INSTRUCTION MANUAL MODEL 6400A SULFUR DIOXIDE ANALYZER SERIAL NO. _______________ TELEDYNE ANALYTICAL INSTRUMENTS 16830 CHESTNUT STREET CITY OF INDUSTRY, CA 91749-1020 TOLL-FREE: FAX: TEL: E-MAIL: WEB SITE: Copyright 1994 888.789.8168 626.961.2538 626.934.1500 tetci_customerservice@teledyne.com www.teledyne-ai.com 02164 REV.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table of Contents 1 HOW TO USE THIS MANUAL ..................................................................1-1 1.1 SAFETY MESSAGES .................................................................................................... 1-2 2 GETTING STARTED.................................................................................2-1 2.1 INSTALLATION .............................................................................................
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6 OPTIONAL HARDWARE AND SOFTWARE............................................6-1 6.1 RACK MOUNT OPTIONS .............................................................................................. 6-1 6.2 ZERO/SPAN VALVES ................................................................................................... 6-1 6.3 INTERNAL ZERO/SPAN (IZS)........................................................................................ 6-3 6.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8 MAINTENANCE ........................................................................................8-1 8.1 MAINTENANCE SCHEDULE ........................................................................................... 8-1 8.2 REPLACING THE SAMPLE PARTICULATE FILTER ............................................................. 8-2 8.3 REPLACING THE PERMEATION TUBE (OPTION)............................................................... 8-4 8.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.4 OPTICAL SENSOR MODULE TROUBLESHOOTING .......................................................... 9-58 9.4.1 PMT ................................................................................................................. 9-58 9.4.2 UV Lamp Adjust or Replacement .................................................................... 9-58 9.4.3 UV Filter Replacement................................................................................
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G List of Figures FIGURE 2-1: REMOVAL OF SHIPPING SCREWS ....................................................................2-3 FIGURE 2-2: REAR PANEL ................................................................................................2-4 FIGURE 2-3: REAR PANEL PNEUMATIC RECOMMENDATIONS ................................................2-5 FIGURE 2-4: FRONT PANEL ............................................................................
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G List of Tables TABLE 2-1: FINAL TEST AND CALIBRATION VALUES ...........................................................2-12 TABLE 2-1: FINAL TEST AND CALIBRATION VALUES (CONTINUED) ......................................2-13 TABLE 4-1: SYSTEM MODES DISPLAY ................................................................................4-6 TABLE 4-2: FRONT PANEL STATUS LED'S .........................................................................
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G TABLE 8-1: PREVENTATIVE MAINTENANCE SCHEDULE ........................................................8-1 TABLE 9-1: TEST FUNCTIONS............................................................................................9-3 TABLE 9-1: TEST FUNCTIONS (CONTINUED) .......................................................................9-4 TABLE 9-1: TEST FUNCTIONS (CONTINUED) .......................................................................
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 1 HOW TO USE THIS MANUAL The Model 6400A has been designed with serviceability, reliability and ease of operation in mind. The 6400A's microprocessor continually checks operating parameters such as temperature, flow, and critical voltages. The instruments modular design uses captive screws to facilitate repair and ease of access. If you encounter any difficulty refer to Section 9 General Troubleshooting Hints.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 1.1 Safety Messages Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 2 GETTING STARTED 2.1 Installation CAUTION To avoid personal injury, always use two persons to lift and carry the Model 6400A. Verify that there is no apparent shipping damage. If damage has occurred please advise shipper first, then TAI. 1. Before operation it is necessary to remove the shipping hold-down screws. Remove the instrument cover, then refer to Figure 2-1 for screw location.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 2. If desired, attach the analog output connections to a strip chart recorder and/or datalogger. Refer to Figure 9-3 for jumper settings for the desired analog output voltage range. Factory default setting is 0-5VDC. 3. Connect the power cord to the correct voltage line, then turn to Section 2.3 Initial Operation. CAUTION High voltages present inside case. DO NOT LOOK AT THE UV LAMP, UV LIGHT COULD CASE EYE DAMAGE.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 2.3 Initial Operation Turn on the instrument power. 1. The display should immediately light, displaying the instrument type (6400A) and the CPU memory configuration. If you are unfamiliar with the 6400A, we recommend that you read the overview Section 4 before proceeding. A diagram of the software menu trees is in Figure 5-1 and Figure 5-2. The 6400A requires about 60 minutes for all internal components to come up to temperature. 2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G The next task is to calibrate the analyzer. There are several ways to do a calibration; they are summarized in Table 7-1. For a preliminary checkout we recommend calibration with zero air and span gas coming in through the sample port. The procedure is: Step 1 - Enter the expected SO2 span gas concentration Step Number Action Comment 1. Press CAL-CONC This key sequence causes the 6400A to prompt for the expected SO2 concentration.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Step 2 - Calibrate the instrument: Zero/Span Calibration Procedure Step Number Action Comment 1. Input Zero gas Allow Zero gas to enter the sample port on the rear of the instrument. 2. Press CAL The 6400A enters the calibrate mode from sample mode. 3. Wait 10 min Wait for reading to stabilize at the zero value. (If you wait less than 10 minutes the final zero value may drift.) 4. Press ZERO The ZERO button will be displayed. 5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Step 3 - Review the quality of the calibration: Calibration Quality Check Procedure Step Number Action Comment 1. Scroll the TEST function menu until the SO2 SLOPE is displayed. Typical SLOPE value is 1.0 +/- 0.3. If the value is not in this range, check Section 7.10 or 9. If the SLOPE value is in the acceptable range the instrument will perform optimally. 2. Scroll the TEST function menu until the SO2 OFFSET is displayed.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 2-1: Final Test and Calibration Values TEST Values Observed Value Units Nominal Range Reference Section RANGE PPB 50 - 20,000 5.3.4 STABIL PPB 0.1 - 2 5.2.1, 9.1.1, Table 9-1, 9.2.5 PRESS in-Hg 25 - 35 9.1.1, 9.3.6, Table 9-1 SAMP FL CC / MIN 650 ± 10% 9.2.2, 9.3.6, Table 9-1 PMT mV 0 - 5000 9.4.1 UV LAMP mV 2000 - 4000 typical 9.4.2 STR. LGT PPB <100 Table 9-1 DRK PMT mV -50 - +200 9.4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 2-1: Final Test and Calibration Values (Continued) Span and Cal Values Parameter Observed Value Units Nominal Range Reference Section PPB 20 - 20,000 Table 7-3 1.0 ± 0.3 7.10 SO2 Span Conc SO2 Slope SO2 Offset mV <250 7.10 Noise at Zero (rms) PPB 0.1 - 0.2 Table 9-1 Noise at Span (rms) PPB 0.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY 3.1 Specifications Ranges Noise at Zero1 Noise at Span1 Lower Detectable Limit2 Zero Drift3 Zero Drift3 Span Drift3 Lag Time Rise Time Fall Time Sample Flow Rate Linearity Precision Temperature Range Temp Coefficient Humidity Voltage Coefficient Dimensions HxWxD Weight, Analyzer Power, Analyzer Power, Analyzer4 Environmental Conditions Recorder Output5 Status Option Measurement Units 1. 