Teledyne 6400EH User manual

Teledyne Analytical Instruments

OPERATING INSTRUCTIONS FOR

Model 6400EH

UV Fluorescence SO

2

Analyzer

DANGER

Dependingon your application, toxic gases may be present in this monitoring

system.

Personal protective equipment may be required when servicing this instrument.

Hazardous voltages exist on certain components internally which may persist

for a time even after the power is turned off and disconnected.

Only authorized personnel should conduct maintenance and/or servicing.

Before conducting any maintenance or servicing, consult with authorized

supervisor/manager.

P/N M77713

Model 6400EH

Teledyne Analytical Instruments ii

stored in a retrieval system, or translated into any other language or computer language in

whole or in part, in any form or by any means, whether it be electronic, mechanical,

magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne

Instruments/ Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-

1580.

Warranty

This equipment is sold subject to the mutual agreement that it is warranted by us free from

defects of material and of construction, and that our liability shall be limited to replacing or

repairing at our factory (without charge, except for transportation), or at customer plant at

our option, any material or construction in which defects become apparent within one year

from the date of shipment, except in cases where quotations or acknowledgements provide

for a shorter period. Components manufactured by others bear the warranty of their

manufacturer. This warranty does not cover defects caused by wear, accident, misuse,

neglect or repairs other than those performed by TI/AI or an authorized service center. We

assume no liability for direct or indirect damages of any kind and the purchaser by the

acceptance of the equipment will assume all liability for any damage which may result from

its use or misuse.

We reserve the right to employ any suitable material in the manufacture of our apparatus,

and to make any alterations in the dimensions, shape or weight of any parts, in so far as

such alterations do not adversely affect our warranty.

Important Notice

This instrument provides measurement readings to its user, and serves as a tool by which

valuable data can be gathered. The information provided by the instrument may assist the user

in eliminating potential hazards caused by his process; however, it is essential that all

personnel involved in the use of the instrument or its interface, with the process being

measured, be properly trained in the process itself, as well as all instrumentation related to it.

The safety of personnel is ultimately the responsibility of those who control process

conditions. While this instrument may be able to provide early warning of imminent

danger, it has no control over process conditions, and it can be misused. In particular, any

alarm or control systems installed must be tested and understood, both as to how they

operate and as to how they can be defeated. Any safeguards required such as locks, labels,

or redundancy, must be provided by the user or specifically requested of TI/AI at the time

the order is placed.

Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser

is responsible for the training of personnel, for providing hazard warning methods and

instrumentation per the appropriate standards, and for ensuring that hazard warning devices

and instrumentation are maintained and operated properly.

Teledyne Instruments/ Analytical Instruments, the manufacturer of this instrument, cannot

accept responsibility for conditions beyond its knowledge and control. No statement

expressed or implied by this document or any information disseminated by the

manufacturer or its agents, is to be construed as a warranty of adequate safety control under

the user’s process conditions.

UV Fluorescence SO2 Analyzer

Teledyne Analytical Instruments iii

Specific Model Information

Instrument Serial Number: _______________________

Instrument Range: _______________

Calibrated for: _______________

Background Gas: _______________

Zero Gas: _______________

Span Gas: _______________

Model 6400EH

Teledyne Analytical Instruments iv

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. The

definition of these symbols is described below:

GENERAL WARNING/CAUTION: Refer to the instructions

for details on the specific danger. These cautions warn of

specific procedures which if not followed could cause bodily

Injury and/or damage the instrument.

CAUTION: HOT SURFACE WARNING: This warning is

specific to heated components within the instrument. Failure

to heed the warning could result in serious burns to skin and

underlying tissue.

WARNING: ELECTRICAL SHOCK HAZARD: Dangerous

voltages appear within this instrument. This warning is

specific to an electrical hazard existing at or nearby the

component or procedure under discussion. Failure to heed this

warning could result in injury and/or death from

electrocution.

Technician Symbol: All operations marked with this symbol

are to be performed by qualified maintenance personnel only.

CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE

PURPOSE AND IN THE MANNER DESCRIBED IN

THIS MANUAL.

IF YOU USE THE ANALYZER IN A MANNER OTHER

THAN THAT FOR WHICH IT WAS INTENDED,

UNPREDICTABLE BEHAVIOR COULD RESULT

POSSIBLY ACCOMPANIED WITH HAZARDOUS

CONSEQUENCES.

UV Fluorescence SO2 Analyzer

Teledyne Analytical Instruments v

This manual provides information designed to guide you through

the installation, calibration operation and maintenance of your new

analyzer. Please read this manual and keep it available.

