SETUP
The following set of instructions assumes that the user is familiar with MODBUS
communications, and provides minimal information to get started. For additional
instruction, please refer to the Teledyne API MODBUS manual, PN 06276. Also
refer to www.modbus.org for MODBUS communication protocols.
Minimum Requirements
 Instrument firmware with MODBUS capabilities installed.
 MODBUS-compatible software (TAPI uses MODBUS Poll

for testing; see

www.modbustools.com)
 Personal computer
 Communications cable (Ethernet or USB or RS232)
 Possibly a null modem adapter or cable

Actions
Set Com Mode parameters
Comm Ethernet:

Slave ID

Reboot analyzer
Make appropriate cable
connections

Specify MODBUS software
settings
(examples used here are for
MODBUS Poll software)

Read the Modbus Poll
Register

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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.
For the settings to take effect, power down the analyzer, wait 5 seconds, and power up the
analyzer.
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).


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.
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.
1.

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Example Read/Write Definition window:

Example Connection Setup window:
Example MODBUS Poll window:

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
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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.teledyneapi.com/manuals/.

6.5.2.1. HESSEN COM PORT CONFIGURATION
Hessen protocol requires the communication parameters of the T803’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

Stop Bits

Parity

None

Even

Duplex

Full

Half

To change the baud rate of the T803’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.

6.5.2.2. ACTIVATING HESSEN PROTOCOL
Once the COM port has been properly configured, the next step in configuring
the T803 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.

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Press:

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

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,

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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

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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 (at the beginning of the
response, (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 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 T803 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 T803 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 T803 analyzer.
GAS ID

An identification number assigned to a specific gas. In the case
of the T803 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 T803 analyzer measures CO2 and O2. The default gas list entries are:

O2, 0, 110, REPORTED
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 value 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:

CO2, 2, 111, REPORTED
would cause only the last CO2 reading while RANGE2 (HIGH) range was active
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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6.5.3. SETTING HESSEN PROTOCOL STATUS FLAGS
Teledyne API’s implementation of Hessen protocols includes a set of status bits
that the instrument includes in responses to inform the host computer of its
condition. Each bit can be assigned to one operational and warning message flag.
The default settings for these bit/flags are:
Table 6-6:

Default Hessen Status Flag Assignments
DEFAULT BIT
ASSIGNMENT

STATUS FLAG NAME
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
In O2 ZERO Calibration Mode

In CO2 ZERO Calibration Mode
In O2 SPAN Calibration Mode

0200

0400
3

0400

In CO2 SPAN Calibration Mode

0800
3

0800

UNITS OF MEASURE FLAGS
UGM

0000

2000

MGM

4000

PPB

PPM

6000
0001, 0002, 0004,
0008, 0010 0020, 0040,
0100, 1000, 8000

SPARE/UNUSED BITS

UNASSIGNED FLAGS (0000)
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

O2 CONC ALARM 22

BOX TEMP WARNING

2
3

126

These status flags are standard for all instruments and should probably not be
modified.
Only applicable if the analyzer is equipped with an alarm option.
It is possible to assign more than one flag to the same Hessen status bit. This
allows the grouping of similar flags, such as all temperature warnings, under the
same status bit. Be careful not to assign conflicting flags to the same bit as each
status bit will be triggered if any of the assigned flags is active.
While these units are assigned flags, they are not applicable in the T803 which
reports in %.

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To assign or reset the status flag bit assignments, press:
SAMPLE
CAL

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X
COMM VARS

SETUP X.X
ID

SECONDARY SETUP MENU
DIAG

EXIT

COMMUNICATIONS MENU

SETUP X.X

HESN COM1 COM2

SETUP X.X

EXIT

HESSEN VARIATION:TYPE1

SET> EDIT

EXIT

EDIT

SETUP X.X

EXIT

BOX TEMP WARNING:0000

PREV NEXT

Continue pressing SET> until ...

EDIT PRNT EXIT

Continue pressing NEXT until desired
flag message is displayed

SETUP X.X

O2 CELL TEMP WARN:0000

PREV NEXT

SETUP X.X

Pess
buttons move the
cursor brackets “[ ]”
left and right along the
bit string.

DEL deletes the
character currently
inside the cursor
brackets.

EDIT PRNT EXIT

O2 CELL TEMP WARNING:[0]000
INS

DEL

[0]

ENTR EXIT

EXIT discards the
new setting
ENTR accepts the
new setting

INS Inserts a the
character at the
current location of the
cursor brackets.

Press the [?] key repeatedly to cycle
through the available character set: 0-9
NOTE: Values of A-F can also be set
but are meaningless.

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

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6.5.4. INSTRUMENT ID CODE
Each instrument on a Hessen Protocol network must have a unique ID code. If
more than one T803 analyzer is on the Hessen network, you will have to change
this code for all but one of the T803 analyzer’s on the Hessen network (see
Section 6.2.4). The default ID code for the T803 analyzers is 803.

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7. DATA ACQUISITION SYSTEM (DAS & APICOM
The T803 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 of the T803 can store
several months 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.
Note

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

7.1. SETUP  DAS: USING THE DATA ACQUISITION
SYSTEM (DAS)
The principal 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 T803 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.

IMPORTANT

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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..

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7.1.1. DAS STATUS
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: SAMPLE LED Status Indicators for DAS
LED STATE

steady off
blinking
steady on

DAS STATUS
System is in calibration mode. Data logging can be enabled or disabled for this mode.
Calibration data are typically stored at the end of calibration periods, concentration data are
typically not sampled, diagnostic data should be collected.
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.
Sampling normally.

The DAS can be disabled, as opposed to suspended, only by disabling or deleting
its individual data channels.

7.1.2. 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 7.1.5.3.



A TRIGGER event that defines when the record is made (e.g. timer; every
time a calibration is performed, etc.). See Section 7.1.5.2.

The specific PARAMETER and TRIGGER events that describe an individual
record are defined in a construct called a DATA CHANNEL (see Section 7.1.3).
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.).
The number of DAS objects are limited by the instrument’s finite storage
capacity. 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.

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7.1.2.1. 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.
Table 7-2:

PROPERTY

DEFAULT
SETTING
“NONE”

TRIGGERING
EVENT

The event that triggers the data channel to measure
and store the datum

ATIMER

NUMBER AND
LIST OF
PARAMETERS

A User-configurable list of data types to be
recorded in any given channel.

1
(PMTDET)

The amount of time between each channel data
point.

000:01:00
(1 hour)

REPORT PERIOD
NUMBER OF
RECORDS
RS-232 REPORT
CHANNEL
ENABLED
CAL HOLD OFF
2

DESCRIPTION
The name of the data channel.

NAME

DAS Data Channel Properties

The number of reports that will be stored in the data
file. Once the limit is exceeded, the oldest data is
over-written.
Enables the analyzer to automatically report
channel values to the RS-232 ports.
Enables or disables the channel. Allows a channel
to be temporarily turned off without deleting it.
Disables sampling of data parameters while
2
instrument is in calibration mode .

100

SETTING RANGE

Up to 6 letters or digits 1.
Any available event
(see Appendix A-5).
Any available parameter
(see Appendix A-5).
000:00:01 to
366:23:59
(Days:Hours:Minutes)
Configuration-dependent,
limited by available
storage space.

OFF

OFF or ON

OFF

OFF or ON

More with APICOM, but only the first six are displayed on the front panel).
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 5.5.)

7.1.3. DEFAULT DAS CHANNELS
CONC: Samples CO2 and O2 concentrations at one-minute intervals and stores an
average every five minutes with a time and date stamp. Readings during
calibration and calibration HOLD OFF are not included in the data..
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.

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CALDAT: Data channels log new slopes and offsets of measurements each time
an O2 zero or span calibration is performed and the result changes the value of the
slope (triggering event: SLPCHG). Although there is a separate data channel for
CO2 (CALCO2), this channel could be configured to include both O2 and CO2.
 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.
 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.

CALCO2: Same as for CALDAT above, but this channel is configured to log
data for CO2.
DETAILED: Samples seven different parameters related to the operating status
of the analyzer’s. For each parameter:
 A value is logged once every minute;
 An average of the last 60 readings is calculated once every minute.
 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 DETAILED 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

132

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:

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Default DAS Channel Setup

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7.1.4. SETUP DAS VIEW: VIEWING DAS CHANNELS AND
INDIVIDUAL RECORDS
DAS data and settings can be viewed on the front panel display through the
following touchscreen button sequence:

SAMPLE
CAL

SETUP X.X

CO2=XXX.XX
NOX= XXXX

MSG

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

DATA ACQUISITION

VIEW EDIT

EXIT

DAS VIEW – Touchscreen Button Functions
Button

FUNCTION

PV10

Moves the VIEW backward 10 records

Moves the VIEW backward 1 record or channel

Moves the VIEW forward 1 record or channel

NX10

Moves the VIEW forward 10 records

Selects the next parameter on the list

Buttonss only appear when applicable.
SETUP X.X

CONC: DATA AVAILABLE

NEXT VIEW

EXIT

SETUP X.X
PV10 PREV

101:21:00 O2CNC1=14.29 %

SETUP X.X
PV10 PREV

EXIT

101:22:00 CO2CN1=4.64 %

EXIT

Continue pressing NEXT to view remaining
DAS channels

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

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7.1.5. SETUP DAS EDIT: ACCESSING THE DAS EDIT MODE
DAS configuration is most conveniently done through the APICOM remote
control program. The following list of touchscreen buttons shows how to edit
using the front panel.
SAMPLE
CAL

SETUP X.X

CO2=XXX.XX
MSG

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

Main iDAS Menu

SETUP X.X

DAS EDIT – Touchscreen Button Functions

DATA ACQUISITION

VIEW EDIT

SETUP X.X
8

EXIT

ENTER PASSWORD:818

ENTR EXIT

EDIT Channel Menu

SETUP X.X
NEXT

0) CONC: ATIMER,3,4032,RS232
INS

DEL

EDIT PRNT EXIT

Button

FUNCTION

Selects the previous data channel in the list

Selects the next data channel in the list

INS

Inserts a new data channel into the list BEFORE the
selected channel

DEL

Deletes the currently selected data channel

EDIT

Enters EDIT mode

Exports the configuration of all data channels to the
RS-232 interface
Buttons only appear when applicable

Enters EDIT mode for the selected channel

When editing the data channels, the Param field of the display indicates some of
the DAS configuration parameters.
For example, the display line, 0) CONC: ATIMER, 3, 4032, RS232, translates
to the following configuration:
0
CONC
ATIMER
3
4032
RS232

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Channel No.
Channel Name
Trigger Event
Parameters – number of parameters included in this channel
Event – number of data points this channel is set up to store
Port via which values automatically reported

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7.1.5.1. EDITING DAS DATA CHANNEL NAMES
To edit the name of a DAS data channel, follow the instruction shown in Section
7.1.5 then press:
Starting at the EDIT CHANNEL MENU

SETUP X.X

0) CONC: ATIMER,3,4032,RS232

SETUP X.X

INS

DEL

EDIT PRNT EXIT

NAME: CONC

SET> EDIT

SETUP X.X
C

EXIT

NAME: CONC
N

—

ENTR EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

Press each button repeatedly to
cycle through the available
character set:
0-9, A-Z, space ’ ~ ! # $ % ^ &
* ( ) - _ = +[ ] { } < >\ | ; : , . / ?

7.1.5.2. 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.
EXO2ZR, EXO2SP, EXO2MP, O2SLPC (exit O2 zero, exit O2 span, O2 slope
change); EXCO2Z, EXCO2S, EXCO2M, CO2SLC (exit CO2 zero, exit CO2
span, CO2 slope change); : Sampling at the end of (irregularly occurring)
calibrations or when the response slope changes. These triggering events create

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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.
WARNINGS: Some data may be useful when stored if one of several warning
messages appears such as CO2TMW, O2TMPW (CO2 or O2sensor 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 7.1.5 then press:

Note

DAS Trigger Events are firmware specific; a list of trigger events can
be found in Appendix A-5 of this manual.

7.1.5.3. 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 T803. DAS parameters include things like CO2

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concentration measurements, temperatures of the various heaters placed around
the analyzer, pressures and flows of the pneumatic subsystem and other
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

PRECISION

STORE NUM.
SAMPLES

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.
0 to 4: Sets the number of digits to the right decimal point for each record.
Example: Setting 4; “399.9865 %”
Setting 0; “400 %”
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 changing 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.

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To modify, add or delete a parameter, follow the instruction shown in Section
7.1.5 then press:

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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.

7.1.5.4. 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.

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To define the REPORT PERIOD, follow the instruction shown in Section 7.1.5
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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7.1.5.5. 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.
7.1.5.6. EDITING THE NUMBER OF RECORDS
The number of data records in the DAS is cumulative across all channels and
parameters, filling about one megabyte of space on the disk-on-module; this
means that the actual number of records is limited by the total number of
parameters and channels and other settings in the DAS configuration. Every
additional data channel (up to 20), parameter (up to 50 per channel), number of
samples setting etc. will govern the maximum amount of data points.
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 button 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
7.1.5 then press:

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7.1.5.7. 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 7.1.5 then press:
Starting at the EDIT CHANNEL MENU

SETUP X.X

Use the PREV and
NEXT buttons to
scroll to the DATA
CHANNEL to be
edited

0) CONC: ATIMER 2, 4032, RS232

PREV NEXT

SETUP X.X

INS

DEL

EDIT PRNT EXIT

NAME: CONC

SET> EDIT

EXIT

Continue pressing until ...

SETUP X.X
EDIT PRNT

SETUP X.X
OFF

Toggle to turn the
RS-232 REPORT
feature
ON/OFF

144

RS-232 REPORT:ON
EXIT

RS-232 REPORT: ON
ENTR EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

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7.1.5.8. 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
7.1.5 then press:
Starting at the EDIT CHANNEL MENU

SETUP X.X

Press PREV and
NEXT to scroll to the
DATA CHANNEL to
be edited

0) CONC: ATIMER 2, 4032, RS232

PREV NEXT

SETUP X.X

INS

DEL

EDIT PRNT EXIT

NAME: CONC

SET> EDIT

EXIT

Continue pressing until ...

SETUP X.X
EDIT

SETUP X.X
OFF

Toggle to turn the
HOLDOFF feature
ON/OFF

CAL.HOLD OFF: OFF
EXIT

CAL.HOLD OFF: OFF
ENTR EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

HOLD OFF also prevents DAS measurements from being made at certain times
when the quality of the analyzer’s O2 measurements may be suspect (e.g. while
the instrument is warming up). In this case, the length of time that the HOLD
OFF feature is active, is determined by the value of the internal variable (VARS),
DAS_HOLD OFF.
To set the length of the DAS_HOLD OFF period, see Section 11.1.3.

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7.1.5.9. 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.
7.1.5.10. 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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7.1.6. 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 7.1.5 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 T803 analyzer).

7.2.1. DAS CONFIGURATION VIA APICOM
Editing channels, parameters and triggering events as described herein, can be
performed via the APICOM remote control program using the graphic interface
shown below. Refer to Section 8 of this manual for details on remote operation
of the T803 analyzer.

Figure 7-2:

148

APICOM Remote Control Program Interface

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Figure 7-3:

Data Acquisition System (DAS & APICOM

APICOM User Interface for Configuring the DAS

Once a DAS configuration is created, 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/.

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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 T803 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 program such as
HyperTerminal or a “dumb” computer terminal.
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).

CR
(carriage return)

BS
(backspace)

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 button.
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
Where

152

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 6.2.4). Example: the
Command “? 803” 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 803.

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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
be executed. Press ? or refer to Appendix A-6 for a list of
available command designators

is a carriage return. All commands must be terminated by a carriage
return (usually achieved by pressing the ENTER button on a
computer).

Table 8-2:

Teledyne API Serial I/O Command Types

COMMAND

COMMAND TYPE

Calibration

Diagnostic

Logon

Test measurement

Variable

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
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.

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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8.2.1.6. COM PORT PASSWORD SECURITY
In order to provide security for remote access of the T803, 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 T803 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.

8.3. REMOTE ACCESS BY MODEM
The T803 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:

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

The DTE-DCE switch on the rear panel is in the DCE position.