2. 3. 4. 5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 3.2 EPA Equivalency Designation Teledyne Analytical Instruments, Model 6400A Sulfur Dioxide Analyzer is designated as Reference Method Number EQSA-0495-100 as defined in 40 CFR, Part 53, when operated under the following conditions: Range: Any range from 50 ppb to 1000 ppb. 1. Ambient temperature range of 5 to 40oC. 2. Line voltage range of 105-125 VAC, 60Hz. 3. With 5-micron TFE filter element installed in the internal filter assembly. 4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 3.3 Warranty WARRANTY POLICY Prior to shipment, TAI equipment is thoroughly inspected and tested. Should equipment failure occur, TAI assures its customers that prompt service and support will be available. COVERAGE After the warranty period and throughout the equipment lifetime, TAI stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G TERMS AND CONDITIONS All units or components returned to TAI 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.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 4 THE 6400A SO2 ANALYZER 4.1 Principle of Operation The operation of the TAI Model 6400A Analyzer is based upon the well proven technology from the measurement of fluorescence of SO2 due to absorption of UV energy. Sulfur Dioxide absorbs in the 190 nm - 230 nm region free of quenching by air and relatively free of other interferences.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Ultraviolet light is focused through a narrow 214 nm bandpass filter into the reaction chamber. Here it excites the SO2 molecules, which give off their characteristic decay radiation. A second filter allows only the decay radiation to fall on the PMT. The PMT transfers the light energy into the electrical signal which is directly proportional to the light energy in the sample stream being analyzed.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 4.2 Instrument Description 4.2.1 Sensor Module, Reaction Cell, Detector The sensor module (Figure 9-7) is where the fluorescence light is generated and detected. It is the most complicated and critical sub-assembly in the entire analyzer. It consists of the following assemblies and functions: 1. The reaction cell 2. Reaction cell heater/thermistor 3. PMT and HVPS (high voltage power supply) 4. PMT cooler/cold block/heatsink/fan 5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G The 6400A is a true computer based instrument. The microprocessor does most of the instrument control functions such as temperature control, valve switching. Data collection and processing are done entirely by the CPU with the final concentration values being sent to a D/A converter to produce the instrument analog output.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 4-1: System Modes Display Mode Meaning SAMPLE xx(1) Sampling normally SAMPLE xx(1) Flashing indicates adaptive filter is on ZERO CAL x(2) Doing a zero check or adjust SPAN CAL x(2) Doing a span check or adjust MP CAL Doing a multi-point calibration SETUP xxx(3) Configuring analyzer (sampling continues) DIAG xxx(4) Diagnostic test mode (1)xx= A (auto) (2)x= M (manual), A (auto), R (remote) (3)xxx= software revision (e.g.H.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Figure 4-2: Front Panel Display 4.2.5.2 Status LED's At the right of the display there are 3 status LED's. They can be in three states, OFF, ON, and Blinking. The meanings of the LED's are given in Table 4-2. Table 4-2: Front Panel Status LED's LED State Meaning Green Off On Blinking NOT monitoring, DAS Disabled or inactive Monitoring normally, taking DAS data Monitoring, DAS in HOLDOFF mode (1) Yellow Off On Blinking Auto cal.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 4.2.5.3 Power Switch The power switch has two functions. The rocker switch controls overall power to the instrument; in addition it includes a circuit breaker. If attempts to power up the 6400A result in a circuit breaker trip, the switch automatically returns to the off position, and the instrument will not power up. If this occurs, consult troubleshooting section or factory. 4.2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5 SOFTWARE FEATURES This section covers the software features of 6400A which is designed as a computer controlled instrument. All major operations are controlled from the front panel display and keyboard through friendly menu. Sample mode is explained for the basic operation of the analyzer including calibration steps.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.1.1 Sample Menu Table 5-1: 6400A Sample Menu Structure Menu Level Description Reference Section TEST TST> Test functions 5.2.1, Table 9-1 CAL Zero/Span calibration w/ gas through sample port 5.2.2.1,7.1 CALZ Zero calibration w/ zero gas from zero valve option or IZS option 5.2.2.2,7.2, Span calibration w/ span gas from span valve option or IZS option tube 5.2.2.3, 7.2, ZERO Press ZERO then ENTR will zero analyzer 5.2.2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.1.2 Set-Up Menu Table 5-2: 6400A Setup Menu Structure Setup Menu #1 Level 1 Level 2 Level 3 Level 4 CFG PREV, NEXT, LIST Description Reference Section CFG is primarily used for showing special configuration options and factory special software 5.3.1 PREV, NEXT can be used to scroll through the configuration list 5.3.1 LIST automatically scrolls the list AUTOCAL Automatic zero/span check or calibration 5.3.2, 6.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 5-3: 6400A Menu Structure - Setup Menu #2 Setup Menu #2 Level 1 Description Reference Section Range control menu 5.3.4 Range mode select - Single, Autorange, Dual 5.3.4 AUTO Automatically select output range 5.3.4 DUAL Independent output ranges for REC and DAS 5.3.4 SINGLE Single range for both REC and DAS outputs 5.3.4 Sets range if mode is Single range 5.3.4.1 LO Sets low range value if Autorange enabled 5.3.4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 5-4: 6400A Menu Structure - Setup Menu #3 Setup Menu #3 Level 1 Level 2 Level 3 Level 4 MORE Description Reference Section Next level of the SETUP menu COMM RS-232 communications control menu BAUD 300120024004800960019.2k ID VARS PREV, NEXT, JUMP, EDIT DIAG PREV, NEXT. 5-6 Set the BAUD rate to 3001200-2400-4800-9600-19.2K 5.3.8, 6.8 Sets the instrument ID(included on all RS-232 messages) 5.3.8, 6.8 Internal variables 5.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.2 Sample Mode 5.2.1 Test Functions NOTE In any of the following TEST functions, if XXXX is displayed, that indicates an off scale and therefore meaningless reading. To use the TEST functions to diagnose instrument faults, refer to Troubleshooting Section 9.1. Range This is the range of the instrument. In standard configuration there is one range for both REC and DAS outputs. Dual range allows a different range for each output.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G PMT Voltage The PMT VOLTAGE measures the PMT signal at the output of the preamp board. The waveform of the PMT voltage can be complex, and vary up to 5000 mV when a high concentration of SO2 is being measured. If the PMT reading is consistently 5000 mV, that indicates an off-scale reading. Typical readings bounce around, which is normal. UV Lamp UV Lamp reading is the measurement voltage from the reference detector preamp board.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G DC Power Supply (DCPS) The DCPS voltage is a composite of the 5 and ±15VDC voltages in the Power Supply Module. This is meant to be a quick indicator to show if the PSM is working correctly. The nominal value is 2500mV ± 200mV. Reaction Cell Temperature This is a measurement of the temperature of the reaction cell. It is controlled by the computer to 50±1oC. Temperatures outside this range will cause the 6400A output to drift.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.2.2 CAL, CALS, CALZ, Calibration Functions The calibration and zero/span checking of the 6400A analyzer is treated in detail in Section 7. Table 7-1 summarizes types of calibration. The basic function of each of these keys is described here. 5.2.2.1 CAL, CALS, CALZ The above keys control the calibration functions of the analyzer.