Occasionally, some instruments are customized for a particular

application or features and/or options added per customer requests.

Please check the front of this manual for any additional information in

the form of an Addendum which discusses specific information,

procedures, cautions and warnings that may be peculiar to your

instrument.

Manuals do get lost. Additional manuals can be obtained from

TI/AI at the address given in the Appendix. Some of our manuals are

available in electronic form via the internet. Please visit our website at:

www.teledyne-ai.com.

Model 6400EH

Teledyne Analytical Instruments vi

Table of Contents

List of Figures .............................................................................. ix

List of Tables ................................................................................ xi

Documentation .............................................................................. 1

1.1. Using This Manual Addendum 2

Specifications, Approvals & Warranty ........................................ 5

2.1. Specifications 5

2.2. CE Mark Compliance 6

2.3. Warranty 7

Getting Started .............................................................................. 9

3.1. Unpacking and Initial Setup 9

3.1.1. Electrical Connections: 10

3.1.1.1. External Pump 10

3.2 Pneumatic Connections 11

3.2.2 Pneumatic Connections to the 6400EH 11

3.2.2.1 Pneumatic Connections to 6400EH Basic

Configuration 11

3.2.2.2 Connections with Internal Valve Options Installed 12

3.2.3 6400EH Layout 13

3.3 Initial Operation 15

3.3.1 Warning Messages 15

3.3.2 Test Functions 15

3.3.3 Interferents for SO2 Measurements 15

Frequently Asked Questions ...................................................... 17

Optional Hardware and Software ............................................... 19

5.1 Zero/Span Valves (Option 50) 19

5.2 Internal Zero/Span Gas Generator (Option 51) 20

UV Fluorescence SO2 Analyzer

Teledyne Analytical Instruments vii

5.3 Zero and Two Span Point Valve Option (OPT 52) 20

5.4 Hydrocarbon Kicker Option (OPT 65) 22

Operating Instructions ................................................................ 25

6.1 Warning Messages 25

6.2 Test Functions 25

6.2.1 Test Channel Output 26

6.2.2 Range Units 26

6.2.3 Using the 6400EH with a Hessen Protocol Network 26

6.2.4 Default iDAS Channels 28

6.2.5 Remote Operation Using the External Digital I/O 28

6.2.5.1 Status Outputs 28

6.2.5.2 Control Inputs 29

Calibration and Calibration Check Procedures ........................ 31

7.1 Manual Calibration with the Zero and Two Span Point

Valve Option (OPT 52) installed 31

7.2 Manual Calibration Check with the Zero and Two Span

Point Valve Option (OPT 52) installed 33

Instrument Maintenance ............................................................. 35

8.1 Maintenance Schedule 35

8.2 Predictive Diagnostics 35

Theory of Operation .................................................................... 37

9.1 The UV Light Path 37

9.1.1 The Reference Detector 38

9.1.2 Direct Measurement Interferences 38

9.2 Pneumatic Operation 39

9.2.1 Sample Gas Flow 39

9.2.2 Pneumatic Sensors 40

9.2.2.1 Sample Pressure Sensor 40

9.2.2.2 Vacuum Pressure Sensor 40

9.2.2.3 Sample Flow Calculation 40

9.3 Electronic Operation 41

Troubleshooting & Repair .......................................................... 43