The T803 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
CAL

SETUP X.X

SETUP

PRIMARY SETUP MENU

CFG ACAL DAS RNGE PASS CLK MORE EXIT

SETUP X.X

SECONDARY SETUP MENU

COMM VARS

SETUP X.X
ID

INET

SETUP X.X
EDIT

EXIT

Continue pressing until ...
SETUP X.X
INIT

SETUP X.X

INITIALIZING MODEM

SETUP X.X

MODEM INITIALIZED

ENTR

EXIT

Test Runs
Automatically
PREV NEXT OFF

EXIT

If there is a problem initializing the
modem the message,
“MODEM NOT INITIALIZED”
will appear.
(The ACAL submenu in the Primary Setup Menu is a special configuration; consult factory).

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9. CALIBRATION PROCEDURES
This section contains a variety of information regarding the various methods for
calibrating a T803 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 of the T803
Analyzer
This section describes the procedure for checking the calibration of the T803 and
calibrating the instrument. Also included are instructions for selecting the
reporting range to be calibrated when the T803 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 T803’s Electronic Subsystems
This section describes how to perform calibrations of the T803’s electronic
systems, including:
 adjusting the analyzers internal flow sensor
 adjusting the analyzers internal pressure sensor

Note

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Throughout this Section are various diagrams showing pneumatic
connections between this instrument 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 5.2 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 T803 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 analyzer’s readings. Teledyne
API recommends using pure N2 when calibrating the zero point of your CO2 or
O2 sensor except if known interferents are involved (please refer to Section
3.3.2.4).

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
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 T803 analyzer, Teledyne API recommends using
21% O2 in N2 when calibrating the span point of the O2 sensor and 16% CO2 in
N2 when calibrating the span point of the CO2 sensor..

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Cylinders of both calibrated O2 and CO2 gas traceable to NIST-Standard
Reference Material specifications (also referred to as SRMs or EPA protocol
calibration gases) are commercially available.
Table 9-1:

NIST SRM's Available for Traceability of O2 Calibration Gases

NIST-SRM

Type

Nominal Concentration

2657a

O2 in N2

2658a

O2 in N2

10 %

2659a

O2 in N2

21%

2619a

CO2 in N2

0.5%

2620a

CO2 in N2

2622a

CO2 in N2

2624a

CO2 in N2

2744b

CO2 in N2

16%

2745

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 T803.


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 T803 provides an internal data acquisition
system (DAS), which is described in detail in Section 7.1

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).

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9.2. MANUAL CALIBRATION CHECKS AND CALIBRATION
OF THE T803 ANALYZER
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 T803.
NEVER press the ENTR button if you are only checking calibration.

9.2.1. SETUP FOR CALIBRATION CHECKS AND CALIBRATION
Connect the Sources of Zero Air and Span Gas as shown below.

Figure 9-1:

162

Pneumatic Connections Using Bottled Span Gas

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9.2.2. PERFORMING A 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.

9.2.3. PERFORMING A MANUAL CALIBRATION
The following section describes the basic method for manually calibrating the
T803.
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.

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9.2.3.1. SETTING THE EXPECTED SPAN GAS CONCENTRATION
NOTE
When setting expected concentration values, consider impurities in your span gas.

The expected CO2 span gas concentration should be 80% of the reporting range
of the instrument (see Section 5.4.1)
The default factory setting is 16% for CO2 or 20.95 % for O2. To set the span
gas concentration, press:

Note

164

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
To perform the zero/span 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 3.5.1 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
068360000) 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.

166



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 values (standard deviation of the CO2
and the O2 concentrations) to evaluate if the analyzer response has properly
leveled off during the calibration procedure.

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9.4. CALIBRATION OF THE T803’S ELECTRONIC
SUBSYSTEMS
9.4.1. PRESSURE CALIBRATION
A sensor in the sample path continuously measures the pressure of the sample
gas. This data is used to compensate the measured CO2 and O2 concentrations for
changes in atmospheric pressure and is stored in the CPU’s memory as the test
function PRES (also viewable via the front panel).
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:

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

The sample gas pump and;



The sample gas-line vent from the sample gas inlet on the instrument’s rear
panel.

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To cause the analyzer to measure and record a value for PRES, press.

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

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9.4.2. FLOW CALIBRATION
The flow calibration allows the user to adjust the values of the sample flow rates
as they are displayed on the front panel and reported through COM ports to match
the actual flow rate measured at the SAMPLE inlet. This does not change the
hardware measurement of the flow sensors, only the software-calculated values.
To carry out this adjustment, connect an external, sufficiently accurate flow meter
to the sample inlet. Once the flow meter is attached and is measuring actual gas
flow, press:
SAMPLE
CAL

SETUP X.X
CFG

SETUP

PRIMARY SETUP MENU

DAS ACAL RANG PASS CLK MORE EXIT

SETUP X.X

SECONDARY SETUP MENU

COMM VARS

SETUP X.X
8

CO2=XXX.XX

DIAG

EXIT

ENTER PASSWORD:818

DIAG

ENTR EXIT

SIGNAL I/O

PREV NEXT

ENTR

EXIT

Continue pressing NEXT until ...

DIAG

FLOW CALIBRATION

PREV NEXT

DIAG FCAL
0
Toggle these buttons to
match the actual flow as
measured by the external
flow meter

ENTR

EXIT

ACTUAL FLOW: 120 CC/M
2

ENTR

EXIT

EXIT discards the new
setting
ENTR accepts the
new setting

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

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PART III
–
MAINTENANCE AND SERVICE

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10. MAINTENANCE SCHEDULE & PROCEDURES
The T803 Analyzer utilizes technologies that are non-depleting and require 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 – 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: T803 Maintenance Schedule

ITEM

ACTION

FREQ

CAL
CHECK
REQ’D.

MANUAL

Particulate
Filter

Replace

Weekly or as
needed

10.3.1

Verify Test
Functions

Record and
analyze

Weekly or after
any
Maintenance or
Repair

11.1.2

Pump
Diaphragm

Replace

Annually

Yes

10.3.2

Perform Flow
Check

Check Flow

Annually

10.3.4

Perform
Leak Check

Verify Leak
Tight

Annually or
after any
Maintenance or
Repair

10.3.3

Pneumatic
lines

Examine and
clean

As needed

Yes if
cleaned

n/a

Chassis

Wipe down

As needed

Only if
cover
removed

n/a

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Table 10-2: T803 Test Function Record
FUNCTION

OPERATING
MODE*

STABIL

O2 ZERO CAL

STABIL

CO2 ZERO
CAL

PRES

SAMPLE

CO2 SLOPE

SPAN CAL

CO2
OFFSET

ZERO CAL

O2 SLOPE

SPAN CAL

O2 OFFSET

ZERO CAL

176

DATE RECORDED

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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
STABIL

CONDITION
CO2 Zero Cal
O2 Zero Cal

BEHAVIOR
Increasing
Increasing > 1”

PRES

Sample
Decreasing > 1”

OFFSET

SLOPE

Zero Cal

Span Cal

Increasing

INTERPRETATION
 Pneumatic Leaks – instrument & sample system





Pneumatic Leak between sample inlet and Sample Cell
Change in sampling manifold
Dirty particulate filter
Pneumatic obstruction between sample inlet and
sensor
 Obstruction in sampling manifold
 Pneumatic Leaks
 Contaminated zero gas

Decreasing

 Contaminated zero gas

Increasing

 Pneumatic Leaks – instrument & sample system
 Calibration system deteriorating

Decreasing

 Calibration system deteriorating

10.3. MAINTENANCE PROCEDURES
The following procedures are to be performed periodically as part of the standard
maintenance of the T803.

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 T803’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 part
number 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 reapply 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
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.

10.3.5. CLEANING EXTERIOR SURFACES OF THE T803
If necessary, the exterior surfaces of the T803 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.

NOTE
QUALIFIED PERSONNEL
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 T803 CO2/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, 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 11.6.6), 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:
SAMPLE

Suppresses the
warning messages

TEST

SYSTEM RESET
CAL

SAMPLE

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

CAL

Once the last warning has
been cleared, the RANGE
function will be displayed in
the analyzer’s main
MESSAGE FIELD.

SAMPLE

Figure 11-1:

MSG returns the active
warnings to the message
field.

SETUP

CO2=XXX.XX
MSG CLR SETUP

SYSTEM RESET
CAL

CO2=XXX.XX

Press CLR to clear the current
message.
If more than one warning is
active, the next message will take
its place.

MSG CLR SETUP

CO2 RNG=100.00 %
CAL

CO2=XXX.XX

MSG

WARNING

SAMPLE
TEST

MSG CLR SETUP

CO2 RNG=100 %
CAL

SAMPLE
TEST

CO2=XXX.XX

CO2=XXX.XX
SETUP

Viewing and Clearing Warning Messages

Table 11-1: Warning Messages - Indicated Failures
WARNING
MESSAGE

FAULT CONDITION

POSSIBLE CAUSES
Bad bench heater
Bad bench temperature sensor
Bad relay controlling the bench heater
Entire relay board is malfunctioning
2
I C bus malfunction
Bad bench heater
Bad bench temperature sensor
Bad relay controlling the bench heater
Entire relay board is malfunctioning
2
I C bus malfunction
o
NOTE: Box temperature typically runs ~7 c warmer than ambient
temperature.
Poor/blocked ventilation to the analyzer.
Stopped exhaust-fan
Ambient temperature outside of specified range

O2 CELL TEMP
WARN

Sensor cell temperature is outside
specified warning limits

CO2 CELL TEMP
WARN

Sensor cell temperature is outside
specified warning limits

BOX TEMP
WARNING

Box Temp is
°
°
< 8 C or > 50 C.

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.

184

Warning only appears on serial I/O COM port(s)
Front panel display will be frozen, blank or will not respond.
Massive failure of motherboard

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WARNING
MESSAGE

Troubleshooting and Service

FAULT CONDITION

POSSIBLE CAUSES
2

RELAY BOARD
WARN

The CPU cannot communicate with
the Relay Board.

SAMPLE FLOW
WARN

Sample flow rate is < 80 cm /min or
3
> 180 cm /min

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).

SYSTEM RESET

The computer has rebooted.

I C bus failure
Failed relay board
Loose connectors/wiring
Failed sample pump
Blocked sample inlet/gas line
Dirty particulate filter
Leak downstream of critical flow orifice
Failed flow sensor/circuitry
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
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 (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 068360000)
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)

TIME

INDICATED FAILURE(S)
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
SAMPLE FL

See Table 11-1 for SAMPLE PRES WARN
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 touchscreen.
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:

Troubleshooting and Service

Example of Signal I/O Function

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

Note

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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
D1
(Red)

Function
I2C bus Health
(Watchdog Circuit)

Fault Status
Continuously ON
or
Continuously OFF

Indicated Failure(s)
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
D6 (Yellow) O2 Sensor Heater
D5 (Yellow) – CO2 Sensor Heater (only with CO2 option)

D1 (RED)
Watchdog Indicator

Figure 11-4:

Relay PCA Status LEDs Used for Troubleshooting

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

Color

Function

Red

Watchdog Circuit

D2-D4

Status When LED Unlit

(Energized State)

(Default State)

Cycles ON/OFF every 3 Seconds
under direct control of the analyzer’s CPU.
SPARE

Yellow

CO2 Sensor Cell heater

Heating

Not Heating

Yellow

O2 Sensor heater

Heating

Not Heating

Green

D82

Green

D10

Green

D11 - 16
2

Status When LED Lit

SPARE

Not Used

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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.
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 T803 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. T803 INTERNAL GAS FLOW DIAGRAMS

Figure 11-5:

190

T803 – Internal Gas Flow

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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.
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.

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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.
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 110-130 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
less than 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:

192



Bad span gas: This can cause a large error in the slope and a small error in
the offset. Delivered from the factory, the T803’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.

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11.4.2. NON-REPEATABLE ZERO AND SPAN
As stated earlier, leaks both in the T803 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 T803 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, sensor temperatures, and sample flow
readings are correct and have steady readings.
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.

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11.5.1. TEMPERATURE PROBLEMS
Individual control loops are used to maintain the set point of the temperatures to
both sensors.. If any of these temperatures are out of range or are poorly
controlled, the T803 will perform poorly.
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.

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

194

NAME

TEST POINT#

TP AND WIRE COLOR

Dgnd

Black

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+5V

Red

Agnd

Green

+15V

Blue

-15V

Yellow

+12V Ret (ground)

Purple

+12V

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).
Table 11-6: DC Power Supply Acceptable Levels
CHECK RELAY BOARD TEST POINTS

POWER
SUPPLY
ASSY

VOLTAGE

PS1
PS1

FROM TEST POINT

TO TEST POINT

MIN V

MAX V

NAME

Dgnd

4.85

5.25

+15

Agnd

+15

13.5

16V

PS1

-15

Agnd

-15V

-13.5V

-16V

PS1

Agnd

Dgnd

-0.05

0.05

PS1

Chassis

Dgnd

Chassis

N/A

-0.05

0.05

PS2

+12

+12V Ret

+12V

11.75

12.5

PS2

Dgnd

+12V Ret

Dgnd

-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

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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.

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
12.6.3.1, 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
Both the CO2 and O2 sensors have 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:

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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:


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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
SAMPLE_PRESSURE or SAMPLE_FLOW.

I/O

function

such



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 5.10.3.4.
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

198

STEP

CURRENT

V(250 OHMS)

CURRENT

V(250 OHMS)

2 mA

0.5V

5.6

1.4

7.2

1.8

9.2

2.3

10.4

2.6

12.8

3.2

13.6

3.4

16.4

4.1

16.8

4.2

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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

SYSTEM OK / ALARM

CONC VALID / CONC
WARNING

CAILIBRATION MODE /
MEASURE MODE

SPAN /ZERO CAL

RNG2 / RNG1 CAL

CO2 / O2 SENSOR CAL

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 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 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 T803 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 “RS232 Programming Notes” Teledyne API PN 013500000.

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11.6.12. CO2 SENSOR STATUS LED’S
There are Two LEDs located on the CO2 sensor PCA.

Figure 11-6:

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 part numbers 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 OR0000001) and the sintered filter (PN FL0000001).
6. If replacing the critical flow orifice itself (PN 000940700), make sure that the
side with the colored window (usually red) is facing downstream 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 11-7:

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 recalibrated, 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
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.

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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. FREQUENTLY ASKED QUESTIONS (FAQ’S)
The following is a list from the Teledyne API’s Technical Support Department of
the most commonly asked questions relating to the 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 analyzer 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?
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?

Section 11.4 has some possible answers to this question.
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 5.10.5; - 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 (see 5.10.3). Alternately, use the data logger itself
as the metering device during calibrations procedures.

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

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QUESTION

ANSWER

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 12.6.10 for more
information.

11.9. TECHNICAL ASSISTANCE
If this manual and its troubleshooting / repair 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:
Email:
Website:

858-657-9816
sda_techsupport@teledyne.com
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 T803 analyzer is a microprocessor-controlled analyzer that determines the
percent concentration of carbon dioxde (CO2) and 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 carbon dioxide measurement is achieved using infrared absorption
technology.
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 both Sensor outputs 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 the
final concentrations.

12.1. O2 SENSOR
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. PARAMAGNETIC MEASUREMENT OF O2
The type of paramagnetic sensor used in the T803 analyzer is called a magnetomechanical 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.
Coil

Light
Source

Photocells

Figure 12-2:

206

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. CO2 SENSOR
12.2.1. NDIR MEASUREMENT OF CO2
The 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

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chamber. This dual wavelength method of measuring CO2 allows the instrument
to compensate for ancillary effects like sensor aging and contamination.

12.3. OPERATION WITHIN THE T803 ANALYZER
Operationally, both the CO2 and O2 sensors are transparently integrated into the
core analyzer operation. All functions can be viewed or accessed through the
front panel.


The CO2 concentration is displayed in the upper right-hand corner, alternating
with O2 concentration.



Test functions for the slope and offset of CO2 and of O2 are viewable from the
front panel along with the analyzer’s other test functions.



Calibration of each sensor is performed via the front panel CAL. See
Section 9 for more details.