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.2.2.5 Formula Values The slope and offset terms should be checked after each calibration. The values for these terms contain valuable information about the internal health of the analyzer. The range of acceptable values and their meanings is given in Section 7.10. To compute the SO2 concentration, the formula for a straight line is used.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.3 Set-Up Mode 5.3.1 Configuration Information (CFG) This menu item will tell if the installed software has factory special features or other non-standard features. If you call TAI service you may be asked for information from this menu. 5.3.2 Automatic Calibration (AutoCal) The AutoCal feature allows the 6400A to automatically operate the Zero/Span Valve or IZS option on a timed basis to check or adjust its calibration.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G will appear. These buttons are used to scroll through the parameters located in each record. The function of each of the default Data Channels is described below: CONC: Samples SO2 concentration at one minute intervals and stores an average every hour with a time and date stamp. Readings during calibration and calibration hold off are not included in the data. The last 800 hourly averages are stored.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G NOTE Only one of the following range choices can be active at any one time. There are 3 range choices: 1. Single Range Auto Range 2. Dual Ranges 5.3.4.1 Single Range This range option selects a single range for both output channels (REC, DAS) of the 6400A. To select Single Range press SETUP-RNGE-MODE-SING, then press ENTR.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.3.4.3 Dual Ranges Dual Ranges allows you to select different ranges for REC and DAS analog output channels. To set up Dual Ranges press SETUP-RNGE-MODE-DUAL, then press ENTR. To set the values press SETUP-RNGE-SET. The 6400A will prompt you for the range of RANGE1 (REC) and RANGE2 (DAS) outputs (refer to Figure 2-2 for corresponding analog output terminals). Key in the desired range for each output channel, then press ENTR after each value.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 3. SELECT RANGE The range selection is the same with dilution as with normal monitoring. See Section 5.3.4 for information on range selection. You should note however, the value entered should be the actual concentration of the calibration gas entering the dilution probe. The units of this number is ppm. CALIBRATION When the above selections have been made, the instrument now must be calibrated through the dilution probe.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.3.5 Password Enable There are two levels of password protection. The most restrictive level requires a password to do instrument calibration. The second level requires a password to do SETUP functions. If both password levels are turned off, no passwords are required, except in the VARS menu where a password is always required. To enable password press SETUP-PASS-ON. A list of passwords is in Table 5-5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5.3.9 Variables Menu (VARS) This menu enables you to change the settings on certain internal variables. The VARS Table 9-5 is located in the Troubleshooting Section 9.1.4. NOTE Before changing the settings on any variables, please make sure you understand the consequences of the change. The variables should only be changed by skilled maintenance people since they can potentially interfere with the performance of the analyzer.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6 OPTIONAL HARDWARE AND SOFTWARE Optional equipment offered with the 6400A includes: Rack mount with slides (P/N 00280). Rack mount without slides, ears only (P/N 01470). Fluorocarbon zero/span valves (P/N 01491). Internal zero/span - IZS (P/N 01441). 4-20mA, isolated outputs (P/N 01471). External pump DB-50 Connector for data inputs 6.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 6-1: Zero/Span Valve Operation Mode Description Reference Section 1. Front panel operation via CALS and CALZ buttons. Calibration Section 7 - Manual Zero/Span Check. 2. Automatic operation using AUTOCAL Setup and use of AUTOCAL is described in and Section 7.4. 3. Remote operation using the RS-232 interface Setup described in Table 6-2 Operation of AUTOCAL described in Section 6.8.5 and Section 7 - Calibration. 4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.3 Internal Zero/Span (IZS) The IZS option includes the Zero/Span Valves described above, a temperature-controlled permeation tube oven, and rear panel mounted zero air scrubber. The IZS system is activated by the same methods as described in Table 6-1 for the zero/span valves. The setup of the IZS is the same as that of the valves and is described in Table 6-2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 6-2: Setup Automatic Zero/Span Calibration Default Description Timer Enable ON Enable or disable automatic calibration timer. Starting Date 01-JAN-95 MM:DD:YY Starting Time 00:00 HH:MM, 0 - 23 hours and 0 - 59 minutes Delta Days 1 Delay days between each calibration (0 - 365 days) Delta Time 00:00 HH:MM, 0 - 23 hours and 0 - 59 minutes Duration 15.0 minutes 1 - 60.0 minutes Calibrate OFF on/off.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Example 2: to perform zero calibration adjust once per day retarding 15 minutes everyday starting at 11:30 pm, 12/20/98. 1) MODE: ZERO 2) TIMER ENABLE: ON 3) STARTING DATE: 12/20/98 4) STARTING TIME: 23:30 5) DELTA DAYS: 0 6) DELTA TIME: 23:45 7) DURATION: 15.0 MINUTES 8) CALIBRATE: ON Example 3: to perform zero-span calibration check once per day at 10:30 pm and zero calibration adjust once per week starting at 11:30 PM, 12/20/98. 1.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.5 Permeation Tube (used with IZS option) SO2 is normally a gas at room temperature and pressure, but can be liquefied at moderate pressures. The permeation tube consists of a small container of SO2 liquid, with a small window of PTFE which is permeable to SO2. The gas slowly permeates through the window at a rate in the nanogram/min range.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Suggested permeation tubes: SO2 Permeation tube SO2 Permeation tube SO2 Permeation tube SO2 Permeation tube uncertified 0.4ppm @ 0.7 lpm certified 0.4ppm @ 0.7 lpm certified 0.8ppm @ 0.7 lpm uncertified 0.8ppm @ 0.7 lpm TAI recommends that you purchase replacement permeation tubes from: VICI METRONICS 2991 Corvin Drive Santa Clara, CA 95051 USA Phone 408-737-0550 Fax 408-737-0346 The 6400A uses 700 cc/min of zero air over the perm tube.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.6 4-20 mA, Current Loop Output The current loop option replaces the voltage output of the instrument with an isolated 4-20 mA current output. The current outputs come out on the same terminals that were used for voltage outputs, see Figure 2-2. The REC and DAS outputs have current loop capabilities. See Troubleshooting Section 9.3.4.4 for electrical specifications and refer drawings 01471 and 01248 for the jumper settings. 6.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.8 RS-232 Interface The RS-232 communications protocol allows the instrument to be connected to a wide variety of computer based equipment. The interface provides two basic functions in the 6400A. 1. First is a comprehensive command interface for operating and diagnosing the analyzer. This interface has in fact more capabilities than the front panel keyboard. The interface can provide an audit trail of analyzer events.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 940331 is the default password. The password can be changed to any number from 0 to 999999 by the variable RS232_PASS. To change the password enter the command V RS232_PASS=xxxxxx which sets the password to the value xxxxxx. Protocol of Port communication The RS-232 interface has two protocols of communication, because if the port is attached to a computer it needs to have different characteristics than if used interactively.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 6-6: RS-232 Terminal Mode Editing Keys Key Function CR (carriage return) Execute command BS (backspace) Backspace one character to the left ESC (escape) Erase entire line Control-R (ASCII 18 decimal) Recall previous command Control-E (ASCII 5 decimal) Recall and execute previous command Commands are not case-sensitive; you should separate all command elements (i.e. keywords, data values, etc.) by spaces.