Model 6400EH

Teledyne Analytical Instruments viii

10.1.1 Fault Diagnosis with Warning Messages 43

10.1.2 Fault Diagnosis with Test Functions 43

10.2 Subsystem Checkout 43

10.2.1 Pneumatic Sensor Assembly 43

10.3 Repair Procedures 44

10.3.1 Repairing the Sample Gas Flow Control Assembly 44

10.3.2 Sensor Module Repair & Cleaning 46

10.3.2.1 Adjusting the UV Lamp (Peaking the Lamp) 47

10.3.2.2 PMT Hardware Calibration (FACTORY CAL) 49

10.4 Technical Assistance 52

Appendix A — Version Specific Software Documentation ...... 53

Appendix A-1: 6400EH Software Menu Trees, Revision C.0 54

Appendix A-2: Setup Variables For Serial I/O, Revision C.0 62

Appendix A-3: Warnings and Test Functions, Revision C.0 69

Appendix A-4: 6400EH Signal I/O Definitions, Revision C.0 72

Appendix A-5: 6400EH iDAS Functions, Revision C.0 77

Appendix A-6: Terminal Command Designators, Revision C.0 79

Appendix B - 6400EH Spare Parts List ...................................... 81

B-1: 6400EH Spare Parts List 81

B-2: Recommended Spare Parts Stocking Levels Model

6400EH 83

B-3: 6400E/EH Expendables Kit 84

Appendix C Warranty Questionnaire ......................................... 85

Appendix D - Electronic Schematics ......................................... 89

UV Fluorescence SO2 Analyzer

Teledyne Analytical Instruments ix

List of Figures

Figure 3-1: Example of Pneumatic Connections to 6400EH

External Pump ............................................................ 12

Figure 3-2: Pneumatic Connections to 6400EH with Zero and Two

Span Point Valve Option ............................................. 12

Figure 3-3: Internal Pneumatic flow for 6400EH in Basic

Configuration .............................................................. 13

Figure 3-4: 6400EH Layout (Basic Unit – No Valve Options) ........ 14

Figure 3-5: Available Functions in the Model 6400EH ................... 16

Figure 5-1: Pneumatic Diagram of the 6400EH With Z/S Option

Installed. ..................................................................... 19

Figure 5-2: Pneumatic Diagram of the 6400EH With 2-Span Point

Option Installed ........................................................... 21

Figure 5-3: Hydrocarbon Scrubber (Kicker) – OPT 65 .................. 23

Figure 5-4: 6400EH Internal Pneumatic Diagram with

Hydrocarbon Scrubber Installed ................................. 23

Figure 9-1: UV Light Path .............................................................. 37

Figure 9-2: Pneumatic Diagram of the6400EH – Base

Configuration .............................................................. 39

Figure 9-3: 6400EH Electronic Block Diagram .............................. 41

Figure 9-4: Model 6400EH Power Distribution Block Diagram ...... 42

Figure 10-1: Flow Control Assembly ............................................. 45

Figure 10-2: Sensor Module Wiring and Pneumatic Fittings .......... 46

Figure 10-3: Shutter Assembly - Exploded View ........................... 47

Figure 10-4: Location of UV Reference Detector Potentiomete

r .... 49

Figure 10-5: Pre-Amplifier Board Layout ....................................... 50

Figure A-1: Basic Sample Display Menu ....................................... 54

Model 6400EH

Teledyne Analytical Instruments x

Figure A-2: Sample Display Menu - Z/S Valve Option installed .... 55

Figure A-3: Primary Setup Menu (Except iDAS) ........................... 56

Figure A-4: Primary Setup Menu (iDAS) ....................................... 57

Figure A-5: Secondary Setup Menu (COMM & VARS) ................. 58

Figure A-6: Secondary Setup Menu (COMM Menu with Ethernet

Card) .......................................................................... 59

Figure A-7: Secondary Setup Menu - HESSEN Submenu ............ 60

Figure A-8: Secondary Setup Menu (DIAG) .................................. 61

UV Fluorescence SO2 Analyzer

Teledyne Analytical Instruments xi

List of Tables

Table 2-1: Model 6400EH Basic Unit Specifications ....................... 5

Table 3-1: Inlet / Outlet Connector Nomenclature ......................... 11

Table 3-2: Possible Warning Messages at Start-Up ...................... 15

Table 5-1: Two-Point Span Valve Operating States ...................... 22

Table 6-1: Additional 6400EH Warning Messages ........................ 25

Table 6-2: Additional 6400EH Test Functions ............................... 25

Table 6-3: Additional 6400 EH Test Parameters Available for

Analog Output A3 ......................................................... 26

Table 6-4: 6400EH Default Hessen Status Bit Assignments ......... 27

Table 6-5: Status Output Signals ................................................... 28

Table 6-6: Control Input Signals .................................................... 30

Table 8-1: Predictive Uses for Test Functions ............................... 35

Table 10-1: Warning Messages - Indicated Failures ..................... 43

Table 10-2: Test Functions - Possible Causes for Out-Of-Range

Values ......................................................................... 43

Table 10-3: Example of HVPS Power Supply Outputs .................. 48

Table A-1: 6400EH Setup Variables, Revision C.0 ....................... 62

Table A-2: 6400EH Warning Messages, Revision C.0 .................. 69

Table A-3: 6400EH Test Functions, Revision C.0 ......................... 70

Table A-4: 6400EH Signal I/O Definitions, Revision C.0 ............... 72

Table A-5: 6400EH DAS Trigger Events, Revision C.0 ................. 77

Table A-6: 6400EH iDAS Functions, Revision C.0 ........................ 77

Table A-7: Terminal Command Designators, Revision C.0 ........... 79

Table B-1: Model 6400EH Spare Parts List ................................... 81

Table D-1: List of Included Electronic Schematics ........................ 89

Model 6400EH

Teledyne Analytical Instruments xii

DANGER

COMBUSTIBLE GAS USAGE

WARNING

This is a general purpose instrument designed for use in a

non-hazardous area. It is the customer's responsibility to

ensure safety especially when combustible gases are being

analyzed since the potential of gas leaks always exist.