Stability of each sensor can be viewed via the front panel (see Section 9).

12.3.1.1. 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.

Figure 12-4.

208

CO2 Sensor PCA Layout and Electronic Connections

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12.4. 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 creates a 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 when the sample is delivered under pressure. There are
several advantages to this “pull through” configuration.


First the pumping process heats and compresses the sample complicating
the measurement process. Both heat and pressure affect the accuracy of
gas measurements.



Additionally, certain physical parts of the pump itself are made of materials
that might chemically react with the sample gas.

Figure 12-5:

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12.5. FLOW RATE CONTROL
To maintain a constant flow rate of the sample gas through the instrument, the
T803 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 orings, the critical flow orifice and the assembly housing.
 A sintered filter: Removes particulates to prevent clogging the orifice

12.5.1. 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.
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.

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CRITICAL
FLOW
ORIFICE
AREA OF
LOW
PRESSURE

AREA OF
HIGH
PRESSURE

Sonic
Shockwave

SPRING

Figure 12-6:

O-RINGS
FILTER

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 T803 is designed to provide a flow rate of
120 cm3/min.

12.5.2. PARTICULATE FILTER
The T803 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

12.5.3. PNEUMATIC SENSORS
12.5.3.1. 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
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.
12.5.3.2. 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

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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.

12.6. ELECTRONIC OPERATION
12.6.1. OVERVIEW
Figure 10-9 shows a block diagram of the major electronic components of the
T803.
The core of 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.
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 gas 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 several ways


Through the analyzer’s touchscreen and LCD display over a clocked, digital,
serial I/O bus (using a protocol called I2C);



RS-232 & RS-485 Serial I/O channels via Ethernet, Modbus®, APICOM or a
terminal emulation program;



Various DCV and DCA analog outputs, and



Several sets of Digital I/O channels.

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.

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COM2
Female

USB COM
port

COM2 (RS-232 or RS-485)

(I2C Bus)

Analog Outputs
TEST CHANNEL OUTPUT

Aout 4

Aout 3

CO2 Range 2

Aout 2

CO2 Range 1

Aout 1

Control
Outputs
1–6

COM1 (RS-232 only)

Status
Outputs
1-8
Optional
Current
Loop
Outputs

Ethernet

Touchscreen

Display

Flow/Pressure Sensor PCA
Sample Pressure
Sensor

Analog Outputs
(D/A)

External Digital I/O

LVDS

transmitter board

Sample Flow
Sensor

Sensor Inputs

Power Up
Circuit

A/D
Converter

PC 104 Bus

CPU
Status
LED

Internal
Digital I/O

Thermistor Interface

Disk on
Module
Flash
Chip

Box
Temperature

O2
Concentration

O2 Sensor

PC 104
CPU Card

MOTHERBOARD

I2C Bus

O2 Sensor
Temperature

RELAY PCA
CO2 Sensor

CO2 Sensor
Temperature

BOX
Temperature

I2C
Status
LED

O2 Cell
Heater

Figure 12-7:

CO2 Sensor
Heater

T803 Electronic Block Diagram

12.6.2. CENTRAL PROCESSING UNIT (CPU)
The unit’s CPU card (Figure 12-8) 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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ANALOG
IN

or USB

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Figure 12-8.

CPU Card

The CPU includes two types of non-volatile data storage: an embedded 2MB
flash chip and a Disk on Module (DOM).
12.6.2.1. 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 7.1). The LEDs on the DOM indicate power and
reading/writing to or from the DOM.
12.6.2.2. FLASH CHIP
This non-volatile, embedded flash chip includes 2MB of storage for calibration
data as well as a backup of the analyzer configuration. Storing these key data on a
less heavily accessed chip significantly decreases the chance of data corruption.
In the unlikely event that the flash chip should fail, the analyzer will continue to
operate with just the DOM. However, all configuration information will be lost,
requiring the unit to be recalibrated.

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12.6.3. 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.
Thermocouple
Signal Output

Status LED’s
(D2 through D16)
Watchdog
Status LED (D1)

(JP5)
Thermocouple
Configuration
Jumpers

DC Power Supply
Test Points

I2C Connector

Heater AC Power
Configuration
Jumpers

(JP7)
Pump AC
Configuration
Jumper

JP2

Valve Control
Drivers

JP6

Pump Power
Output

Power
Connection
for DC
Heaters

Valve Control
Connector

AC Power
IN
(J2)
Connector for
AC Relays
K4 & K5
(J18)
Connector for AC Relays K4 & K5

Figure 12-9:

DC Power
Distribution
Connectors

Relay PCA Layout (PN 04135)

CAUTION
ELECTRICAL SHOCK HAZARD
Only those relays actually required by the configuration of the T803 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 12-10).
Never remove this retainer while the instrument is plugged in and turned on. The contacts of
the AC relay sockets beneath the shield carry high AC voltages even when no relays are
present.

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Retainer
Mounting
Screws

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

12.6.3.1. 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 T803
are described in Table 12-1, and their locations are illustrated in Figure 12-11.
Table 12-1: Relay PCA Status LEDs
Status When LED Unlit

(Energized State)

(Default State)

Color

Function

Red

Watchdog Circuit

Yellow

CO2 Sensor Cell heater

Heating

Not Heating

Yellow

O2 Sensor heater

Heating

Not Heating

Green

D82

Green

D2-D4

D10

D11 - 16
2

Status When LED Lit

LED

Cycles ON/OFF every 3 Seconds
under direct control of the analyzer’s CPU.
SPARE

Green
SPARE

Not Used.

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D6 (Yellow) O2 Sensor Heater
D5 (Yellow) –CO2 Sensor

D1 (RED)
Watchdog Indicator
Figure 12-11: Status LED Locations – Relay PCA

12.6.3.2. 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.

12.6.4. HEATER CONTROL
12.6.4.1. 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.

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12.6.5. 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.
12.6.5.1. 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
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 T803 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 5.10.3 for instructions on performing this calibration.
12.6.5.2. 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.
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.
12.6.5.3. 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

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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).
12.6.5.4. 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 5.10). 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.
12.6.5.5. 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 3.3.1.4).
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.

12.6.6. I2C DATA BUS
An I2C data bus is used to communicate data and commands between the CPU
and the touchscreen interface and the relay board. 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.
Interface circuits on the keyboard/display interface and relay boards convert the
I2C data to parallel inputs and outputs. An additional, interrupt line from the
keyboard to the motherboard allows the CPU to recognize and service key
presses on the keyboard.
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.

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12.6.7. 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 12-12, 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.

Figure 12-12: Power Distribution Block Diagram

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12.6.8. FRONT PANEL TOUCHSCREEN/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.

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

12.6.8.1. 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.
12.6.8.2. FRONT PANEL TOUCHSCREEN/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:

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

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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12.6.9. SOFTWARE OPERATION
The T803 Analyzer is at its heart a high performance, 386-based microcomputer
running MS-DOS. Inside the DOS shell, special software developed by Teledyne
API interprets user commands via the various interfaces, performs procedures and
tasks, stores data in the CPU’s various memory devices and calculates the
concentration of the sample gas.
Windows CE
API FIRMWARE
Memory Handling
IDAS Records
Calibration Data
System Status Data

Analyzer Operations
Calibration Procedures
Configuration Procedures
Autonomic Systems
Diagnostic Routines

PC/104 BUS

ANALYZER
HARDWARE
Interface Handling
Sensor Input Data
Display Messages
Touchscreen
Analog Output Data
RS232 & RS485
External Digital I/O

Measurement
Algorithm

PC/104 BUS

Linearization Table

Figure 12-14: Basic Software Operation

12.6.10. ADAPTIVE FILTER
Unlike other analyzers that average the output signal over a fixed time period, the
T803 averages over a set number of samples, where each sample is 1 second.
This 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.
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. Second, the instantaneous concentration must exceed the average in the
long filter by a portion, or percentage, of the average in the long filter.
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).

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12.6.11. CALIBRATION - SLOPE AND OFFSET
Calibration of the analyzer is performed exclusively in software.
During instrument calibration the user enters expected values for span via the
front panel touchscreen; values are not entered during a zero operation,
commanding 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 concentrations
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 3.5.1)

12.6.12. TEMPERATURE AND PRESSURE COMPENSATION
Changes in ambient pressure can have a noticeable effect on the CO2 and O2
concentration calculations. To account for this, the T803 software includes a
feature which allows the instrument to compensate both CO2 and O2 calculations
based on changes in ambient pressure. Both sensors are housed inside
temperature controlled manifolds. This minimizes temperature effects on the
measured concentrations.

12.6.13. 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 7.1

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13. A PRIMER ON ELECTRO-STATIC DISCHARGE
Teledyne API considers the prevention of damage caused by the discharge of
static electricity to be extremely important part of making sure that your analyzer
continues to provide reliable service for a long time. This section describes how
static electricity occurs, why it is so dangerous to electronic components and
assemblies as well as how to prevent that damage from occurring.

13.1. HOW STATIC CHARGES ARE CREATED
Modern electronic devices such as the types used in the various electronic
assemblies of your analyzer, are very small, require very little power and operate
very quickly. Unfortunately, the same characteristics that allow them to do these
things also make them very susceptible to damage from the discharge of static
electricity. Controlling electrostatic discharge begins with understanding how
electro-static charges occur in the first place.
Static electricity is the result of something called triboelectric charging which
happens whenever the atoms of the surface layers of two materials rub against
each other. As the atoms of the two surfaces move together and separate, some
electrons from one surface are retained by the other.
Materials
Makes
Contact

Materials
Separate

PROTONS = 3
ELECTRONS = 3

NET CHARGE = 0

Figure 13-1:

PROTONS = 3
ELECTRONS = 2

PROTONS = 3
ELECTRONS = 4

NET CHARGE = -1

NET CHARGE = +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
Table 13-1: Static Generation Voltages for Typical Activities
MEANS OF GENERATION

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10-25% RH

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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

100

VMOS

1800

NMOS

100

GaAsFET

2000

EPROM

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

SCR

500

1000

Schottky TTL

500

2500

Potentially damaging electro-static discharges can occur:
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.

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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.
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.

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As long as my analyzer is properly installed, it is safe from damage caused
by static discharges: It is true that when properly installed the chassis ground of
your analyzer is tied to earth ground and its electronic components are prevented
from building static electric charges themselves. This does not prevent
discharges from static fields built up on other things, like you and your clothing,
from discharging through the instrument and damaging it.

13.4. BASIC PRINCIPLES OF STATIC CONTROL
It is impossible to stop the creation of instantaneous static electric charges. It is
not, however difficult to prevent those charges from building to dangerous levels
or prevent damage due to electro-static discharge from occurring.

13.4.1. GENERAL RULES
Only handle or work on all electronic assemblies at a properly set up ESD station.
Setting up an ESD safe workstation need not be complicated. A protective mat
properly tied to ground and a wrist strap are all that is needed to create a basic
anti-ESD workstation.
Protective Mat

Wrist Stra

Ground Point

Figure 13-2:

Basic Anti-ESD Workbench

For technicians that work in the field, special lightweight and portable anti-ESD
kits are available from most suppliers of ESD protection gear. These include
everything needed to create a temporary anti-ESD work area anywhere.
Always wear an Anti-ESD wrist strap when working on the electronic
assemblies of your analyzer. An anti-ESD wrist strap keeps the person wearing
it at or near the same potential as other grounded objects in the work area and
allows static charges to dissipate before they can build to dangerous levels. AntiESD 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.
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.

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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, pinkpoly 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 equalizes 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.

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.

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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.
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:
7. Follow the instructions listed above for working at the instrument rack and
workstation.
8. Never carry the component or assembly without placing it in an anti-ESD bag
or bin.
9. 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.

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If you are at an anti-ESD workbench, lay the container down on the
conductive work surface.
In either case wait several seconds.
10. Place the item in the container.
11. Seal the container. If using a bag, fold the end over and fastening it with antiESD 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.
12. 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
13. Open the container.

13.4.2.3. OPENING SHIPMENTS FROM TELEDYNE API
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 by:
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 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

13.4.2.4. PACKING COMPONENTS FOR RETURN
Always pack electronic components and assemblies to be sent to Teledyne API
Technical Support in anti-ESD bins, tubes or bags.

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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 bubblepack, 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 antiESD 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

232

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 11.8 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

Corona Discharge, a frequently luminous discharge, at the surface of a conductor
or between two conductors of the same transmission line, accompanied by
ionization of the surrounding atmosphere and often by a power loss

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

general abbreviation for hydrocarbon

HNO3

nitric acid

H2S

hydrogen sulfide

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

molecular oxygen

ozone

SO2

sulfur dioxide

07276B DCN6418

233

Index

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Term

Description/Definition

cm3

metric abbreviation for cubic centimeter (replaces the obsolete abbreviation “cc”)

CPU

Central Processing Unit

DAC

Digital-to-Analog Converter

DAS

Data Acquisition System

DCE

Data Communication Equipment

DFU

Dry Filter Unit

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

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

GFC

Gas Filter Correlation

I2C bus

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

Integrated Circuit, a modern, semi-conductor circuit that can contain many basic
components such as resistors, transistors, capacitors etc in a miniaturized
package used in electronic assemblies

Internet Protocol

234

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Term

Index

Description/Definition

IZS

Internal Zero Span

LAN

Local Area Network

LCD

Liquid Crystal Display

LED

Light Emitting Diode

LPM

Liters Per Minute

MFC

Mass Flow Controller

M/R

Measure/Reference

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

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®

07276B DCN6418

235

Index

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Term

Description/Definition

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

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

236

07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Index

INDEX
A
AC Power 60 Hz, 35
AIN, 99
ALRM, 64, 101
ANALOG CAL WARNING, 52
Analog Inputs, 99
Analog Outputs, 36, 37, 63, 64, 66, 67, 81
Ain Calibration, 99
CONC1, 54
CONC2, 54
Configuration & Calibration, 64, 86, 87, 88, 89, 91, 93, 95,
96, 99
Automatic, 29, 63, 89
Manual-Current Loop, 92, 94
Manual-Voltage, 90
Electrical Connections, 36
Electronic Range Selection, 85
Output Loop Back, 219
Over-Range Feature, 95
Pin Assignments, 36
Recorder Offset, 96
Reporting Range, 63
Test Channel, 97
Chassis Temp, 97
NONE, 97
SAMPLE FLOW, 97
SAMPLE PRESS, 97
Analyzer Operating Modes, 60
APICOM, 104, 129, 149, 151, 161, 177
and DAS System, 131, 146, 148, 149
configuration failure, 142
front panel edit, 135
Interface Example, 148
Software Download, 149, 151
user manual, 149
ATIMER, 131, 135, 136
AUTO, 68
AutoCal, 60, 62, 87

B
Baud Rate, 119
BOX TEMP, 52, 62, 186, 194
BOX TEMP WARNING, 52, 184

C
Cal Gas Line, 50
CAL HOLD OFF, 39, 79, 131, 145
CAL Mode
Remote, 40
CALDAT, 132
Calibration
AIN, 99
Analog Ouputs, 29, 63, 89
07276B DCN6418

Analog Outputs
Current Loop, 92, 94
Voltage, 90
Calibration Checks, 159, 162
Calibration Current Meter, 92
Calibration Gases, 160
Span Gas, 164
Standard Reference Materials (SRM’s)
CO Span Gas, 49
Zero Air, 48, 160
Calibration Voltmeter, 90
CANNOT DYN SPAN, 52, 126, 184
CANNOT DYN ZERO, 52, 126, 184
Clock, 77
CLOCK_ADJ, 79
CO2, 62, 123, 161
AUTO MODE, 72
CO2 CAL
Remote, 40
CO2 CELL TEMP, 62
CO2 CELL TEMP WARNING, 52
CO2 CONC ALRM1 WARNING, 52
CO2 CONC ALRM2 WARNING, 52
CO2 OFFSET, 62
CO2 Sensor, 83, 207, 208
operation, 208
Troubleshooting, 201
CO2 SLOPE, 62
COMM Ports, 103, 104, 119
and DAS System, 144
Baud Rate, 106
COM1, 121
Default Settings, 43
COM2, 44, 104, 121
Default Settings, 43
Communication Modes, 103, 104
DCE – DTE, 103
Machine ID, 47, 108
Parity, 104, 119
RS-485, 105
Security, 155
testing, 107
Communication
External, 64
CONC, 131, 135
CONC ALRM1 WARNING, 126
CONC ALRM2 WARNING, 126
CONC Key, 79
CONC VALID, 199
CONC_PRECISION, 79
CONC1, 54
CONC2, 54
Concentration Alarms, 101, 102
Concentration Field, 29
CONFIG INITIALIZED, 52, 184
Contact, 231
Continuous Emission Monitoring (CEM), 73