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 6-9: RS-232 Interface Command Types First Character Message Type C Calibration status D Diagnostic R DAS report T Test measurement V Variable W Warning There are 6 different types of messages output by the 6400A. They are grouped below by type in Table 6-9 - Table 6-14. The meanings of the various messages are discussed elsewhere in the manual. The TEST, DIAGNOSTIC and WARNING messages are discussed in Section 9.1, 9.2, 9.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.8.3 TEST Commands and Messages Table 6-10: RS-232 Test Messages Name Message Description RANGE1 RANGE=xxxxx PPB2 Analyzer range STABILITY STABIL=xxxx.x PPB Std. Deviation of last 25 SO2 concentration values SAMPPRESS PRES=xxx.x IN-HG-A Sample pressure SAMPFLOW SAMPLE FL=xxx CC/M Sample flow rate PMTDET PMT=xxxxxx MV PMT output UVDET UV LAMP=xxxx MV Instantaneous UV lamp reading STRAYLIGHT STR LGT=xxx.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G The T command lists TEST messages. Examples of the T command are: T LIST Lists test messages currently enabled with T SET T LIST ALL Lists all test messages T RCELLTEMP Prints the temperature of the reaction cell T SO2CONC Prints SO2 concentration message T LAMPRATIO Prints Lamp Ratio 6.8.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Whenever a warning message is reported on the analyzer display, if the RS-232 interface is in the normal mode (i.e. not in quiet mode) the warning message is also sent to the RS-232 interface. These messages are helpful when trying to track down a problem with the analyzer and for determining whether or not the DAS reports are actually valid.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G An example of an actual sequence of calibration status messages is: C DDD:HH:MM IIII START MULTI-POINT CALIBRATION C DDD:HH:MM IIII FINISH MULTI-POINT CALIBRATION There are several methods of both checking the calibration and calibrating the 6400A, these are discussed in Section 7. C LIST lists the calibration commands available.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G The following is a summary of the Diagnostic commands. Table 6-14: RS-232 Diagnostic Command Summary Command Description D LIST Prints all I/O signal values. See Table 9-4 for Sig I/O definitions. D name=value Examines or sets I/O signal. For a list of signal names see Table 9-4 in Section 9. Must issue D ENTER SIG command before using this command.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G In all of the commands, brackets ([ ]) denote optional parameters. The ID parameter is the instrument ID, useful when the multi-drop protocol is being used. The NAME parameter is the data channel’s name. It must be enclosed in quotes (i.e. D PRINT “CONC”). The RECORDS parameter of the REPORT command indicates how many records from the most recent record and prior to print. If the RECORDS parameter is not specified, all of the records are printed.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Data Report Format: A data report format looks like the following: D 31:10:06 0412 CONC :AVG CONCI=6.8 PPB This report uses the traditional TAI format of a leading first character (“D” in this example), a time stamp (“31:10:06”), and the instrument ID (“0412”). The other fields in the report are the data channel name (“CONC”), the sampling mode (“AVG”), the parameter (“CONC1”), the parameter value (“6.8”), and the units (“PPB”).
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6.8.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G A list of variables and their settings can be requested over the RS-232 port by: V LIST Lists internal variables and values The output from this command is quite long and will not be shown here.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7 CALIBRATION AND ZERO/SPAN CHECKS There are several ways to check and adjust the calibration of the 6400A. These different methods are summarized in the following Table 7-1. In addition, all of the methods described in this section can be initiated and controlled via the RS-232 port, see Section 6.8 for details. NOTE If you are using the 6400A for EPA monitoring, it is recommended to follow the calibration method described in Section 7.8.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-1: Types of Zero/Span Checks and Calibrations Section Type of Cal or Check Description 7.1 Manual Z/S Check - Cal gas through sample port This calibration option expects the calibration gas coming in through the sample port. IZS and Zero/Span valves do not operate. 7.2 Manual Z/S Check or Calibration with Z/S valve Option How to operate Zero/Span Valve Option. Can be used to check or adjust calibration. 7.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.1 Manual Zero/Span Check or Calibration through the Sample Port The zero and span calibration of the instrument can be checked or adjusted using gases supplied through the normal sample port. This method is often used when the calibration gas is supplied from an external calibrator system. This mode provides a calibration mechanism if the instrument is purchased without IZS or Zero/Span Valve options.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Enter the expected SO2 span gas concentration: Table 7-3: Enter Expected Span Gas Concentrations Procedure Step Number Action Comment 1. Press CALCONC This key sequence causes the 6400A to prompt for the expected SO2 concentration. Enter the SO2 span concentration value by pressing the key under each digit until the expected value is set. This menu can also be entered from CALS. 2. Press ENTR ENTR stores the expected SO2 span value. 3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.2 Manual Zero/Span Check or Calibration with Zero/Span Valves Option The Zero/Span valve option can be operated from the front panel keyboard. In the Zero/Span valve option the zero and span gas come into the valves through ports on the rear panel of the instrument. Table 7-5: Manual Zero Calibration Procedure - Z/S Valves Step Number Action Comment 1. Press CALZ The analyzer enters the zero calibrate mode.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.3 Manual Zero/Span Check with IZS Option The Internal Zero/Span (IZS) system can be operated from the front panel keyboard. When the 6400A is in the SAMPLE mode, and the IZS option is installed, the CALS (Calibrate-Span) or CALZ (Calibrate-Zero) buttons will be visible. When the buttons are pressed, valves are switched to allow zero air or SO2 span gas to be input into the instrument.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.6 Calibrate on SO2 Permeation Tube If the 6400A is equipped with the IZS option, it is possible to span the instrument on the permeation tube(refer to Section 6.5). If this feature is enabled, the instrument internal valves are set so that SO2 gas is routed through the permeation tube. The software is programmed to use this known SO2 gas concentration to span the instrument by pressing CALS button.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-7: IZS or Z/S Valves Modes with Remote Contact Closure Ext Zero CC Ext Span CC Operation Contact Open Contact Open State when in SAMPLE mode, normal monitoring. Contact Open Contact Closed Span check or calibrate* Contact Closed Contact Open Zero check or calibrate* * Calibrate only if Dynamic Calibration is enabled (see Table 9-5). 7.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G All monitoring instrument systems are subject to some drift and variation in internal parameters and cannot be expected to maintain accurate calibration over long periods of time. Therefore, it is necessary to dynamically check the calibration relationship on a predetermined schedule. Zero and span checks must be used to document that the data remains within control limits. These checks are also used in data reduction and validation.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-8: Activity Matrix for Calibration Equipment & Supplies Frequency and method of measurement Action if requirements are not met Compatible with output signal of analyzer; min.