The customer should ensure that the principles of operating

this equipment are well understood by the user. Misuse of

this product in any manner, tampering with its components,

or unauthorized substitution of any component may

adversely affect the safety of this instrument.

Since the use of this instrument is beyond the control of

Teledyne Analytical Instruments, referred as TAI, no

responsibility by TAI, its affiliates, and agents for damage or

injury from misuse or neglect of this equipment is implied or

assumed.

UV Fluorescence SO2 Analyzer Documentation

Teledyne Analytical Instruments 1

Documentation

Note: Throughout this manual, words printed in capital, bold letters,

such as SETUP or ENTR represent messages as they appear

on the analyzer’s front panel display

Note: The flowcharts in this manual contain typical

representations of the analyzer’s display during the

various operations being described. These representations

are not intended to be exact and may differ

slightly from the actual display of your instrument.

Thank you for purchasing the Model 6400EH UV Fluorescence

SO

2

Analyzer.

The electronic manual is in Adobe

®

Systems Inc. “Portable

Document Format”. The Adobe

®

Acrobat Reader® software, which is

necessary to view these files, can be downloaded for free from the

internet at http://www.adobe.com/.

The electronic version of the manual has many advantages:

 Keyword and phrase search feature

 Figures, tables and internet addresses are linked so that clicking on

the item will display the associated feature or open the website.

 A list of chapters and sections as well as thumbnails of each page

are displayed to the left of the text.

 Entries in the table of contents are linked to the corresponding

locations in the manual.

 Ability to print sections (or all) of the manual

Additional documentation for the Model 6400EH UV Fluorescence

SO

2

Analyzer is available from Teledyne Instruments’ website at

http://www.teledyne-ai.com/manuals/

Documentation Model 6400EH

Teledyne Analytical Instruments 2

 APICOM software manual

 Multi-drop manual

 DAS Manual

1.1. Using This Manual Addendum

This manual addendum has the same overall structure as that of the

6400E operator’s manual, to simplify referring between the two. The

manual has the following sections:

Table of Contents:

Outlines the contents of the addendum in the order the information

is presented. This is a good overview of the topics covered in the

manual. There is also a list of tables, a list of figures and a list of

appendices.

Specifications and Warranty

This section contains a list of the analyzer’s performance

specifications, a description of the conditions and configuration under

which EPA equivalency was approved and Teledyne Instrument’s

warranty statement.

Getting Started:

A concise set of instructions for setting up, installing and running

your analyzer for the first time.

FAQ:

Answers to the most frequently asked questions about operating the

analyzer.

Optional Hardware & Software:

A description of optional equipment to add functionality to your

analyzer.

Operation Instructions:

This section includes step by step instructions for operating the

analyzer and using its various features and functions.

Calibration Procedures:

UV Fluorescence SO2 Analyzer Documentation

Teledyne Analytical Instruments 3

General information and step by step instructions for calibrating

your analyzer.

Instrument Maintenance:

Description of preventative maintenance procedures that should be

regularly performed on you instrument to assure good operating

condition.

Theory of Operation:

This section describes the aspects of 6400EH operation that differ

from the 6400E manual.

Maintenance & Troubleshooting Section:

This section includes pointers and instructions for diagnosing

problems that are specific to the 6400EH. The 6400E manual has a more

complete troubleshooting section, most of which also applies to the

6400EH.

Appendices:

For easier access and better updating, some information has been

separated out of the manual and placed in a series of appendices at the

end of this addendum. These include: software menu trees, warning

messages, definitions of iDAS & serial I/O variables, spare parts list,

repair questionnaire, interconnect listing and drawings, and electronic

schematics.