237

Index

Control Inputs
Electrical Connections, 39
Control Inputs
Pin Assignments, 40
Control Inputs, 60
Control Inputs, 219
CPU, 182, 185, 186, 188, 199, 200, 212, 218, 219, 222
AIN Calibration, 99
Analog to Digital Converter, 52, 83
and Relay Board, 215
AOUTS Calibration Values, 83
CLOCK_ADJ, 77
COMM Port Connections, 43
DAS, 66, 129
Pressure Calibration, 167
Status LED, 188
Watchdog LED, 189, 216
Critical Flow Orifice, 131, 180, 185, 191, 201, 210, 211
Current Loop Outputs, 37, 92, 93, 94
Manual Calibration, 92

D
DAS
disabling, 130
DAS System, 29, 53, 54, 63, 66, 79, 129, 161, 166, 177, 184,
214, 223
and APICOM, 148
Channel Enabeled, 131
Channel Names, 136
Channel setup, 133
Channels, 130
CALDAT, 132
CONC, 131
DETAIL, 132
FAST, 132
PNUNTC, 131
Compact Data Report, 146
HOLD OFF, 39, 79, 131, 145
Number of Records, 131
Parameters, 130, 131, 133, 137
CONC, 135
NXCNC1, 135
PMTDET, 131
Precision, 138
Predictive Diagnostics, 132
Report Period, 131, 142, 146
Report Period editing, 140
Sample Mode
AVG, 138, 140, 142
INST, 138, 140, 142
MAX, 138
MIN, 138, 140, 142
SDEV, 138, 140, 142
Sample Period editing, 140
setting number of records, 143
setup, 63
Starting Date, 146
Store Number of Samples, 138, 140, 142
time stamp, 62
Trigger, 130
Triggering Events, 131, 133, 136
ATIMER, 131, 135, 136

238

Teledyne API T803 CO2/O2 Analyzer Operation Manual

EXITZR, 136
SLPCHG, 132, 136
Triggerning Events, 137
DAS_HOLD_OFF, 79
data acquisition. See DAS System
DATA INITIALIZED, 184
Warning, 53
DB-25M, 19, 155
DB-9F, 19, 155
DC Power, 40
DCE – DTE Switch, 31
Default Settings
DAS System, 131
Ethernet, 110
Hessen Protocol, 122, 126
VARS, 79
DHCP, 54, 109, 110
DIAG AIO, 81
DIAG AOUT, 81
DIAG FCAL, 81
DIAG I/O, 81
DIAG Menu
password, 76
DIAG Mode, 60
DIAG TCHN, 81
Diagnostic Menu (DIAG), 64, 75
Ain Calibrated, 83, 99
Analog I/O
AOUT Calibration Configuration, 83, 88
Conc_Out_1, 83
Conc_Out_2, 83
Conc_Out_3, 83
Analog I/O Configuration, 81, 84, 85, 86, 87, 88, 89, 91, 93,
95, 96, 99
Analog Output Step Test, 81
Flow Calibration, 81
Pressure Calibration, 81
Signal I/O, 186
SIGNAL I/O, 81, 188
Test Chan Output, 81
Test Output, 83
diagnostic tools, 81
Dilution Ratio (Option), 73
Display Precision, 79
DUAL, 68, 70, 71, 159

E
EEPROM
Disk on Module, 140
Electrical Connections
AC Power, 34
Analog Outputs, 36
Current Loop, 92
Voltage Ranges, 90
Analog Outputs pin assignments, 67
Control Inputs, 39
Ethernet, 109
Modem, 155, 156
Status Outputs, 38
Electro-Static Discharge, 45, 229, 230
Warning, 232
ENTR Key, 64, 142
07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Environmental Protection Agency(EPA), 161
Ethernet, 108, 109, 110
Configuration, 109–14
Property Defaults, 110
using DHCP, 109
DHCP, 54, 109, 110
HOSTNAME, 114
Exhaust Gas, 32, 210
Exhaust Gas Outlet, 32, 50
EXIT Key, 64
EXITZR, 136
External Pump, 18

F
features, T803, 17
Final Test and Validation Data Sheet, 54, 166
Flash Chip, 214
Flow Rate
Zero Air, 50
FlowRate
Span Gas, 50
Front Panel, 27
Concentration Field, 29
Display, 52, 81, 97
Keypad Definition Field, 29
Message Field, 29
Mode Field, 29
Status LED’s, 29

G
Gas Inlets
Sample, 32
Span, 32
ZERO AIR, 32
Gas Outlets
Exhaust, 32, 50

H
Heaters, 189, 215, 216, 217
Hessen Protocol, 104, 118, 119, 120, 121, 122, 126
Activation, 119
and Reporting Ranges, 123
Default Settings, 122
Gas List, 124, 125
ID Code, 128
Latency Period, 119
response Mode, 122
Setup Parameters, 119
Status Flag
Default Settings, 126
Modes, 126
Unassigned Flags, 126
Unused Bits, 126
Warnings, 126
Status Flags, 126
types, 120
Hostname, 114

Index

I
2

I C, 188, 215
Status LED, 188
I2C bus, 184, 185, 188, 195, 212, 218, 219
Power Up Circuit, 219
iDAS
configuration
Remote, 148
Infrared Radiation (IR), 205, 207
interference
Other Gases, 49
Internal Pneumatics, 51
Basic Model 803E, 190
Internal Pump, 51, 131, 167, 178, 179, 180, 185, 191, 192, 194,
197, 201, 209, 210, 211, 220
Internal Pump Exhaust, 49

K
Keypad Definition Field, 29

L
Local Area Network (LAN), 54, 108, 109, 110, 112

M
Machine ID, 47, 108
magnetic field, 205, 206
magneto-mechanical sensor, 205, 206
Menu access
passwords, 75
Menu Keys
CONC, 79
ENTR, 64, 142
EXIT, 64
MENUS
AUTO, 72, 159
AUTO, auto range, 68
DUAL, 70, 71, 159
DUAL, dual range, 68
SNGL, 69
SNGL, single range, 68
Message Field, 29
Mode Field, 29
modem, 43, 44, 104, 151, 155, 156, 157, 200
Modem, 155, 156
Troubleshooting, 200
Motherboard, 83, 92, 188
Multidrop, 104, 108, 118

N
National Institute of Standards and Technology (NIST)
Standard Reference Materials (SRM), 49, 161
CO2, 161

O
O2, 62, 123, 159, 161, 164, 166, 167
paramagnetic sensor, 207

07276B DCN6418

239

Index

O2 CELL TEMP, 62, 186
O2 CELL TEMP WARNING, 53, 184
O2 CONC ALRM1 WARNING, 53
O2 CONC ALRM2 WARNING, 53
O2 M-P CAL, 60
O2 OFFSET, 62, 186
O2 RANGE #1
AUTO, 72
O2 RANGE #2
AUTO, 72
O2 sensor, 62, 160
zero cal, 48
O2 SLOPE, 62, 186
OFFSET, 92, 96, 176, 177
Operating Modes, 81
Calibration Mode, 126
Calibration Mode
O2 M-P CAL, 60
SPAN CAL [type], 60
ZERO CAL [type], 60
DIAG Mode, 60
Diagnostic Mode (DIAG), 81
SAMPLE A1, 60
Sample Mode, 29, 60, 79
Secondary Setup, 64
SETUP [X.X], 60
Outlet, 50

P
paramagnetic, 17, 196, 205, 217
paramagnetic sensor, 205, 206
Particulate Filter, 177, 185, 211
Password
menu access, 75
photocells, 206
Pneumatic Set Up
Basic Model 803E
Bottled Gas, 162
Bottled Gas, 49
Calibration Gases, 48
PNUMTC, 131
Predictive Diagnostics, 151
PRES, 62, 176, 177, 179, 186
PTFE, 177, 178

R
RANGE, 62, 83, 123, 186
RANGE1, 62, 123
RANGE2, 62, 123
RANGE2 CAL
Remote, 40
REAR BOARD NOT DET, 53, 126, 184
Rear Panel
Analog Outputs, 67
Basic T803, 31
Recorder Offset, 96
Relay Board
Troubleshooting, 196
Relay Board Warning, 53, 185
relay PCA, 215, 217
Relay PCA, 216

240

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Status LED’s, 188, 189, 216, 217
Troubleshooting, 188, 189
Reporting Range
Upper Span Limit:, 69
Reporting Range, 63, 66
Configuration, 63, 66
Modes
SNGL, 69
Reporting Range
Upper Span Limit
Dual, 71
Reporting Range, 72
Reporting Range
Configuration
AUTO, 72
Reporting Range
Dilution Feature (Option), 73
Reporting Range Configuration
DUAL, 70
SNGL, 69
RJ45, 19
RS-232
DCE – DTE, 31, 103
RS-232, 44
RS-232, 46
RS-232, 103
RS-232
Troubleshooting, 200
RS-232, 212
RS-485, 104, 105, 108, 212

S
Safety Messages
Electric Shock, 34, 215
Electro-Static Discharge, 232
General, 25, 35, 48, 49, 92, 160, 181
Qualiified Personnel, 181
Strong Oxidizer, 173, 179, 181
SAMPLE A1, 60
SAMPLE FL, 62, 186
Sample Flow Sensor, 211
Sample Flow Warning, 53, 185
Sample Flow Warning, 126
Sample Gas
Venting, 50
Sample Gas Line, 50
Sample Inlet, 32
Sample Mode, 29, 59, 60, 79
Sample Press Warning, 53, 185, 186
Sample Pressure Sensor, 211
Sensor Inputs, 196, 218
Sample Pressure And Flow, 218
Thermistor Interface, 218
Serial I/O Ports
Modem, 155, 156
Multidrop, 104, 108
RS-232, 44, 131, 151
RS-485, 104
SETUP [X.X], 60
Setup Mode, 59
SLOPE, 176, 177
SLPCHG, 132, 136
07276B DCN6418

Teledyne API T803 CO2/O2 Analyzer Operation Manual

SNGL, 68, 69
SPAN, 40
SPAN CAL, 176, 199
SPAN CAL [type], 60
Span Gas
Concentration, 161, 164
Flow Rate, 50
Initial Cal, 54
Pressure Leak Check, 179
Troubleshooting, 185, 186, 191, 192, 193
Venting, 50
with Alarm Options, 101
Span Inlet, 32
Specifications, 21
STABIL, 62, 176, 177, 186
STABIL_GAS, 79
Status
CAL MODE, 39
CO2 Output, 39
CONC VALID, 39
RANGE2 CAL, 39
SPAN CAL, 39
SYSTEM OK, 39
Status LED’s
I2C, 188
Relay PCA, 188, 216, 217
Watchdog, 188, 189, 216, 217
Status LED's
CO2 Sensor, 201
CPU, 188
Status Outputs, 72, 219
Electrical Connections, 38
Pin Assignments, 39
System
Default Settings, 131
SYSTEM OK, 199
SYSTEM RESET, 185
System Reset Warning, 53

T
Teledyne Contact Information
Email Address, 18, 22, 204
Fax, 18, 22, 204
Phone, 22, 204
Phone, direct, 18
Phone, toll free, 18
Technical Assistance, iii, 204
Website, 18, 204
Terminal Mode, 152
Command Syntax, 152
Computer mode, 104
Interactive mode, 152
Test Channel, 81, 83, 97
Chassis Temp, 97
NONE, 97
SAMPLE FLOW, 97
SAMPLE PRESS, 97
Test Function
RANGE, 83, 123
Test Functions, 61, 83, 97
BOX TEMP, 62, 186, 194
CO2 CELL TEMP, 62
07276B DCN6418

Index

CO2 OFFSET, 62
CO2 SLOPE, 62
Defined, 62
O2 CELL TEMP, 62, 186
O2 OFFSET, 62, 186
O2 RANGE #1
AUTO, 72
O2 RANGE #2
AUTO, 72
O2 SLOPE, 62, 186
OFFSET, 176, 177
PRES, 62, 176, 177, 179, 186
RANGE, 62, 123, 186
RANGE1, 62, 123
RANGE2, 62, 123
SAMPLE FL, 62, 186
SLOPE, 176, 177
STABIL, 62, 176, 177, 186
TIME, 62, 186
TIME, 62, 186
Touch screen Interface Electronics
Troubleshooting, 195

V
VARS Menu, 64, 75, 79, 131
clock adjust, 77
password, 76
Variable Default Values, 79
Variable Names
CLOCK_ADJ, 79
CONC_PRECISION, 79
DAS_HOLD_OFF, 79
STABIL_GAS, 79
Ventilation Clearance, 27
Venting, 50
Exhaust Line, 50
Sample Gas, 50
Span Gas, 50
Zero Air, 50

W
Warm-up Period, 52
Warnings
ANALOG CAL WARNING, 52
BOX TEMP WARNING, 52, 184
CANNOT DYN SPAN, 52, 126, 184
CANNOT DYN ZERO, 52, 126, 184
CO2 CELL TEMP WARNING, 52
CO2 CONC ALRM1 WARNING, 52
CO2 CONC ALRM2 WARNING, 52
CONC ALRM1 WARNING, 126
CONC ALRM2 WARNING, 126
CONFIG INITIALIZED, 52, 184
DATA INITIALIZED, 53, 184
O2 CELL TEMP WARNING, 53, 184
O2 CONC ALRM1 WARNING, 53
O2 CONC ALRM2 WARNING, 53
REAR BOARD NOT DET, 53, 126, 184
RELAY BOARD WARN, 53, 185
SAMPLE FLOW WARN, 53, 126, 185
SAMPLE PRESS WARN, 53, 185, 186

241

Index

SYSTEM RESET, 53, 126, 185
Warranty, 21
Watchdog Circuit, 188
Status LED, 188, 189, 216

Teledyne API T803 CO2/O2 Analyzer Operation Manual

Flow Rate, 50
Initial Cal, 54
Troubleshooting, 177, 186, 191, 192, 193
Venting, 50
ZERO AIR Inlet, 32
ZERO CAL, 176, 199
ZERO CAL [type], 60

Zero Air, 48, 159, 160

242

07276B DCN6418

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

APPENDIX A – Version Specific Software Documentation
APPENDIX A-1: 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)/A3 (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 Versions 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

07276B DCN6418

A-1

Appendix A

Models T803, 803E Appendix A Menu Trees (06763C DCN6418)

This page intentionally left blank.

A-2

07276B DCN6418

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

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

SAMPLE

TEST1

CO2

SETUP

Press to
cycle
through the
active
warning
messages.

LOW
HIGH
CO2 RNG=[Value] %
3
CO2 RN1=[Value] %
CO2 RN2=[Value] % 3
O2 RNG=[Value]%
STABIL=[Value] %
ZERO SPAN
CONC
PRES=[Value]IN-HG-A
SAMP FL=[Value]CC/M
O2 SLOPE=[Value]
CO2
O2
O2 OFFSET=[Value]MV
CO2 SLOPE=[Value]
CO2 OFFSET=[Value]MV
O2 CELL TEMP=[Value]ºC
CO2 CELL TEMP=[Value]ºC
BOX TEMP=[Value]ºC
4
TEST=[Value]MV
CFG
ACAL
TIME=[HH:MM:SS]

CLR

Press to
clear an
active
warning
messages.

PRIMARY SETUP
MENU

DAS

RNGE

PASS

CLK

Only appears when warning messages are active.
Only appears on units with alarm option enabled.
3
Only appears if the Range Mode is set of DUAL or AUTO
4
Only appears if analog output A4 is actively reporting a TEST FUNCTION
ACAL is a special configuration; consult factory.