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-9: Activity Matrix for Calibration Procedure Frequency and method of measurement Action if requirements are not met NIST traceable Assayed against an NIST-SRM semiannually, Sec. 2.0.7, (Q.A. Handbook) Working gas standard is unstable, and/or measurement method is out of control; take corrective action such as obtaining new calibration gas. Dilution gas Zero air, free of contaminants See Section 2.9.2 (Q.A.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.8.5 SO2 Calibration Procedure There are two calibration procedures for 6400A such as dynamic dilution procedure using compressed gas cylinder or using permeation tube. The procedures for multipoint calibration of the SO2 analyzer are specified in the Code of Federal Regulation.1 This section applies those general procedures to the case of the 6400A.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Zero calibration procedure. Table 7-10: EPA Zero Calibration Procedure Step Number Action Comment 1. Press CAL The 6400A enters the calibrate mode from sample mode. Allow the zero gas through the sample port. 2. Wait 10 min Wait for reading to stabilize at the zero value. 3. Press ZERO To select a zero calibration. 4. Press ENTR Pressing ENTR actually changes the equations 5. Press EXIT 6400A returns to the CAL menu. 1.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Figure 7-2: Diagram Of Calibration System Table 7-11: EPA Expected Span Gas Concentration Procedure Step Number 1. Action Comment Press CALCONC This key sequence causes the 6400A to prompt for the expected SO2 concentration. Enter the SO2 span concentration value by pressing the key under each digit until the expected value is set. 2. Press ENTR ENTR stores the expected SO2 span value. 3. Press EXIT Returns instrument to SAMPLE mode.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-12: EPA Span Calibration Procedure Step Number Action Comment 1. Press CAL The 6400A enters the calibrate mode from sample mode. 2. Wait 10 min Wait for readings to stabilize at span values. 3. Press SPAN If you change your mind after pressing SPAN, you can still press EXIT here without spanning the instrument. 4. Press ENTR Pressing ENTR actually changes the calculation equations. 5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 1. Zero calibration procedure is identical to Table 7-11. 2. Generate the SO2 concentration to approximately 80% of the URL of the range. Calculate the expected concentration as follows. P × 103 [SO2 ] = . ×10 −4 --------------------------------------- Equation 7.2 × 382 Fc + F4 [SO2] P Fc Fd = SO2 gas concentration, ppm = permeation flow rate at the specific temperature, ug·SO2 /min.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G By rearranging Equation 7.2 it is possible to calculate total air flow which is sum of Fc and Fd. Ftotal = Fc + Fd Ftotal P × 103 . × 10 −4 Equation 7.3 = × 382 [SO2 ] Total air flow rate should exceed the analyzer's sample flow rate demand by margin of 10% to 50%. 3. Enter the expected concentration [SO2] from Equation 7.2 using the procedure in Table 7-12. 4. Sample the generated concentration until the SO2 response is stabilized. 5.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.8.6 Calibration Frequency To ensure accurate measurements of the SO2 concentrations, calibrate the analyzer at the time of installation, and re-calibrate it: 1. No later than three months after the most recent calibration or performance audit which indicated analyzer calibration to be acceptable. 2. An interruption of more than a few days in analyzer operation. 3. Any repairs which might affect its calibration. 4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-13: Definition of Level 1 and Level 2 Zero and Span Checks (from Section 2.0.9 of Q.A. Handbook for Air Pollution Measurement Systems) LEVEL 1 ZERO AND SPAN CALIBRATION A Level 1 zero and span calibration is a simplified, two-point analyzer calibration used when analyzer linearity does not need to be checked or verified.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.8.8 Summary of Quality Assurance Checks The following items should be checked on a regularly scheduled basis to assure high quality data from the 6400A. See Table 7-14 for a summary of activities also the QA Handbook should be checked for specific procedures.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.8.9 ZERO and SPAN Checks A system of Level 1 and Level 2 zero span checks (see Table 7-1) is recommended. These checks must be conducted in accordance with the specific guidance given in Subsection 9.1 of Section 2.0.9 (Q.A. Handbook). It is recommended Level 1 zero and span checks conducted every two weeks. Level 2 checks should be conducted in between the Level 1 checks at a frequency desired by the user.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.8.9.2 Precision Check A periodic check is used to assess the data for precision. A one-point precision check must be carried out at least once every 2 weeks on each analyzer at an SO2 concentration between 0.08 and 0.10 ppm. The analyzer must be operated in its normal sampling mode, and the precision test gas must pass through all filters, scrubbers, conditioners, and other components used during normal ambient sampling.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 7-15: NIST-SRM's Available for Traceability of Calibration and Audit Gas Standards NIST-SRM4 Type Nominal concentration 1693 SO2 in N2 50 ppm 1694 SO2 in N2 100 ppm Permeation Tubes NIST-SRM4 Type Permeation rate, ug/min @ 25oC Concentration, ppm at flow rates of: 1 L/min / 5 L/min 1625 SO2 permeation tube 2.8 1.07 1626 SO2 permeation tube 1.4 0.535 / 0.107 1627 SO2 permeation tube 0.56 0.214 / 0.0428 / 0.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 6400A with IZS option can be used to calibrate zero/span of one Range #, but not both. Other Range # should be calibrated using external zero/span gas through sample port. Pressing CALZ (for zero) or CALS (for span) keys will lead to show #1 and #2 the same way as CAL key except CALZ is dedicated for zero air calibration while CALS is dedicated for span gas calibration.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 7.11 References 1. Environmental Protection Agency, Title 40, Code of Federal Regulations, Part 50, Appendix A, Section 10.3. 2. Quality Assurance Handbook for Air Pollution Measurement Systems - Volume II, Ambient Air Specific Methods, EPA-600/4-77-027a, 1977. Catalog of NBS Standard Reference Materials. NBS Special Publication 260, 1975-76 Edition. U.S. Department of Commerce, NBS. Washington, D.C. June 1975.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8 MAINTENANCE NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only. 8.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8.2 Replacing the Sample Particulate Filter The particulate filter should be inspected often for signs of plugging or contamination. It is also common for dirt particles to absorb SO2, thus causing those readings to be lower than the actual value. Very dirty filter can cause serious monitoring problem such as very slow and low response, unable to span, and contamination of the analyzer.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8.3 Replacing the Permeation Tube (option) The permeation tube is contained in the oven at the rear left of the instrument, refer to Figure 2-5 for its location. 1. Turn off the instrument power. 2. Remove the rubber insulation from the top of the assembly (refer to Figure 6-1). 3. Remove the oven cover by removing the three screws holding down the cover. 4. Remove the old permeation tube.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 3. Replace with charcoal. 4. Re-install felt pad and re-tighten the cap. Make sure the o-ring in the cap is in good shape and squarely seated. 5. Leak check the assembly, then re-attach scrubber to fitting and clip on the bracket. 8.5 Cleaning Orifice and Orifice Filter The sample flow across the internal pneumatic system is fixed by the critical flow control orifice and has no adjustment. 1. Turn off the instrument power. 2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8.6 Cleaning the Reaction Cell The reaction cell should be cleaned whenever troubleshooting points to it as the cause of the trouble (refer Figure 8-2). A dirty cell will cause excessive noise, unstable span or zero, high stray light, or slow response. Use the following guide: 1. Turn off the instrument power. 2. Remove the three screws at the sensor shock absorber mounts. 3. Tilt the sensor up to provide access to the reaction cell cover. 