Documentation Model 6400EH

Teledyne Analytical Instruments 4

UV Fluorescence SO2 Analyzer Specifications/Warranty

Teledyne Analytical Instruments 5

Specifications, Approvals & Warranty

2.1. Specifications

Table 2-1: Model 6400EH Basic Unit Specifications

Min/Max Range

(Physical Analog Output)

In 1 ppb increments from 10ppm to 5,000 ppm, dual

ranges or auto ranging

Measurement Units ppm, mg/m3 (user selectable)

Zero Noise

1

0.05 ppm rms

Span Noise

1

< 0.5% of reading (above 50 ppm)

Lower Detectable Limit

2

0.1 ppm rms

Zero Drift (24 hours) < 1 ppm

Zero Drift (7 days) < 2 ppm

Span Drift (7 Days) < 0.5% FS

Linearity 1 % of full scale

Precision 0.5% of reading1

Temperature Coefficient < 0.1% per oC

Voltage Coefficient < 0.05% per V

Lag Time

1

5 sec

Rise/Fall Time

1

95% in < 30 sec

Sample Flow Rate 700 cm

3

/min. ±10%

Temperature Range 5-40oC

Humidity Range 0 - 95% RH, non-condensing

Dimensions H x W x D 7" x 17" x 23.5" (178 mm x 432 mm x 597 mm)

Weight, Analyzer

(Basic Configuration)

45 lbs (20.5 kg) w/internal pump

Weight, Pump Pack 16 lbs (7 kg)

AC Power Rating

100 V, 50/60 Hz (3.25A); 115 V, 60 Hz (3.0 A);

220 – 240 V, 50/60 Hz (2.5 A)

Environmental

Installation category (over-voltage category) II; Pollution

degree 2

Analog Outputs Three (3) Outputs

Specifications/Warranty Model 6400EH

Teledyne Analytical Instruments 6

Analog Output Ranges

100 mV, 1 V, 5 V, 10 V, 2-20 or 4-20 mA isolated

current loop.

All Ranges with 5% Under/Over Range

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

Status Outputs 8 Status outputs from opto-isolators

Control Inputs 6 Control Inputs, 3 defined, 3 spare

Serial I/O

One (1) RS-232; One (1) RS-485 (2 connecters in

parallel)

Baud Rate : 300 – 115200: Optional Ethernet Interface

Certifications

EN61326 (1997 w/A1: 98) Class A,

FCC Part 15 Subpart B Section 15.107 Class A,

ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548

(w/A1 & A2; 97) Class A.

IEC 61010-1:90 + A1:92 + A2:95,

1 As defined by the USEPA.

2 Defined as twice the zero noise level by the USEPA.

2.2. CE Mark Compliance

Emissions Compliance

The TAI UV Fluorescence SO

2

Analyzer 6400EH was tested and

found to be fully compliant with:

EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B Section

15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS

3548 (w/A1 & A2; 97) Class A.

Tested on 21 February 2003 - 08 March 2003 at CKC Laboratories,

Inc., Report Number CE03-021 A.

Safety Compliance

The TAI UV Fluorescence SO

2

Analyzer 6400EH was tested and

found to be fully compliant with:

I EC 61010-1:90 + A1:92 + A2:95,

Issued by CKC Laboratories on 4 April 2003, Report Number WO-

80146.

UV Fluorescence SO2 Analyzer Specifications/Warranty

Teledyne Analytical Instruments 7

2.3. Warranty

Warranty Policy (02024d)

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. All

maintenance and the first level of field troubleshooting is to be

performed by the customer.

NON-TAI MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by TAI is warranted and

will be repaired to the extent and according to the current terms and

conditions of the respective equipment manufacturers warranty.

GENERAL

During the warranty period, TAI warrants each Product

manufactured by TAI to be free from defects in material and

workmanship under normal use and service. Expendable parts are

excluded.

If a Product fails to conform to its specifications within the

warranty period, TAI shall correct such defect by, in TA's discretion,

repairing or replacing such defective Product or refunding the purchase

price of such Product.

The warranties set forth in this section shall be of no force or effect

with respect to any Product: (i) that has been altered or subjected to

misuse, negligence or accident, or (ii) that has been used in any manner

other than in accordance with the instruction provided by TAI, or (iii)

not properly maintained.

THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES

THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED

WARRANTIES OF MERCHANTABILITY, FITNESS FOR PARTICULAR

PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED

OR IMPLIED. THE REMEDIES SET FORTH IN THIS SECTION ARE THE

EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED

HEREIN. TAI SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR

Specifications/Warranty Model 6400EH

Teledyne Analytical Instruments 8

CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS

AGREEMENT OF TAI'S PERFORMANCE HEREUNDER, WHETHER FOR

BREACH OF WARRANTY OR OTHERWISE

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.

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Teledyne 6400EH User manual

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