SECONDARY
SETUP MENU

COMM
Figure A-1:
07276B DCN6418

VARS

DIAG

ALAR2

Basic Sample Display Menu
A-3

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

SAMPLE

CFG

PASS

CLK

OFF
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

TIME

MODE

SET

SNGL DUAL AUTO

DIL1
CO2 RANGE #13
CO2 RANGE #23
O2 RANGE

DATE

Go to
SECONDARY SETUP
Menu Tree

Only appears if Dilution option is active.
Only appears if Hessen protocol is active.
3
Only appears if the DUAL or AUTO range
modes are selected.
ACAL is a special configuration; consult factory.
2

Figure A-2:
A-4

Primary Setup Menu (Except iDAS)
07276B DCN6418

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)
SETUP

SAMPLE

CFG

ACAL

DAS

PASS

RNGE

VIEW
PREV

EDIT

ENTER PASSWORD: 818

CONC
PNUMTC
CALDAT
DETAIL
FAST

NX10

INS

CONC
PNUMTC
CALDAT
DETAIL
FAST

VIEW
PV10

NEXT
YES1

Cycles through list
of available trigger
events2

PRNT

NX10

Create/edit the name of the channel

NAME
EVENT
PARAMETERS
REPORT PERIOD
NUMBER OF RECORDS
RS-232 REPORT
CHANNEL ENABLE
NO
CAL MODE

Selects the data point to be viewed

EDIT1

DEL
YES

PRM>

NO
Sets the maximum number of
records recorded by this channel

EDIT

PRNT

PARAMETER

Cycles through list of available &
currently active parameters for this
channel

Figure A-4:
07276B DCN6418

SAMPLE MODE

INST

AVG

PRECISION

MIN

MAX

Editing an existing DAS channel will erase any
data stored on the channel options.
2
Changing the event for an existing DAS channel
DOES NOT erase the data stored on the
channel.
ACAL is a special configuration; consult factory.

Primary Setup Menu (iDAS)
A-5

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

Go to
COMM / Hessen
Menu Tree

6
6
6

Go to
1

E-Series: only appears if optional Ethernet PCA is
installed.
When Ethernet PCA is present
COM2 submenu disappears.
Only appears if
mode is ON
(See
&
submenu above).

,
editable when

Figure A-5:

A-6

&
is

are only

Although
is editable regardless of the
state, do not change the setting for this property.

Menu Tree

is only editable when

ACAL is a special configuration; consult factory.
T-Series only

Secondary Setup Menu (COMM & VARS)
07276B DCN6418

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

SAMPLE
CFG

DAS

ACAL

RNGE PASS

SETUP
MORE

CLK

COMM
HESN2

INET1

COM1

COM2

ENTER PASSWORD: 818

RESPONSE MODE

BCC

TEXT

EDIT

Go to COMM / VARS Menu
Tree

GAS LIST

Go to DIAG Menu Tree

STATUS FLAGS

CMD

INS

DEL

EDIT

PRNT

O2, 110, REPORTED
YES

CO2, 111, REPORTED

1
2

E-Series: only appears if Ethernet Option is installed.
Only appears if HESSEN PROTOCOL mode is ON.
ACAL is a special configuration; consult factory.

GAS TYPE
GAS ID
REPORTED

ON
OFF

CO2
O2

Set/create unique gas ID number

Figure A-6:
07276B DCN6418

Secondary Setup Menu - HESSEN Submenu
A-7

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Figure A-7:

A-8

Appendix A

Secondary Setup Menu (DIAG)
07276B DCN6418

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

APPENDIX A-2: Setup Variables For Serial I/O, Software Versions 1.0.3 (T-Series)/A3 (E-Series)
Table A-1:
Setup Variable

Numeric
Units

Setup Variables
Default
Value

Value Range

Description

Low Access Level Setup Variables (818 password)
DAS_HOLD_OFF

Minutes

STABIL_GAS

—

15
O2

0.5–20
5

CO2

O2 ,
4

CO2

Duration of DAS hold off period.
Selects gas for stability
measurement. Enclose value in
double quotes (") when setting
from the RS-232 interface.

TPC_ENABLE

—

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.

0,
1,
2,
3,
4
CLOCK_ADJ

Sec./Day

-60–60

Time-of-day clock speed
adjustment.

SERVICE_CLEAR8

—

OFF

OFF
ON

ON resets the service interval
timer.

TIME_SINCE_SVC
8

SVC_INTERVAL

Hours

0–500000

Time since last service.

Hours

0–100000

Sets the interval between service
reminders.

Medium Access Level Setup Variables (929 password)
DAYLIGHTSAVING_ENABLE8

—

LANGUAGE_SELECT

—

ENGL

OFF, ON

Enables/disables automatic
Daylight Savings Time change.

ENGL,

Selects the language to use for
the user interface. Enclose value
in double quotes (“) when setting
from the RS-232 interface.

SECD,
EXTN
MAINT_TIMEOUT

Hours

0.1–100

Time until automatically
switching out of softwarecontrolled maintenance mode.

LATCH_WARNINGS8

—

ON, OFF

ON enables latching warning
messages; OFF disables
latching.

CONV_TIME

—

33 MS

33 MS, 66 MS,

Conversion time for O2 and CO2
detector channels. Enclose value
in double quotes (“) when setting
from the RS-232 interface.

133 MS,
266 MS,
533 MS,
1 SEC, 2 SEC
07276B DCN6418

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

A-9

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable

Numeric
Units

Default
Value

Value Range

Description

NEG_CONC_SUPPRESS

—

OFF

OFF, ON

ON pegs negative concentrations
at zero; OFF permits negative
concentrations

O2_DWELL3

Seconds

0.1–30

Dwell time before taking each
sample.

O2_FILT_ADAPT3

—

ON, OFF

ON enables O2 adaptive filter;
OFF disables it.

O2_FILT_SIZE3

Samples

1–500

O2 moving average filter size in
normal mode.

O2_FILT_ASIZE3

Samples

1–500

O2 moving average filter size in
adaptive mode.

O2_FILT_DELTA3

0.1–100

Absolute change in O2
concentration to shorten filter.

O2_FILT_PCT3

0.1–100

Relative change in O2
concentration to shorten filter.

O2_FILT_DELAY3

Seconds

0–300

Delay before leaving O2 adaptive
filter mode.

O2_DIL_FACTOR3

—

0.1–1000

Dilution factor for O2. Used only if
is dilution enabled with
FACTORY_OPT variable.

O2_CELL_SET3

ºC

30–70

O2 sensor cell temperature set
point and warning limits.

Warnings:
45–55
3

O2_CELL_CYCLE

Seconds

0.5–30

O2 cell temperature control cycle
period.

O2_CELL_PROP3

—

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

0.1–30

Dwell time before taking each
sample.

CO2_FILT_ADAPT 1

—

ON, OFF

ON enables CO2 adaptive filter;
OFF disables it.

CO2_FILT_SIZE 1

Samples

1–300

CO2 moving average filter size in
normal mode.

CO2_FILT_ASIZE 1

Samples

1–300

CO2 moving average filter size in
adaptive mode.

CO2_FILT_DELTA 1

0.1–10

Absolute change in CO2
concentration to shorten filter.

CO2_FILT_PCT 1

0.1–100

Relative change in CO2
concentration to shorten filter.

CO2_FILT_DELAY 1

Seconds

0–300

Delay before leaving CO2
adaptive filter mode.

A-10
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable

Numeric
Units

Default
Value

Value Range

Appendix A

Description

CO2_DIL_FACTOR 1

—

0.1–1000

Dilution factor for CO2. Used only
if is dilution enabled with
FACTORY_OPT variable.

CO2_CELL_SET 1

ºC

30–70

CO2 sensor cell temperature set
point and warning limits.

Warnings:
45–55
1

Seconds

0.5–30

CO2 cell temperature control
cycle period.

CO2_CELL_PROP 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

—

0.5–2

O2 slope for range 1.

CO2_CELL_CYCLE

O2_OFFSET1

-10–10

O2 offset for range 1.

CO2_TARG_SPAN11

0.1–1000

Target CO2 concentration during
span calibration of range 1.

CO2_SLOPE11

—

0.5–5

CO2 slope for range 1.

CO2_OFFSET11

-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

—

0.5–2

O2 slope for range 2.

O2_OFFSET25

-10–10

O2 offset for range 2.

CO2_TARG_SPAN24

0.1–1000

Target CO2 concentration during
span calibration of range 2.

CO2_SLOPE24

—

0.5–5

CO2 slope for range 2.

CO2_OFFSET24

-10–10

CO2 offset for range 2.

RANGE_MODE

—

SNGL

SNGL,
AUTO

Range control mode. Enclose
value in double quotes (“) when
setting from the RS-232
interface.

DUAL,

CONC_RANGE1

100

0.1–500

D/A concentration range 1

CONC_RANGE2

100

0.1–500

D/A concentration range 2

0.1–500

D/A concentration range 3

CONC_RANGE3

07276B DCN6418

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

A-11

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable
SAMP_FLOW_SET

Numeric
Units
cc/m

Default
Value
120

Value Range

Description

0–6000

Sample flow set point for flow
calculation and warning limits.

Warnings:
80–180
SAMP_FLOW_SLOPE

—

0.5–1.5

Sample flow slope correction
factor (adjusted flow = measured
flow x slope).

SAMP_PRESS_SET

"Hg

29.92

0–100

Sample pressure set point for
pressure compensation and
warning limits.

5–60

Box temperature warning limits.
Set point is not used.

0–65535

RS-232 COM1 mode flags. Add
values to combine flags.

Warnings:
15–35
BOX_SET

ºC

30
Warnings:
8–50

RS232_MODE

BitFlag

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,

RS-232 COM1 baud rate.
Enclose value in double quotes
(“) when setting from the RS-232
interface.

4800,
9600,
19200,
38400,
57600,
115200

A-12
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable

Numeric
Units

Default
Value

Value Range

Appendix A

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

0–65535

RS-232 COM2 mode flags.
(Same settings as
RS232_MODE.)

BAUD_RATE2

—

19200

300,
1200,
2400,

RS-232 COM2 baud rate.
Enclose value in double quotes
(“) when setting from the RS-232
interface.

4800,
9600,
19200,
38400,
57600,
115200
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

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,

Diagnostic analog output ID.
Enclose value in double quotes
(“) when setting from the RS-232
interface.

SAMPLE
PRESSURE
,
SAMPLE
FLOW,
O2 CELL
TEMP 3,
CO2 CELL
TEMP 1,
CHASSIS
TEMP

07276B DCN6418

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

A-13

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable
REMOTE_CAL_MODE

Numeric
Units
—

Default
Value

Value Range

O2 RANGE1 5

3
O2 RANGE1 ,

CO2 RANGE1

O2 RANGE2 5,

CO2 RANGE1
,

Description
Range to calibrate during
contact-closure and Hessen
calibration. Enclose value in
double quotes (“) when setting
from the RS-232 interface.

CO2 RANGE2

PASS_ENABLE

—

OFF

OFF, ON

ON enables passwords; OFF
disables them.

STABIL_FREQ

Seconds

1–300

Stability measurement sampling
frequency.

STABIL_SAMPLES

Samples

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,

Front panel display intensity.
Enclose value in double quotes
(“) when setting from the RS-232
interface.

MED,
LOW,
DIM
I2C_RESET_ENABLE

—

OFF, ON

I2C bus automatic reset enable.

A-14
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Setup Variable
CLOCK_FORMAT

Numeric
Units
—

Default
Value
“TIME=%H:%
M:%S”

Value Range
Any character
in the allowed
character set.
Up to 100
characters
long.

Appendix A

Description
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

07276B DCN6418

Cycles

1–100

Number of times concentration
must exceed limit to trigger
alarm.

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

A-15

Appendix A

Setup Variable
FACTORY_OPT

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Numeric
Units
BitFlag

Default
Value
0

Value Range
0–0x7fffffff

Description
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
6
inputs

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

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

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

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

T-Series/E-Series: 802 only.

T Series external analog input option.

E Series internet option.

T Series only.

A-16
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

APPENDIX A-3: Warnings and Test Measurements, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-2:
Name 1

Warning Messages

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

O2 ALARM 2 WARN

O2 concentration alarm limit #2 exceeded

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.

WCO2ALARM1

The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”.

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

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

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

T-Series/E-Series: 802 only.

T-Series/E-Series: 803 only.

T-Series/E-Series: 802 with CO2 option.

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

External analog input option.

07276B DCN6418

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

A-17

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Table A-3:
Name 1

Test Measurements

Message Text

Description

Test Measurements
O2RANGE 5

O2 RNG=500.0 %
4

CO2RANGE

CO2 RNG = 500.0 %

O2RANGE1 5
CO2RANGE1
O2RANGE2

O2 RN1=500.0 %
4

O2 RN2=500.0 %
CO2 RN2=500.0 %

O2RANGE 6

O2 RNG=100 %
7

D/A 2 range in independent range mode.
D/A 3 range.

CO2 RNG=100 %
STABIL=0.0 % 8

STABILITY

D/A 1 range in independent range mode.

CO2 RN1=500.0 %

CO2RANGE2 4
CO2RANGE

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

Concentration stability.

O2 STB=0.0 % 2 or
CO2 STB=0.0 % 2
SAMPPRESS

PRES=29.9 IN-HG-A

Sample pressure.

SAMPFLOW

SAMP FL=100 CC/M

Sample flow rate.

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=0.00 %

O2 concentration.

O2SLOPE

CO2

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.

A-18

07276B DCN6418

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

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)
Name 1

Message Text

Appendix A

Description

Test Measurements
CLOCKTIME

TIME=10:38:27

Current instrument time of day clock.

The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”.

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

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

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

T-Series/E-Series: 802 only.

T-Series/E-Series: 803 only.

T-Series/E-Series: 802 with CO2 option.

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

External analog input option.

07276B DCN6418

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

A-19

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

APPENDIX A-4: Signal I/O Definitions, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-4:
Signal Name

Signal I/O Definitions

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
I2C_RESET

0–5

Spare

1 = reset I2C peripherals
0 = normal

I2C_DRV_RST

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 = go into calibration mode
1 = exit calibration mode and go into measure mode

EXT_CAL_SPAN

0 = calibrate span
1 = calibrate zero

EXT_CAL_RANGE2

EXT_CAL_CO2 1

0 = calibrate range #2
1 = calibrate range #1
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
ST_SYSTEM_OK2,
MB_RELAY_36

1 = system OK
0 = any alarm condition or in diagnostics mode
Controlled by MODBUS coil register

ST_CONC_ALARM_1,

MB_RELAY_37 3

1 = conc. limit 1 exceeded
0 = conc. OK
Controlled by MODBUS coil register

ST_CONC_ALARM_2,

MB_RELAY_38 3

1 = conc. limit 2 exceeded
0 = conc. OK
Controlled by MODBUS coil register

ST_AUTO_RANGE2,
MB_RELAY_39

1 = auto-range 2 in use
0 = auto-range 1 in use
Controlled by MODBUS coil register

A-20
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Signal Name

Bit or Channel
Number

Appendix A

Description

A status outputs, U24, J1017, pins 1–8 = bits 0–7, default I/O address 323 hex
ST_SYSTEM_OK

0 = system OK
1 = any alarm condition

ST_CONC_VALID

0 = conc. valid
1 = warnings or other conditions that affect validity of
concentration

ST_CAL_MODE

ST_CAL_SPAN

0 = in calibration mode
1 = in measure mode
0 = calibrating span
1 = calibrating zero

ST_CAL_RANGE2

0 = calibrating range 2
1 = calibrating range 1

ST_CAL_CO2

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
2

Front panel I C 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

AUDIBLE_BEEPER

14 (output)

0 = beeper on (for diagnostic testing only)

1 = off
1 = off
Relay board digital output (PCF8575), default I2C address 44 hex
RELAY_WATCHDOG

CO2_CELL_HEATER

Alternate between 0 and 1 at least every 5 seconds to keep
relay board active

1–3

Spare

0 = CO2 sensor cell heater on
1 = off

O2_CELL_HEATER

0 = O2 sensor cell heater on
1 = off

CAL_VALVE 6

0 = let cal. gas in
1 = let sample gas in

O2_SPAN_VALVE

4, 6

0 = let O2 span gas in
1 = let zero gas in

07276B DCN6418

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

A-21

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Signal Name
CO2_SPAN_VALVE 2, 6

Bit or Channel
Number
8

Description
0 = let CO2 span gas in
1 = let zero gas in

VENT_VALVE 6

0 = open vent valve
1 = close vent valve

10–15

Spare

Rear board primary MUX analog inputs
0–3

Spare

Temperature MUX

Spare

O2_CONC_SENSOR 4

O2 concentration sensor

SAMPLE_PRESSURE

Sample pressure

Spare

4.096V reference from MAX6241

REF_4096_MV
SAMPLE_FLOW

Sample flow rate

CO2_CONC_SENSOR 2

CO2 concentration sensor

12–13

Spare (thermocouple input?)