4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 8.8 Leak Check Procedure There are two methods of leak checking. First one is the vacuum method which is simplest but it does not show the location of a leak. This vacuum method described below is the general method when a Leak Checker (refer to Figure 9-10) is not readily available. The second method is using pressure and this method can be used to find the exact location of a leak by using bubble solution.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 10. Verify leak by pressurizing the pneumatic system and close the shut-off valve. If the gauge pressure drops more than 1 PSI within 5 minutes, then repeat steps 7 through 10 until the leak stops. 11. When no more leaks can be found reinstall inlet and outlet fittings of the pump, remove the cap from the sample inlet port and the plug from the zero air scrubber. 8.9 Light Leak Check Procedure 1. Scroll the TEST functions to PMT. 2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9 DIAGNOSTIC, TROUBLESHOOTING NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only. This section of the manual contains information on diagnosing and corrective action procedure for the instrument performance problems. It contains information on how to use and interpret TEST and DIAGNOSTIC data as well as WARNING messages the instrument generates.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Check the TEST functions: A. Compare the TEST functions to the factory values in Table 2-1. This will often provide important clues as to the problem. B. Check for the sign of the drift, particularly the slope and offset readings: The slopes are the software equivalent of the span pot on an analog instrument. If the slopes are not 1.0 ± 0.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1 Operation Verification - 6400A Diagnostic Techniques 9.1.1 Fault Diagnosis with TEST Variables The Table 9-1 indicates possible fault conditions that could cause the TEST functions to be outside the acceptable range. Table 9-1: Test Functions Test Function Factory Set-Up Comment RANGE 500 PPB This is the Range of the instrument. In standard configuration all 2 outputs have the same range.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment PRES Check value in Final Test Values Table 2-1 Reaction cell pressure is measured to monitor sample pressure and to compensate any sample pressure variation. Reaction cell pressure is typically 2 Hg-In lower than the ambient pressure due to the internal pressure drop.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment PMT 0 - 5000 mV This is the instantaneous output of the PMT. The PMT voltage values will be relatively constant when: Electric test - variation in the 2000 mV signal observed will be noise of the V/F board and preamp noise. See Section 9.1.3.2. Optic test - variation in the 2000 mV signal will be PMT dark current, preamp, HVPS plus item 1 above. See Section 9.1.3.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment STR LGT 0 - 100 ppb Stray light is the background light of the reaction cell expressed in ppb while sampling zero gas. High stray light could be caused by : Aging UV filter. Contaminated reaction cell. Light leak. Pneumatic leak. DRK PMT -50 - +200 mV This is the reading of the PMT signal without the UV lamp.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment SLOPE 1.0 ± 0.3 The slope can be thought as a gain term which determines the steepness of the calibration curve. The 6400A will operate normally even the slope is out of range, however it is preferred within the range for optimum operation of the analyzer. Slope out of range could be due to: Analog gain pot needs adjustment (see Section 9.1.6).
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment RCELL TEMP 50 ± 1oC The reaction cell temperature is controlled to 50oC ± 1oC by the computer. It should only read other values when the instrument is warming up. If the value is outside the acceptable range, go to the procedure for diagnosing the Reaction cell temp supply. The alarm limits are less than 45oC and greater than 55oC.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.2 Fault Diagnosis with WARNING Messages The 6400A monitors several internal values for alarm conditions. If the condition for an alarm is met, the alarm is displayed on the front panel and the warning is transmitted out the RS-232 port. Any time the instrument is powered up the SYSTEM RESET alarm will be displayed.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-2: Front Panel Warning Messages (Continued) Message Description IZS TEMP WARNING IZS temp. out of spec. The warning message is most often present during initial warm-up or poor electrical contact. PMT TEMP WARNING PMT temp. out of spec. The PMT temp has its own control circuit on the preamp (01141A) board. Warnings will occur during initial warm up period.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.3 Fault Diagnosis using DIAGNOSTIC Mode Diagnostic mode can be looked at as a tool kit of diagnostics to help troubleshoot the instrument. To enter DIAG mode press: SETUP-MORE-DIAG The diagnostic modes are summarized in Table 9-3. To access these functions, after you have pressed SETUP-MORE-DIAG, then press NEXT, PREV to select the desired mode then press ENTR to select that mode.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-3: Summary of Diagnostic Modes DIAG Mode Description SIGNAL I/O Gives access to the digital and analog inputs and outputs on the V/F board. The status or value of all of the signals can be seen. Some of the signals can be controlled from the keyboard. Table 94 gives details on each signal and information on control capabilities. NOTE - some signals can be toggled into states that indicate warnings or other faults.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.3.1 Signal I/O Diagnostic Table 9-4: Diagnostic Mode - Signal I/O No Signal Control Description 0 DSP_BROWNOUT NO Display brownout is used to keep the display from getting corrupted during low line voltage conditions. Circuitry on the Status/Temp board (01086A) senses low line voltage and sets this bit. The CPU reads this and generates the BROWNOUT_RST signal described below.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-4: Diagnostic Mode - Signal I/O (Continued) No Signal Control Description 10 BROWNOUT_RESET YES Brownout reset works in conjunction with DSP_BROWNOUT. When DSP_BROWNOUT is set the CPU sends a signal to reset the display and clear the DSP_BROWNOUT.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-4: Diagnostic Mode - Signal I/O (Continued) No Signal Control Description 34 DAC_CHAN_2 NO Output of spare (DAC2) channel in mV. 35 DAC_CHAN_3 NO Test Channel (DAC3) output. 36 UVLAMP_SIGNAL NO Current UV lamp signal voltage in mV. Same as UV LAMP in TEST menu. Bi-polar, typically 0-5000 mV range. A constant value of 5000 mV indicates offscale.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G NOTE If the SO2 concentration display is not within the nominal range of 1000 ± 100 ppb, then the lamp ratio may need to be updated. See Section 9.1.6, step 2 of PMT Calibration procedure. 9.1.3.3 Optic Test Optic test turns on a small LED inside the PMT housing which simulates the signal from the reaction cell. OT tests the entire signal detection subsystem.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.3.5 DAC Calibration The Digital to Analog Converters (DAC) are calibrated when the instrument is set up at the factory. Re-calibration is usually not necessary, but is provided here in case the V/F board needs to be replaced and re-calibrated. The procedure for using the DAC Calibration routines are in the Troubleshooting Section 9.3.3.1. 9.1.3.6 RS-232 Port Test This test is used to verify the operation of the RS-232 port.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 9-5: Model 6400A Variables Name Units Default Value Value Range 0 DAS_HOLD_OFF MIN 15.0 0.5-20.0 Hold off duration after calibration or diagnostic mode.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.5 Test Channel Analog Output Many of the TEST functions have an analog voltage associated with them. As a diagnostic aid it is possible to route any one of the various test voltages out the 4th analog output port(see Figure 2-2). Following Table 9-6 lists the test measurements which may be routed to test channel output.