DAC MUX

Ground reference

REF_GND

Rear board temperature MUX analog inputs
BOX_TEMP
CO2_CELL_TEMP
O2_CELL_TEMP 4

Internal box temperature

Spare

CO2 sensor cell temperature

Spare

O2 sensor cell temperature

5–7

Spare
Rear board DAC MUX analog inputs

DAC_CHAN_1

DAC channel 0 loopback

DAC_CHAN_2

DAC channel 1 loopback

DAC_CHAN_3

DAC channel 2 loopback

DAC_CHAN_4

DAC channel 3 loopback

CONC_OUT_1,

Rear board analog outputs
DATA_OUT_1
CONC_OUT_2,

Data output #1
1

DATA_OUT_2
CONC_OUT_3 1

DATA_OUT_4

Concentration output #2,
Data output #2

DATA_OUT_3
TEST_OUTPUT,

Concentration output #1,

Concentration output #3,
Data output #3

Test measurement output,
Data output #4

A-22
Error! Unknown document property name.Error! Unknown document property name.
Error!
07276B DCN6418
Unknown document property name.Error! Unknown document property name.

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Signal Name

Bit or Channel
Number

Appendix A

Description

External analog input board, default I2C address 5C hex
7

External analog input 1

XIN2 7

External analog input 2

XIN3

External analog input 3

XIN4

External analog input 4

XIN5

External analog input 5

XIN6

External analog input 6

XIN7 7

External analog input 7

External analog input 8

XIN1

XIN8
1

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

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

MODBUS option.

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

future

Future valve option.

T-Series: External analog input option.

07276B DCN6418

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

A-23

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

APPENDIX A-5: DAS Triggering Events, Parameters, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-5:

DAS Trigger Events

Name
ATIMER

Description
Automatic timer expired

EXO2ZR

EXO2SP

Exit O2 zero calibration mode
Exit O2 span calibration mode

EXO2MP 3

Exit O2 multi-point calibration mode

O2SLPC 3

O2 slope and offset recalculated

EXCO2Z

Exit CO2 zero calibration mode

EXCO2S

Exit CO2 span calibration mode

EXCO2M

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
CO2TMW

O2 sensor cell temperature warning

CO2 sensor cell temperature warning

SFLOWW

Sample flow warning

SPRESW

Sample pressure warning

BTEMPW

Box temperature warning

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

future.

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

A-24

07276B DCN6418

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

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

Table A-6: DAS Parameters
Name

Description

Units

O2 slope for range #1

—

O2SLP2 4

O2 slope for range #2

—

O2OFS1

O2 offset for range #1

O2OFS2

O2 offset for range #2

CO2SL1

CO2 slope for range #1

—

CO2SL2

CO2 slope for range #2

—

CO2OF1 1

CO2 offset for range #1

CO2OF2 3

O2SLP1

CO2 offset for range #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

O2 concentration for range #1

O2CNC2

O2 concentration for range #2

CO2CN1

CO2 concentration for range #1

CO2CN2

O2ZSC1

STABIL
O2TEMP 2
O2DUTY

CO2 concentration for range #2

Concentration stability #1

O2 sensor cell temperature

C

O2 sensor cell temperature controller duty cycle

Fraction
(0.0 = off,
1.0 = on full)

CO2TMP

CO2 sensor cell temperature

C

CO2DTY

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)

RF4096

4096 mV reference (REF_4096_MV)

07276B DCN6418

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

A-25

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Name
XIN1 5

Description

Units

External analog input 1 value

Volts

XIN1SLPE 5

External analog input 1 slope

eng unit / V

XIN1OFST

External analog input 1 value

eng unit

External analog input 2 value

Volts

XIN2SLPE 5

External analog input 2 slope

eng unit / V

External analog input 2 value

eng unit

XIN2

XIN2OFST
XIN3

External analog input 3 value

Volts

XIN3SLPE

External analog input 3 slope

eng unit / V

XIN3OFST

External analog input 3 value

eng unit

External analog input 4 value

Volts

XIN4SLPE 5

External analog input 4 slope

eng unit / V

XIN4 5
XIN4OFST

External analog input 4 value

eng unit

External analog input 5 value

Volts

XIN5SLPE 5

External analog input 5 slope

eng unit / V

External analog input 5 value

eng unit

XIN5

XIN5OFST
XIN6

External analog input 6 value

Volts

XIN6SLPE

External analog input 6 slope

eng unit / V

XIN6OFST

External analog input 6 value

eng unit

External analog input 7 value

Volts

XIN7SLPE 5

External analog input 7 slope

eng unit / V

XIN7 5
XIN7OFST

External analog input 7 value

eng unit

External analog input 8 value

Volts

XIN8SLPE 5

External analog input 8 slope

eng unit / V

External analog input 8 value

eng unit

XIN8

XIN8OFST
1

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

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

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

T-Series/E-Series: 802 only.

T-Series: External analog input option.

A-26

07276B DCN6418

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

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

APPENDIX A-6: Terminal Command Designators, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
Table A-7:

COMMAND

Terminal Command Designators

ADDITIONAL COMMAND SYNTAX

? [ID]

DESCRIPTION
Display help screen and commands list

LOGON [ID]

password

LOGOFF [ID]

T [ID]

W [ID]

C [ID]

D [ID]

V [ID]

Establish connection to instrument
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

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

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

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=][TO=][VERBOSE|COMPACT|HEX]
(Print DAS records)(date format: MM/DD/YYYY(or YY)
[HH:MM:SS]

Print DAS records

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

MODE

Print current instrument mode

DASBEGIN [] 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.

07276B DCN6418

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

A-27

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

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

A-28

LF (line feed)

Execute command

Ctrl-T

Switch to terminal mode

07276B DCN6418

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

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

Appendix A

APPENDIX A-7: MODBUS® Register Map, Software Versions 1.0.3 (T-Series)/A.3 (E-Series)
MODBUS Register
Address

Description

Units

(dec., 0-based)
MODBUS Floating Point Input Registers
(32-bit IEEE 754 format; read in high-word, low-word order; read-only)
04

O2 slope for range 1

—

O2 slope for range 2

—

O2 offset for range 1

O2 offset for range 2

O2 concentration for range 1 during zero/span calibration, just
before computing new slope and offset

10 6

O2 concentration for range 2 during zero/span calibration, just
before computing new slope and offset

12 4

O2 concentration for range 1

O2 concentration for range 2

O2 sensor cell temperature

C

O2 sensor cell temperature control duty cycle

Fraction

Concentration stability

Sample flow

cc/m

Sample pressure

“Hg

Internal box temperature

C

Ground reference (REF_GND)

4096 mV reference (REF_4096_MV)

100 1

CO2 slope for range 1

—

102

CO2 slope for range 2

—

104

CO2 offset for range 1

106

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

CO2 concentration for range 2

116

CO2 sensor cell temperature

C

118

CO2 sensor cell temperature control duty cycle

Fraction

Error!
07276B DCN6418

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

A-29

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

MODBUS Register
Address

Description

Units

(dec., 0-based)
130 7

External analog input 1 value

Volts

132

External analog input 1 slope

eng unit /V

134

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

External analog input 2 offset

eng unit

142

External analog input 3 value

Volts

144

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

External analog input 4 slope

eng unit /V

152

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

External analog input 5 offset

eng unit

160

External analog input 6 value

Volts

162 7

External analog input 6 slope

eng unit /V

164

External analog input 6 offset

eng unit

166

External analog input 7 value

Volts

168

External analog input 7 slope

eng unit /V

170

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

External analog input 8 offset

eng unit

176

MODBUS Floating Point Holding Registers
(32-bit IEEE 754 format; read/write in high-word, low-word order; read/write)
4

Maps to O2_TARG_SPAN1 variable; target conc. for range 1

Maps to O2_TARG_SPAN2 variable; target conc. for range 2

100

Maps to CO2_TARG_SPAN1 variable; target conc. for range 1

102

Maps to CO2_TARG_SPAN2 variable; target conc. for range 2

A-30
Error! Unknown document property name.Error! Unknown document property name.
Error!
Unknown document property name.Error! Unknown document property name.
07276B DCN6418

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)
MODBUS Register
Address

Description

Appendix A
Units

(dec., 0-based)
MODBUS Discrete Input Registers
(single-bit; read-only)
0
1

Box temperature warning
4

O2 cell temperature warning

Sample flow warning

Sample pressure warning

System reset warning

Rear board communication warning

Relay board communication warning

Front panel communication warning

Analog calibration warning

Dynamic zero warning

Dynamic span warning

Invalid concentration

12 4

In O2 zero calibration mode

13 4

In O2 span calibration mode

In O2 multi-point calibration mode

System is OK (same meaning as SYSTEM_OK I/O signal)

O2 concentration alarm limit #1 exceeded

O2 concentration alarm limit #2 exceeded

In Hessen manual mode

100

CO2 cell temperature warning

101

In CO2 zero calibration mode

102 1

In CO2 span calibration mode

103

In CO2 multi-point calibration mode

104

CO2 concentration alarm limit #1 exceeded

105

CO2 concentration alarm limit #2 exceeded

Error!
07276B DCN6418

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

A-31

Appendix A

Models T803, 803E Appendix A Menu Trees (Reference: 06763C DCN6418)

MODBUS Register
Address

Description

Units

(dec., 0-based)
MODBUS Coil Registers
(single-bit; read/write)
0

Maps to relay output signal 36 (MB_RELAY_36 in signal I/O list)

Maps to relay output signal 37 (MB_RELAY_37 in signal I/O list)

Maps to relay output signal 38 (MB_RELAY_38 in signal I/O list)

Maps to relay output signal 39 (MB_RELAY_39 in signal I/O list)

3,4

Triggers O2 zero calibration of range 1 (on enters cal.; off exits cal.)

3,4

Triggers O2 span calibration of range 1 (on enters cal.; off exits cal.)

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.)

1,3

Triggers CO2 zero calibration of range 1 (on enters cal.; off exits cal.)

1,3

Triggers CO2 span calibration of range 1 (on enters cal.; off exits cal.)

5,3

Triggers CO2 zero calibration of range 2 (on enters cal.; off exits cal.)

5,3

Triggers CO2 span calibration of range 2 (on enters cal.; off exits cal.)

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

future.

Set DYN_ZERO or DYN_SPAN variables to ON to enable calculating new slope or offset. Otherwise a calibration check
is performed.

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

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

T-Series/E-Series: 802 only.

T-Series: External analog input option.

A-32
Error! Unknown document property name.Error! Unknown document property name.
Error!
Unknown document property name.Error! Unknown document property name.
07276B 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.

07276B DCN6418

B-1

This page intentionally left blank.

B-2

07276B DCN6418

T80X Spare Parts List
(Ref: 072690000A DCN6431, 2012 April 12)

PARTNUMBER
000940700
001763500
003290000
009690200
009690300
016290000
016300800
037860000
040010000
040030100
042410500
043420000
045230200
055100200
058021100
066970000
067240000
067300000
067300100
067300200
067900000
068810000
069500000
072150000
072740000
072750000
072760000
073770100
073780100
073790100
CN0000073
CN0000458
CN0000520
FL0000001
FM0000004
HE0000017
HW0000005
HW0000020
HW0000036
HW0000101
HW0000453
HW0000685
KIT000219
KIT000253
KIT000254
OP0000030

07276B DCN6418

DESCRIPTION
CD, ORIFICE, .005 YELLOW
ASSY, FLOW CTL, 110CC, 1/4" ELBOW‐B
THERMISTOR, BASIC (VENDOR ASSY)(KB)
AKIT, TFE FLTR ELEM (FL19,100=1) 47mm
AKIT, TFE FLTR ELEM (FL19, 30=1) 47mm
WINDOW, SAMPLE FILTER, 47MM (KB)
ASSY, SAMPLE FILTER, 47MM, ANG BKT, 1UM
ORING, TEFLON, RETAINING RING, 47MM (KB)
ASSY, FAN REAR PANEL (B/F)
PCA, PRESS SENSORS (1X), w/FM4
ASSY, PUMP, INT
ASSY, HEATER/THERM, O2 SEN
PCA, RELAY CARD
ASSY, OPTION, PUMP, 240V *
PCA, MOTHERBD, GEN 5‐ICOP
PCA, INTRF. LCD TOUCH SCRN, F/P
CPU, PC‐104, VSX‐6154E, ICOP *(KB)
PCA, AUX‐I/O BD, ETHERNET, ANALOG & USB
PCA, AUX‐I/O BOARD, ETHERNET
PCA, AUX‐I/O BOARD, ETHERNET & USB
LCD MODULE, W/TOUCHSCREEN(KB)
PCA, LVDS TRANSMITTER BOARD
PCA, SERIAL & VIDEO INTERFACE BOARD
ASSY. TOUCHSCREEN CONTROL MODULE
MANUAL, T801, OPERATORS
MANUAL, T802, OPERATORS
MANUAL, T803, OPERATORS
DOM, w/SOFTWARE, STD, T801 *
DOM, w/SOFTWARE, STD, T802 *
DOM, w/SOFTWARE, STD, T803 *
POWER ENTRY, 120/60 (KB)
PLUG, 12, MC 1.5/12‐ST‐3.81 (KB)
PLUG, 10, MC 1.5/10‐ST‐3.81 (KB)
FILTER, SS (KB)
FLOWMETER (KB)
HTR, 12W/120V (50W/240V), CE AP (KB)
FOOT
SPRING
TFE TAPE, 1/4" (48 FT/ROLL)
ISOLATOR
SUPPORT, CIRCUIT BD, 3/16" ICOP
LATCH, MAGNETIC, FRONT PANEL
AKIT, 4‐20MA CURRENT OUTPUT
ASSY & TEST, SPARE PS37
ASSY & TEST, SPARE PS38
OXYGEN TRANSDUCER, PARAMAGNETIC

B-3

T80X Spare Parts List
(Ref: 072690000A DCN6431, 2012 April 12)

OR0000001
OR0000094
PU0000022
RL0000015
SW0000006
SW0000025
SW0000059
WR0000008

B-4

ORING, 2‐006VT *(KB)
ORING, 2‐228V, 50 DURO VITON(KB)
REBUILD KIT, FOR PU20 & 04241 (KB)
RELAY, DPDT, (KB)
SWITCH, THERMAL, 60 C (KB)
SWITCH, POWER, CIRC BREAK, VDE/CE *(KB)
PRESSURE SENSOR, 0‐15 PSIA, ALL SEN
POWER CORD, 10A(KB)

07276B DCN6418

Appendix C
Warranty/Repair Questionnaire
T80X, M80XE
(06532C DCN 5798)
CUSTOMER: _______________________________

PHONE: _____________________________________

CONTACT NAME: ___________________________

FAX NO. _____________________________________

SITE ADDRESS: ___________________________________________________________________________
MODEL TYPE: ______________ SERIAL NO.: ________________ FIRMWARE REVISION: ____________
Are there any failure messages? _______________________________________________________________
________________________________________________________________________________________________________________________________

________________________________________________________________________

(Continue on back if necessary)

PLEASE COMPLETE THE FOLLOWING TABLE:

PARAMETER
O2 RANGE

RECORDED VALUE

ACCEPTABLE VALUE

1
1

O2 CELL TEMP

0-100%

ºC

50 ± 5

1.0 ± 0.3

O2 SLOPE

O2 OFFSET

CO2 RANGE

-10 to 10%

%
1

ºC

CO2 CELL TEMP
CO2 SLOPE

0 to 20%
50 ± 5

CO2 OFFSET

1.0 ± 0.3

-10 to 10%

STABIL

PRESS

in-Hg-A

 0.2% with zero air
ambient ± 1

SAMPLE FLOW

120 ± 20

cm /min

BOX TEMP

ºC

ambient ± 5ºC

following values are under the signal i/o submenu

REF_4096_MV

4096mV ±2 mV and Must be Stable

REF_GND

0± 0.5 and Must be Stable

Not all models are equipped with both an O2 and a CO2 sensor.