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.1.6 Factory Calibration Procedure (Quick Cal) This procedure is referred to in other TAI instruments as the "Quick Cal" procedure. It is used at the factory when the instrument is first set-up. The Factory Cal procedure balances the PMT, preamp, and software gain factors so the instrument has optimum noise, linearity, and dynamic range.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Recalibrate the instrument for both zero and span to calculate the slope and offset. (Refer to Section 7). Above procedure is to assure that the instrument will operate with optimum noise, linearity, and dynamic range. 9.1.6.1 Electric Test (ET) Procedure: 1. Any time the gain of the PMT buffer amplifier circuit (R19) is changed (refer component location label inside of the Preamp cover), that will change the ET reading.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2 Performance Problems When the response from a span check is outside the control limits, the cause for the drift should be determined, and corrective action should be taken. Some of the causes for drift are listed below: NOTE Before starting troubleshooting, it has been our experience that about 50% of all analyzer performance problems are sooner or later traced to leaks. 1. Fluctuations in flow. Such as leaks or plugged orifices.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.2 Flow Check 1. Check TEST function SAMP FLOW - Should be 650 ± 65cc/min. 2. Check that pump is running. Observe pump for proper operation. 3. Test that pump is producing vacuum by removing fitting at the inlet of the pump and checking for suction at fitting. 4. Check for flow at the reaction cell. A. Remove the 1/8" fitting from the reaction cell and plug the fitting on the reaction cell with your finger and note the weak vacuum produced. B.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.4 Negative Concentration Display 1. Mis-calibration. The 'zero' gas that was used to zero the 6400A contained some SO2 gas that is it had more SO2 gas than that of the sample air. May also be caused by doing a zero calibration using ambient air. 2. Broken PMT temperature control circuit, causing high zero offset. Check PMT temperature which should be 7 ± 1oC. 3. Aging UV filter causing high stray light. Check STR. LGT reading of TEST function.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.6 Unstable Span Common causes are: 1. Leak in pneumatic system. 2. Unstable UV lamp output - replace lamp. 3. Sample lines or sample filter dirty - clean or replace. 4. Plugged sample inlet orifice - clean with methanol and sonic cleaner. 5. Defective HVPS - use optic test and electric test to isolate the HVPS. See also Section 9.3.10 HVPS test procedure. 6. Bad or defective PMT detector - check Optic test. 7.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.7 Unstable Zero Common causes are: 1. Leak in pneumatic system. 2. Light leak - check the sensor module with strong light. 3. If equipped with IZS, zero air scrubber exhausted - replace charcoal and check broken DFU filter. 4. Sample lines or sample filter dirty - clean or replace. 5. Zero gas source unstable - verify quality of zero air and the flow rate. 9.2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.9 Inability to Zero If the ZERO button is not illuminated when attempting to zero, that means the reading is outside of the software gain ranges allowed. In an analog instrument it would be the equivalent to the zero pot hitting the maximum. Here are some things to check: Select the PMT - TEST function. With zero gas going into the instrument, the value should be less than 250 mV, typically 80 - 160 mV.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.2.11 Slow Response Contaminated or dirty sample delivery pneumatics A. Dirty/plugged sample filter or sample lines. B. Dirty reaction cell. C. Check leak. 1. Flow rate too low. 2. Wrong materials in contact with sample - use glass or Teflon. 3. Insufficient time allowed for purging of lines upstream of analyzer. 4. Insufficient time allowed for SO2 cal gas source to become stable or cal gas flow is too low. 9.2.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3 Electronic Subsystem Troubleshooting and Adjustments 9.3.1 Computer, Display, Keyboard The purpose of this section is to determine if the computer subsystem electronics hardware are working properly. Assessment will make it the board level. 9.3.1.1 Front Panel Display The front panel display is a 2 line by 40 character display. It has its own microprocessor to decode commands and display characters. It contains a self test feature.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Like the display, the overall functioning of the CPU can be confirmed by a simple test. 1. Locate the CPU board on the mother board by referring to Figure 2-5. 2. Power the instrument on. 3. Locate the red LED at the top left edge of the board. 4. It should be flashing at a frequency of about once per second. 5. This flashing indicates the board is powered up and is executing instructions. RS-232 diagnostic procedures are described in Section 9.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.1.3 Front Panel Keyboard The keyboard consists of 8 keys and 3 LED's. Key strokes are sent to the SBC40 computer's parallel port. The computer software detects the key strokes via interrupts. The bottom line of the display consists of 40 characters which is divided into 8 - 5 character fields. Each field defines the function of the key immediately below it. The definition of the keys is variable and depends on the menu level of the software.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Figure 9-2: RS-232 Pin Assignments 9.3.2.1 RS-232 Connection Examples Example 1 Connecting the 6400A (using supplied cable) to an IBM-PC AT compatible computer (DB-25 external connector, or DB-25 end of DB-9 to DB-25 Adapter). In this case, the PC is wired as DTE and the analyzer’s jumpers are set as DCE, therefore a null modem is not needed. The wiring is "straight through" i.e. pin 1 to pin 1, pin 2 to pin 2, etc.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Example 2 Connecting the TAI analyzer to a serial printer. In this case, it will be necessary to determine whether the printer is DCE or DTE. Some printers can be configured for either DCE or DTE by jumper or DIP switch settings. Consult the user manual for the printer. If the DB-25 connector pinout shows that data is output on pin 2 (from the printer), then it is DTE and the TAI analyzer’s jumpers should be set to DCE mode.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.2.2 RS-232 Diagnostic Procedures There are several features of the 6400A to make connecting to RS-232 and diagnosing RS-232 faults easier. There are two LED's on the rear panel Connector Board which are connected to pin 2 and 3 of the DB-9 connector on the board. If the jumper block is in the DCE position (default) the red LED is connected to pin 3 of the DB-9 connector.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 2. Analog output channel test. In the DIAGNOSTIC menu on the front panel, there is a test that outputs a step voltage to the 4 analog outputs. This test is useful for calibrating chart recorders and dataloggers attached to the 6400A. The test can also be useful in diagnosing faults in the V/F board. A. Turn on the instrument. B. Enter the SETUP-MORE-DIAG menu. C. Scroll to select the ANALOG OUTPUT test.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.3.1 ADC/DAC Calibration Procedure Due to the stability of modern electronics this procedure should not have to be performed more than once a year or whenever a major sub-assembly is exchanged or whenever analog output voltage range is changed. To calibrate the 4-20 mA current option output, proceed second part of the procedure for the calibration of 4-20 mA current output.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G EXIT to terminate. The exact voltage values depend on the DIP switch settings on the analog output buffer amplifiers. To calibrate the 4-20 mA current output option, do the following: Verify ± 5 volt output DIP switch setting (refer Figure 9-3) for 4-20 mA option before proceeding with the following procedure, since the input voltage of the isolated 4-20 mA converter hardware is configured for 0 - 5 volt range (0 - 10 volt for non-isolated).
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.3.2 Changing Output Voltage Ranges Several different output voltage ranges can be selected by DIP switch setting on the V/F board. See Figure 9-3 for the DIP switch settings. If you change the analog output voltage range, then you must reset the power of the instrument and do a ADC/DAC calibration per Section 9.3.3.1.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.4 Status/Temp Board The Status/Temp Board is a multifunction board that: 1. Converts the resistance readings of the thermistors to voltages 2. Provides status output circuitry 3. Provides circuitry for contact closure inputs 4. Provides circuitry for display brown-out/reset at low line voltage 5. Provides sockets for voltage-to-current modules 9.3.4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G These 3 outputs are controlled by a common pot (R34) on the upper edge of the card. If the temperature readouts are in error: 1. Adjust R34 of the Status/Temp board to read 2.577 VDC between test point 6 and test point 2. This will cause all of the readouts to accurately measure their respective temperatures. 9.3.4.2 Display Brownout During low AC line conditions the display can lock up due to insufficient voltage.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 1. Voltage method - preferred method. Digital type Multi-meters (DMM) are ideally suited for this type of measurement because of their high input impedance - usually 10M ohm or greater. The total load resistance should be between a 200ohm (min) to 1000 (max), precision load resistor of .1% tolerance or better is recommended. 2. Current method.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.5 Power Supply Module The Power Supply Module consists of several subassemblies described in Table 9-7 below. Table 9-7: Power Supply Module Subassemblies Module Description Linear Power Supply Board The linear power supply board takes multiple voltage inputs from the power transformer and produces +5, +15, -15, +12 VDC outputs. The outputs are routed to two external connectors, P2 and P3. See Figure 9-4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.5.1 PSM Diagnostic Procedures The Linear Power Supply board can be tested by checking the DCPS - TEST function on the front panel. It should read 2500 mV ± 200 mV. If the value is outside this range, individual output voltages can be tested on connector P3, see Schematic in the Appendix for pinouts. The Switching Power Supply output can be tested by observing the temperature of the PMT cold block using the PMT TEMP - TEST function.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.6 Flow/Pressure Sensor The flow/pressure sensor board consists of 1 pressure sensor and a flow sensor. See Figure 9-6 for a diagram of this board. From these two sensors pressure and flow rate values are computed and displayed on the front panel TEST functions. They are: 1. Sample gas pressure - measured directly S1, adjust R1. 2. Sample Flow - measured directly S3, adjust R3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.3.7 Reaction Cell Temp The reaction cell temperature is controlled by the CPU. It operates by reading a thermistor amplifier on the 01086 Status/Temp board. First LED from the front indicates the control power on-off status which can be seen from the cover of the PSM through the slot. 9.3.8 Preamp Board The Preamp Board is a multifunction board providing circuitry to support the following functions. 1.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 1. Remove three screws that hold the sensor assembly (refer to Figure 2-1 they are located adjacent to the shipping screws). 2. Remove four screws that hold the fan duct and unplug cable plugs from the fan duct assembly. 3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 5. Pull out PMT, LED, and thermistor carefully from the cooler block. Be careful not to contaminate the window of the PMT with thermal compound of thermistor. PMT is fragile, so handle carefully. 6. Replace two desiccant bags inside of the PMT housing with new bags. 7. Replace cooler assembly (P/N 01461) and assemble by reversing above steps. 9.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9. Use Figure 9-10 to check the voltages at each pin of the supply, and the overall voltage. 10. Turn off the instrument power, and re-connect the PMT tube, then re-assemble the sensor. If any faults are found in the test, you must obtain a new HVPS as there are no user serviceable parts inside the supply.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.4 Optical Sensor Module Troubleshooting 9.4.1 PMT The PMT detects the light emitted by the secondary emission of the SO2 molecules. It has very high gain and low noise to detect the weak light source optimally. It is not possible to test the detector outside of the instrument in the field. The best way to determine if the PMT is working is by using Optic test. OT operation is described in Section 9.1.3.3.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only. If the UV LAMP display is lower than 1000mV after peak adjustment, it is recommended to replace the lamp. Most UV lamps that produces UV lamp reading above 1000 mV are still in good condition. UV LAMP reading below 600 mV will cause the instrument to display XXXXX.X. 9.4.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Without leaving DIAG menu, Scroll until PMT_SIGNAL is shown. It should display near 0 ± 200 mV. If reading is greater than +200 mV, then verify if + 12VDC is supplied for the terminal located at the shutter cover (see Figure 9-7). If + 12VDC is present, then open the shutter cover and verify if shutter or solenoid is mechanically faulty. Replace as necessary. 9.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 9.5.4 Z/S Valves & IZS Permeation Tube Oven The Z/S Valves and IZS are both options in the instrument. Before troubleshooting this subassembly, check that the options were ordered, and that they are enabled in the software (if not call factory). Check for the Z/S valves: 1. Check for the physical presence of the valves. See Figure 2-5 for Z/S Valve location. Check front panel for option presence.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G 10 TAI 6400A SPARE PARTS LIST Note: Use of replacement parts other than those supplied by TAI may result in noncompliance with European Standard EN61010-1.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 10-3: TAI MODEL 6400A 37 mm Expendables Kit PART NO. DESCRIPTION 014740000A 6400A 37 MM FILTER EXPENDABLES KIT INCLUDES:` QTY 003690100A Filter, TFE, 37 mm, Qty. 25 (872-006300) 2 FL0000001A Sintered Filter (002-024900) 1 HW0000020A Spring, Flow Control 1 OR0000001A O-Ring, Flow Control 2 PU0000022A Pump Rebuild Kit, KNF Model #NO5ATI 1 Table 10-4: TAI MODEL 6400A 47 mm Expendables Kit PART NO.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G Table 10-6: TAI MODEL 6400A Spares Kit For 1 Unit PART NO.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev. G APPENDIX A MAINTENANCE SCHEDULE FOR 6400A DATE INSTRUMENT RECEIVED _____________ JAN FEB MAR APR MAY JUNE JULY AUG SEPT OCT NOV DEC PARTICULATE FILTER ELEMENT REPLACE WEEKLY AS NEEDED. CHARCOAL ZERO AIR SCRUBBER REPLACE QUARTERLY. DFU PARTICULATE FILTER FOR ZERO AIR REPLACE ANNUALLY. PNEUMATIC LINES EXAMINE AND REPLACE AS NECESSARY. LEAK CHECK AND QUICK CAL CHECK ANNUALLY. SEE SECTION IN MANUAL.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
TAI Model 6400A SO2 Analyzer Operator Manual, 02164, Rev.