Cap the SAMPLE inlet and record the flow rate and pressure readings:
What is PRESS____________________in-Hg-A
What is the SAMPLE FLOW__________ cc/min
What are the failure symptoms? __________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
What test have you done trying to solve the problem? ________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
TELEDYNE API CUSTOMER SERVICE
EMAIL: api-customerservice@teledyne.com
PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816

07276B DCN6418

C-1

Appendix C
Warranty/Repair Questionnaire
T80X, M80XE
(06532C DCN 5798)
____________________________________________________________________________________
If possible, please include a portion of a strip chart pertaining to the problem. Circle pertinent data.
OTHER NOTES:____________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
Thank you for providing this information. Your assistance enables Teledyne API to respond faster to the
problem that you are encountering.
TELEDYNE API CUSTOMER SERVICE
EMAIL: api-customerservice@teledyne.com
PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816

C-2

07276B DCN6418

APPENDIX D – Wire List and Electronic Schematics

07276B DCN6418

D-1

This page intentionally left blank.

D-2

07276B DCN6418

T80X Interconnect List
(Reference: 073800100A DCN6418)

FROM
Cable PN Signal
Assembly
PN
J/P
036490100 CBL ASSY, AC POWER
AC Line
AC Neutral
Power Grnd
Power Entry
CN0000073
Power Grnd
Power Entry
CN0000073
AC Line Switched
Power Switch
SW0000025
AC Neu Switched
Power Switch
SW0000025
Power Grnd
Power Entry
CN0000073
AC Line Switched
PS2 (+12)
PS0000038 SK2
AC Neu Switched
PS2 (+12)
PS0000038 SK2
Power Grnd
PS2 (+12)
PS0000038 SK2
AC Line Switched
PS1 (+5, ±15)
PS0000037 SK2
AC Neu Switched
PS1 (+5, ±15)
PS0000037 SK2
Power Grnd
PS1 (+5, ±15)
PS0000037 SK2
038290000 CBL ASSY, DC POWER TO MOTHERBOARD
DGND
Relay Board
045230100
J7
+5V
Relay Board
045230100
J7
AGND
Relay Board
045230100
J7
+15V
Relay Board
045230100
J7
AGND
Relay Board
045230100
J7
-15V
Relay Board
045230100
J7
+12V RET
Relay Board
045230100
J7
+12V
Relay Board
045230100
J7
Chassis Gnd
Relay Board
045230100
J7
040230000 CBL, I2C, RELAY BOARD TO MOTHERBOARD
I2C Serial Clock
Motherboard
058021100 P107
I2C Serial Data
Motherboard
058021100 P107
I2C Reset
Motherboard
058021100 P107
I2C Shield
Motherboard
058021100 P107
041050000 CBL, INTERFACE BOARD TO MOTHERBOARD
Kbd Interupt
LCD Interface PCA
066970000
J2
DGND
LCD Interface PCA
066970000
J2
SDA
LCD Interface PCA
066970000
J2
SCL
LCD Interface PCA
066970000
J2
Shld
LCD Interface PCA
066970000
J2
041760000 CBL, DC POWER TO RELAY BOARD
DGND
Relay Board
045230100
P8
+5V
Relay Board
045230100
P8
+15V
Relay Board
045230100
P8
AGND
Relay Board
045230100
P8
-15V
Relay Board
045230100
P8
+12V RET
Relay Board
045230100
P8
+12V
Relay Board
045230100
P8
046710000 CBL, MOTHERBOARD TO XMITTER BD (MULTIDROP OPTION)
GND
Motherboard
058021100
P12
RX0
Motherboard
058021100
P12
RTS0
Motherboard
058021100
P12
TX0
Motherboard
058021100
P12
CTS0
Motherboard
058021100
P12
RS-GND0
Motherboard
058021100
P12
RTS1
Motherboard
058021100
P12
CTS1/485Motherboard
058021100
P12
RX1
Motherboard
058021100
P12
TX1/485+
Motherboard
058021100
P12
RS-GND1
Motherboard
058021100
P12
RX1
Motherboard
058021100
P12
TX1/485+
Motherboard
058021100
P12
RS-GND1
Motherboard
058021100
P12
063750000 CBL, CO2, O2 SENSOR THERM/HTR
O2-L
Relay Board
045230100
P18
O2-N
Relay Board
045230100
P18
Shield
Relay Board
045230100
P18
O2TA
O2 sensor therm./htr
043420000
P1
O2TB
O2 sensor therm./htr
043420000
P1
CO2THA
CO2 sensor therm./htr 041920000
P1
CO2THB
CO2 sensor therm./htr 041920000
P1
CO2-11B
Relay Board
045230100
P18
CO2-12B
Relay Board
045230100
P18
CO2-11A
Relay Board
045230100
P18
CO2TS1
Relay Board
045230100
P18
CO2TS2
Relay Board
045230100
P18
CO2-12A
Relay Board
045230100
P18

07276B DCN6418

TO
Pin Assembly

J/P

SW0000025
SW0000025

1
3
2
1
3
2

Power Switch
Power Switch
Shield
Chassis
PS2 (+12)
PS2 (+12)
PS2 (+12)
PS1 (+5, ±15)
PS1 (+5, ±15)
PS1 (+5, ±15)
Relay Board
Relay Board
Relay Board

PS0000038
PS0000038
PS0000038
PS0000037
PS0000037
PS0000037
045230100
045230100
045230100

SK2
SK2
SK2
SK2
SK2
SK2
J1
J1
J1

1
3
2
1
3
2
1
3
2

1
2
3
4
5
6
7
8
10

Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard

058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100
058021100

J15
J15
J15
J15
J15
J15
J15
J15
J15

1
2
3
4
5
6
7
8
9

3
5
2
6

Relay Board
Relay Board
Relay Board
Relay Board

045230100
045230100
045230100
045230100

P3
P3
P3
P3

1
2
4
5

7
2
5
6
10

Motherboard
Motherboard
Motherboard
Motherboard
Motherboard

058021100
058021100
058021100
058021100
058021100

J106
J106
J106
J106
J106

1
8
2
6
5

1
2
4
5
6
7
8

Power Supply Triple
Power Supply Triple
Power Supply Triple
Power Supply Triple
Power Supply Triple
Power Supply Single
Power Supply Single

PS0000037
PS0000037
PS0000037
PS0000037
PS0000037
PS0000038
PS0000038

J1
J1
J1
J1
J1
J1
J1

3
1
6
4
5
3
1

2
14
13
12
11
10
8
6
9
7
5
9
7
5

Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop
Xmitter bd w/Multidrop

069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000

J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4
J4

2
14
13
12
11
10
8
6
9
7
5
9
7
5

9
10
12
3
1
2
1
1
1
2
3
4
5

O2 sensor therm./htr
O2 sensor therm./htr
O2 sensor therm./htr
Motherboard
Motherboard
Motherboard
Motherboard
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater
CO2 Cell Heater

043420000
043420000
043420000
058021100
058021100
058021100
058021100
040400000
040400000
040400000
040400000
040400000
040400000

P1
P1
P1
P27
P27
P27
P27
P1
P2
P3
P4
P5
P6

4
2

L
N

4
11
6
13
4
6
3
1
2
5

D-3

T80X Interconnect List
(Reference: 073800100A DCN6418)
FROM
Cable PN Signal
Assembly
PN
066470000 CBL, CO2 & O2 SENSORS DC PWR
O2 SIGNAL Motherboard
058021100
O2 SIGNAL +
Motherboard
058021100
Shield
Motherboard
058021100
DGND
O2 Sensor
OP0000030
+5V
O2 Sensor
OP0000030
+12V RET
CO2 Sensor
OP0000033
+12V
CO2 Sensor
OP0000033
066830000 CBL, FLOW MODULE
DGND
LCD Interface PCA
066970000
+5V
LCD Interface PCA
066970000
DGND
LCD Interface PCA
066970000
+5V
LCD Interface PCA
066970000
+12V RET
Relay Board
045230100
+12V
Relay Board
045230100
P/Flow Sensor AGND
Relay Board
045230100
P/Flow Sensor +15V
Relay Board
045230100
Pressure signal 1
P/Flow Sensor board 040030100
Pressure signal 2
P/Flow Sensor board 040030100
Flow signal 1
P/Flow Sensor board 040030100
Shield
P/Flow Sensor board 040030100
CO2+
CO2 Sensor
OP0000033
CO2CO2 Sensor
OP0000033
06737
CBL, I2C to AUX I/O (ANALOG IN OPTION)
ATXMotherboard
058021100
ATX+
Motherboard
058021100
LED0
Motherboard
058021100
ARX+
Motherboard
058021100
ARXMotherboard
058021100
LED0+
Motherboard
058021100
LED1+
Motherboard
058021100
06738
CBL, CPU COM to AUX I/O (MULTIDROP OPTION)
RXD
CPU PCA
067240000
DCD
CPU PCA
067240000
DTR
CPU PCA
067240000
TXD
CPU PCA
067240000
DSR
CPU PCA
067240000
GND
CPU PCA
067240000
CTS
CPU PCA
067240000
RTS
CPU PCA
067240000
RI
CPU PCA
067240000
06738
CBL, CPU COM to AUX I/O (USB OPTION)
RXD
CPU PCA
067240000
DCD
CPU PCA
067240000
DTR
CPU PCA
067240000
TXD
CPU PCA
067240000
DSR
CPU PCA
067240000
GND
CPU PCA
067240000
CTS
CPU PCA
067240000
RTS
CPU PCA
067240000
RI
CPU PCA
067240000
06739
CBL, CPU ETHERNET TO AUX I/O
ATXCPU PCA
067240000
ATX+
CPU PCA
067240000
LED0
CPU PCA
067240000
ARX+
CPU PCA
067240000
ARXCPU PCA
067240000
LED0+
CPU PCA
067240000
LED1
CPU PCA
067240000
LED1+
CPU PCA
067240000
06741
CBL, CPU USB TO FRONT PANEL
GND
CPU PCA
067240000
LUSBD3+
CPU PCA
067240000
LUSBD3CPU PCA
067240000
VCC
CPU PCA
067240000
07482
CBL, HDMI, T-SERIES
LCD Interface PCA
066970000

D-4

TO
J/P

Pin Assembly

J/P

P109
7 O2 Sensor
P109
1 O2 Sensor
P109
9
P1
5 Relay Board
P1
6 Relay Board
P1 GND Relay Board
P1
L Relay Board

OP0000030
OP0000030

P1
P1

9
10

045230100
045230100
045230100
045230100

P5
P5
P5
P5

1
2
7
8

P14
P14
P14
P14
P11
P11
P11
P11
P1
P1
P1
P1
P1
P1

8
1
2
3
7
8
3
4
2
4
5
S
V
O

Relay Board
Relay Board
Relay Board
Relay Board
Chassis fan
Chassis fan
P/Flow Sensor board
P/Flow Sensor board
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard
Motherboard

045230100
045230100
045230100
045230100
040010000
040010000
040030100
040030100
058021100
058021100
058021100
058021100
058021100
058021100

P10
P10
P11
P11
P1
P1
P1
P1
P110
P110
P110
P110
P110
P110

1
2
1
2
1
2
3
6
6
5
4
12
3
9

J106
J106
J106
J106
J106
J106
J106

1
2
3
4
5
6
8

Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA

067300000
067300000
067300000
067300000
067300000
067300000
067300000

J2
J2
J2
J2
J2
J2
J2

1
2
3
4
5
6
8

COM1 1
COM1 2
COM1 3
COM1 4
COM1 5
COM1 6
COM1 7
COM1 8
COM1 10

069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000
069500000

J3
J3
J3
J3
J3
J3
J3
J3
J3

1
2
3
4
5
6
7
8
10

COM1 1
COM1 2
COM1 3
COM1 4
COM1 5
COM1 6
COM1 7
COM1 8
COM1 10

Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA

0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02
0673000 or -02

J3
J3
J3
J3
J3
J3
J3
J3
J3

1
2
3
4
5
6
7
8
10
1
2
3
4
5
6
7
8

LAN
LAN
LAN
LAN
LAN
LAN
LAN
LAN

1
2
3
4
5
6
7
8

Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA
Aux I/O PCA

06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX
06730XXXX

J2
J2
J2
J2
J2
J2
J2
J2

USB
USB
USB
USB

8
6
4
2

LCD Interface PCA
LCD Interface PCA
LCD Interface PCA
LCD Interface PCA

066970000
066970000
066970000
066970000

J9
J9
J9
J9

Transmitter PCA

068810000

J15

07276B DCN6418

Analog
Out J1020

Status
Out J1017

Control
In J1004

RS-232
J1013

06739
CN5 CN4

CPU 06724
Xmitter
06881

04671
MD OPT
J12

06746
J110

J15

J109

04023

OP33
J1 801-Standard
802-Option
803-Standard

06737

Fan

03829

O2 Sensor
OP30

Press/Flow
PCA J1
0400301

CO2 Sensor
Therm
04342

J107

CO2 Sensor

ANALOG IN OPT
06760

AC POWER
ENTRANCE

06375

06738
MD OPT
J106

'
J27

J3
W/MD
06950

AUX I/O 06730

RS-485
J1010 & 1011

Motherboard
058021100

CN3

DOM
CP34

06738
USB OPT

J1 801-N/A

036490100

CO2 Sensor
Heater
04040

AC POWER
SWITCH

O2 Sensor

P1 Therm/Htr

802-Standard
803-Standard

04342
JP6

06647

Htr Config Plug
04030XXXX

PS1 (+5, 15)
PS37
SK2

J18

SK1

04001
04176

RELAY BOARD
0452301

SK1

TC Prog Plug
04976XXXX

07482
04105

J15
J9

06741

JP7

Pump Config Plug
04289XXXX

J20

J14

Cntrl Mod
07215

LCD Interface J2
06697

J10

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.

07276B DCN6418

J11
JP5

J10

06683

PS2 (+12)
PS38
SK2

Int Pump
0424105

LCD w/Touchscreen
06790

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Data Image
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FG0700A0DSWBG01
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1-2, 4-5, 7-8, 10-11, 13-14, 16-17
3-2, 6-5, 9-8, 12-11, 15-14, 18-17
2-3, 4/ 5/ 6 NC, 7/ 8/ 9 NC, 10-11, 13-14, 16/ 17/ 18 NC

JP3
1-2, 4-5, 7-8, 10-11
2-3, 5-6, 8-9, 11-12
2-3, 5-6, 8-9, 11-12

D
Title

GUI Interface
Size
B
Date:
File:

07276B DCN6418

Number

Revision
06698

6/24/2010
N:\PCBMGR\..\06696.P1.R3.schdoc

D
Sheet 1 of 4
Drawn By: RT
6

D-15

A
TP5
AVdd: +10.4V
R8

3.3V

R13
9.76

D3
BAT54S

R14
2.0

C16

0.33
21

CAT4139TD-GT3

FDV305N
1

D
S

C18
0.33

R16
464K

R18
80.6K

5V-GND

3.3V

8
13
22

BACKL

C35
0.1
R25
10K

R26
10K

14
15

SCL
SDA

AO
A1
A2
SCL
SDA

P0
P1
P2
P3
P4
P5
P6
P7
INT

4
5
6
7
9
10
11
12
13

FBP
VGH

PGND

VCOM
CTRL

C19
0.33

R17
806K

HTSNK

Vgh: +16V

3.3V

R31
A
B

C22
24pf

C23

C24

C25

C26

43pf

0.1

TP10
Vcom: +4V

C27
1.0
GMK107BJ105KA

Default:R31B

R22 jumper

Backlight Brightness Control
R22
R27
Control Mode
Remote – Video Port
NO
A
Remote – I2C
YES
B
Fixed Bright (default)
NO
B

S1
S2
SW_46

Vcom

3.3V

Default: NI

Maint_SW
Lang_Select

R19
66.5K

TP9

SW_46
Opt. Main Sw

Opt. Lang. Sw.

R31
NO
NO
B

PCF8574

+5V

CPI

PGND

R23
33K

10K

Vss

1
2
3

TPS65150PWP

Vgh

R27
jumper
Default:R27B

5V-GND
U3

C12
TMK325BJ226MM
22uf/25V

D4
BAT54S

C17
0.33

DRVP

GND

C21
470pf

R24
10K

Vdd

COMP

R11
806K

R15
100K

FBN

ADJ

C20
0.220

+5V

C13
24pf

SUP
FB

REF

GMK107BJ105KA
C15
1.0

DRVN

FDLY

Vgl

Bklght-

R12

5V-GND

DLY2

K A

MBRM120LT1G

SHDN

DLY1

GND

Vin

3.9uH

Vgl: -7V

TP7

C14
1.0
GMK107BJ105KA

VIN

TP8

R10
10K

C11
22uF/6.3V
JMK316BJ226KL

AVdd

Bklght+

22uH
C10
4.7uF/16V

487K

CD214A-B140LF
D1

L1
C9
4.7uF/16V

C8 0.001

+5V

309K

TP6

5V-GND
5V-GND

D
Title

GUI Interface
Size
B
Date:
File:
1

D-16

Number

Revision
06698

6/24/2010
N:\PCBMGR\..\06696.P2.R3.schdoc

D
Sheet 2 of 4
Drawn By: RT
6

07276B DCN6418

+5V

VBUS
DD+
ID
GND

USB-B-MINI
6

CHASSIS

SHTDN

A
JP4

C28
1uF

C29
470pf

C30
1uF

5V-GND

3.3V

U4
D_N
D_P

USB3.3V

3.3V-REG
OUT

1
2
3
4
5

GND

FB13
C38
USB3.3V

4
3

J11

SDA
R32

5V-GND

SDA
5V-GND
1
2
3
4

0.1uF
R39
100K

5V-GND

R33
100K

4
3
2
1

8
7
6
5

C39

28
29
30
31
32
33
34
35
36

VBUS
USB3.3V
FBMH3216HM501NT

CHASSIS

R36
12K

GND

SUS/R0
+3.3V
USBUSB+
XTL2
CLK-IN
1.8VPLL
RBIAS
+3.3PLL

C34
0.1

+5V

FB8

PWR3
OCS2
PWR2
3.3VCR
U8
+1.8V
USB2514-AEZG
OCS1
PWR1
TEST
+3.3V

18
17
16
15
14
13
12
11
10

CHASSIS

C32
1uF

5V-GND

C41

FB9

0.1

1
2
3
4

USB3.3V

C33
0.1uF

5V-GND

C43
0.1uF

DS2
GRN

5V-GND

F2
+5V

5V-GND

0.1uF

5V-GND
1
2
3
4

FB11

8
7
6
5

+5V
FB12 0.5A/6V

5V-GND

0.1uF

C45

5V-GND

D
Title

GUI Interface
Size
B
Date:
File:

07276B DCN6418

USB-A_VERT
J6

Configuration Select
Mode
R32
R45
Default
A
A
MBUS
B
B
Install 100K for A, 0 Ohm for B

5V-GND

4
GND
3
D+
2
D1
+5V

U11

C36
0.1uF

5V-GND

C42

CHASSIS

5V-GND

USB-A_VERT
J5

FB10 0.5A/6V

USB3.3V
5V-GND

4
GND
3
D+
2
D1
+5V

5V-GND

C44
1uF

R37
100K

8
7
6
5
U9

C60
0.1uF

D4_P
D4_N
D3_P
D3_N
D2_P
D2_N

C40

5V-GND

D1_N
D1_P

R38

0.5A/6V
0.1uF

5V-GND

1
2
3
4
5
6
7
8
9

5V-GND

B
USB-A_R/A
J4

5V-GND
37

0.1
C59

FB5

CHASSIS

+5V

0.1

GND
D+
D+5V
F1

27
26
25
24
23
22
21
20
19

R20
49.9

FB7

R45

5V-GND

SCL

C31

BUS +5

SCL

USB3.3V

2
1

5
4
3
2
1

VBUS-DET
RESET
HS-IND/S1
SCL/S0
+3.3V
SDA/R1
OCS4
PWR4
OCS3

CHS

-V

5V-GND

R30
100K

5V-GND

70553-004

+5V

OUT

D1D1+
D2D2+
+3.3V
D3D3+
D4D4+

CHS

R35
100K

6
7
8
9
10

GND
LL
GND
RL
D+ SHLD
DRT
+5
LT

TSHARC-12C
A1

+V
E
24MHZ

DS1

GND

R29

To old TScreen
J12

1
2
3
4
5

0.01uF

70553-004

YEL

C37

To new TScreen

LL
RL
SD
RT
LT

1uF

5V-GND

1
2
3
4
5

JP5

R34
100K

J10
RT
RL
SD
LL
LT

Number

Revision
06698

6/24/2010
N:\PCBMGR\..\06696.P3.R3.schdoc

D
Sheet 3 of 4
Drawn By: RT
6

D-17

A
3.3V

TOUCH SCREEN INTERFACE CIRCUITRY ( TBD)
FB15
FBMH3216HM501NT

C61
0.1

J13
J15

CHASSIS

7
2
9
4
5
6
3
8
1
12
11
10
13
14
15
16
17
18
19
G3168-05000202-00

Y0_P1

0 R49

Y0_N1
Y1_P1

0 R50

0 R51

Y1_N1 0 R52
Y2_N1
0 R54
Y2_P1
CLKOUT_N1
CLKOUT_P1

2
U6

Y0_P
Y0_N
Y1_P
Y1_N
Y2_N
Y2_P

6
7
8

0 R53
9

0 R55

9
8
11
10
14
15

11
12

0 R56

bDCLK

13
14

CLKOUT_N
CLKOUT_P

R40
3.3V
10K

FB18
3.3V

R41
100

R42
100

R43
100

28
36
42
48

R44
100

12
20

FBMH3216HM501NT

7
13
18

C62
FB6

19
21

0.1
FB14
Vcc PIN 28
C46
22uF/6.3V
JMK316BJ226KL

23
16
17
22

HEADER-7X2

Option

MH1
MH2
MH3
MH4

Vcc PIN 36

Vcc PIN 42

Vcc PIN 48

Y0P
Y0M
Y1P
Y1M
Y2M
Y2P

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20

CLKOUT
CLKINM
CLKINP
SHTDN
NC
VCC
VCC
VCC
VCC
LVDS/VCC
PLLVCC
LVDSGND
LVDSGND
LVDSGND
PLLGND
PLLGND

GND
GND
GND
GND
GND

24
26
27
29
30
31
33
34
35
37
39
40
41
43
45
46
47
1
2
4
5

aR2
aR3
aR4
aR5
aR6
aR7
aG2
aG3
aG4
aG5
aG6
aG7
aB2
aB3
aB4
aB5
aB6
aB7

BACKL
aData Enable

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.

3
25
32
38
44

SN75LVDS86A

C49

C47

C50

C48

C51

C53

C52

C54

0.1

0.01

0.1

0.01

0.1

0.01

0.1

0.01

C
C55

C56

C57

C58

0.1

0.01

0.1

0.01

D
Title

GUI Interface
Size
B
Date:
File:
1

D-18

Number

Revision
06698

6/24/2010
N:\PCBMGR\..\06696.P4.R3.schdoc

D
Sheet 4 of 4
Drawn By: RT
6

07276B DCN6418

MT1

MT2

From ICOP CPU

CHASSIS-0 CHASSIS

+3.3V

VAD6
VAD8
VAD10
B

VBD2
VBD4
VBD6
VBD10

VAD6
VAD7
VAD8
VAD9
VAD10
VAD11
VBD10
VBD11
VAD0
VAD1
VAD2
VAD3
VBD2
VBD3
VBD4
VBD5
VBD6
VBD7

44
45
47
48
1
3
4
6
7
9
10
12
13
15
16
18
19
20
22
BACKL 23
VBDE 25

Header 22X2
1
3
5
7
9
11
13
15
17
19
21
23
25
27
29
31
33
35
37
39
41
43

VAD0
VAD2

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44

To LCD Display

VAD1
VAD3
VAD7
VAD9
VAD11

VBD3
VBD5
VBD7
VBD11
22.1

VBGCLK
VBDE

5
11
17
24
46

R1
10K

D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D11
D12
D13
D14
D15
D16
D17
D18
D19
D20
GND
GND
GND
GND
GND

Y0M
Y0P
Y1M
Y1P
Y2M
Y2P
CLKIN
CLKOUTM
CLKOUTP
SHTDN
NC
NC
VCC
VCC
VCC
LVDSVCC
PLLVCC
VLDSGND
VLDSGND
VLDSGND
PLLGND
PLLGND

41
40
39
38
35
34

Y0_N
Y0_P
Y1_N
Y1_P
Y2_N
Y2_P

J1
Y2_P
Y2_N
Y1_P

CLKIN
26
33 CLKOUT_N
32 CLKOUT_P
27

Y1_N
Y0_P
+3.3V

Y0_N
CLKOUT_P

14
43

CLKOUT_N

2
8
21
37
29
42
36
31

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

30
28

MH1
MH2
MH3
MH4

CHASSIS

+3.3V

G3168-05000101-00

SN75LVDS84A
C

+3.3V

BACKL
J3
Y0_P
Y1_P
Y2_N
CLKOUT_N
+3.3V

1
2
3
4
5
6
7
8
9 10
11 12
13 14

Y0_N
Y1_N
Y2_P
CLKOUT_P

Header 7X2

C1
22uF/6.3V
JMK316BJ226KL

C10

C11

0.1

0.01

0.1

0.01

0.1

0.01

0.1

0.01

0.1

0.01

Title
Size
A
Date:
File:

1
07276B DCN6418

LVDS, Transmitter Board

Number

Revision
B

06882
5/7/2010
N:\PCBMGR\..\06882-P1-R0.SchDoc

Sheet 1 of 1
Drawn By: RT
4
D-19

R19

.01/2KV

A
75

R20

C18

1
CHASSIS

R13
0

J1
12

SP3050

11
1
2
3
4
5
6
7
8
9

16
15
14
13
10

ATX+
ATXARX+
LED0LED0+
ARXLED1+
LED1-

2
1
4
3
6
5
8
7

STRAIGHT THROUGH ETHERNET

DF11-8DP-2DS(24)
CHASSIS

CONN_RJ45_LED

TP1

1
2
3
4
5
6
7
8

+5V

SDA

Header 8

+5V-ISO

P3
U8

1
2
3
4
5
6
7
8

SDA

SCL

4
12
11
1

R10
2.2k

Header 8

VDD1

VDD2

LME0505
GND1

GND2

5
14
13
7

+5V-OUT

TP2

L1
47uH
C

C28
4.7uF

R16
1k

C17
100uF
TP3
ISO-GND

DS3
GRN
GND
GND
Title

Size

DCN:6092

1
D-20

Auxiliary I/O Board (PWR-ETHERNET)
A

PRINTED DOCUMENTS ARE UNCONTROLLED

Date:
File:

Number

Revision
B

06731
5/6/2011
Sheet 1 of 3
N:\PCBMGR\..\06731-1_ETHERNET.SchDoc
Drawn By: RT
4

07276B DCN6418

V-BUS

C19
0.1uF
4.7uF

R11
2.2k

C24

DS4

6
9
11

12
J4
D+
D-

3
2
1
4

4
5
7
8

V-BUS

C23
0.1uF

GND

18
19
20
21
22

R12
4.75k

GRN

D+
DVBUS
GND

C22
0.1uF

3.3V

VDD
RST
SUSPEND

TXD
RTS
DTR

SUSPEND

RXD
CTS
DSR
DCD
RI
GND

D+ U10
DVREG-I
VBUS

26
24
28

TXD-A
RTS-A
DTR-A

14
13
12

25
23
27
1
2
3

RXD-A
CTS-A
DSR-A
DCD-A
RI-A

19
18
17
16
15

U11
17
16
15
14
13
10

USB

CHASSIS

3
C

28
24
1
2

CP2102

21
22

C20
0.1uF

GND
U9

C1+
C1C2+
C2-

VCC
ONLINE
VV+

TI1
TI2
TI3

TO1
TO2
TO3

RO1
RO2
RO3
RO4
RO5

RI1
RI2
RI3
RI4
RI5

STAT
SHTDN

RO2
GND

26
23
3
27

GND
J3

9 TXD-B
10 RTS-B
11 DTR-B
4
5
6
7
8

1
7
5
9
4
8
3
2
10
6

RXD-B
CTS-B
DSR-B
DCD-B
RI-B

20
25

C26
1uF

RXD
CTS
DSR
N/C
TXD
RTS
DTR
DCD
RI
GND

DF11-10DP-2DS(24)
0
R14

SP3243EU

C25
0.1uF

C21
0.1uF

GND

0
R15

NUP2202W1

GND

MT1

MT2
MT-HOLE

CHASSIS

MT-HOLE

CHASSIS
Title

Size

DCN:6092

PRINTED DOCUMENTS ARE UNCONTROLLED
1
07276B DCN6418

Auxiliary I/O Board (USB)

Date:
File:
3

Number

Revision
B

06731
5/6/2011
N:\PCBMGR\..\06731-2_USB.SchDoc

Sheet 2 of 3
Drawn By: RT
4
D-21

+5V-ISO

R9
4.99

A
+5V-ADC

AGND

C2
0.1uF

C3
0.1uF

C5
0.1uF

C6
0.1uF

C7
0.1uF
U1
AN-CH0
AN-CH1
AN-CH2

1
2
3
4
5
6
7
8
9
B

C4
0.1uF

C27
4.7uF

C1
0.1uF

AN-CH3
AN-CH4
AN-CH5
AN-CH6
AN-CH7
U2

ANALOG INPUT

C8
0.1uF

1
2
3

C9
0.1uF

4
7
8
11
22
24
14

U3
6
5
4

1
2
3

6
5
4
SMS12

SMS12

15
16
17
18
19
20
21
23

CH0
CH1
CH2
CH3
CH4
CH5
CH6
CH7

1
2
13

VDD
VDD
SHTDN

ISO-GND

9
5
10
12
6

SDA
SCL
A2
A1
A0

NC
NC
REF
NC
REF-AJ
NC
NC
NC
NC
NC
AGND DGND

ISO-GND

27
26

28
25
3

C10
4.7uF

C11
0.01uF

C30
1nF

MAX1270BCAI+
TP4

C15
.01/2KV

C29
1nF

AGND

ISO-GND
ISO-GND

AGND

49.9

R17
+5V-ISO

CHASSIS

49.9
+5V

R18

+5V-ISO

TP5

+5V-ISO

TP6

C13
0.1uF

C14
0.1uF

R5
2.2k

R6
2.2k

U5
14
15
12
13
10
11
16
9

GND
SDA

SCL

NC7WZ17P6X
6
U4A

VDD2
NC
SDA2
NC
NC
SCL2
GND2
GND2

VDD1
NC
SDA1
NC
NC
SCL1
GND1
GND1

TP8

3
2
5
4
8
6
1
7

ISO-GND

R3
1K

R4
1K

SDA
DS1

SCL
DS2

BLU

TP7

C12
0.1uF

ISO-GND
ISO-GND
3

4
U4B
NC7WZ17P6X

ADuM2250
Title

GND

Size

DCN:6092

PRINTED DOCUMENTS ARE UNCONTROLLED
1
D-22

Date:
File:
2

Auxiliary I/O Board (ADC)

ISO-GND

Number

Revision
B

06731
5/6/2011
N:\PCBMGR\..\06731-3_ADC.SchDoc

Sheet 3 of 3
Drawn By: RT
4
07276B DCN6418

Source Exif Data:

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Teledyne Tablet Accessory T803 Users Manual

T803 to the manual 7f502ed6-1d3f-42e0-86a3-1c6199c27c96

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