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Teledyne SERIES 4030 manual

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  • Page 1

    Series 4030 Teledyne Analytical Instrume nts INSTRUCTION, OPERA TING AND MAINTENANCE MANUAL FOR SERIES 4030 HEA TED THC TELEDYNE ANALYTICAL INSTRUMENTS BYPASS FLOW SPAN GAS TEMP. G AUGE SAMPLE SPAN DANGER Toxic and/or flammable gases or liquids ma y be present in this monitoring system. Personal protective equipment may be requi red when servicing [...]

  • Page 2

    Series 4030 Teledyne Analytical Instrume nts Copyright © 2004 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, 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, m[...]

  • Page 3

    Series 4030 Teledyne Analytical Instrume nts i Safety Messages Your safety and the safety of othe rs are very important. We have provided many important safety m essages in this manual. Please read these messages carefully. A safety message alerts you to pot ential hazards that could hurt you or others. Each safety message is a ssociated with a saf[...]

  • Page 4

    Series 4030 Teledyne Analytical Instrume nts ii CAUTION: THE ANALYZER SHOULD ONLY BE US ED FOR THE PURPOSE AND IN TH E MA NNER DESCRIBE D IN THIS MANUAL. IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTEND ED, UNPREDICTABLE BEHAVI OR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDO US CONSEQUENCES. This manual provides informa[...]

  • Page 5

    Series 4030 Teledyne Analytical Instrume nts iii Additional Safety Information DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage 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 ex[...]

  • Page 6

    Series 4030 Teledyne Analytical Instrument s iv system. See the procedures for purging and leak checking this instrument on the following pages. If toxic gases or other hazardous materials are introduced into the sample system, the same precautions regarding leak checking and purging apply to the sample lines and sample supply or delivery lines. WA[...]

  • Page 7

    Series 4030 Teledyne Analytical Instrume nts v Procedure for Removal of Internal Inaccessible Shock Hazards CAUTION: SERVICING OR MAINTENAN CE OF THE ANALYZER SHOULD ONLY BE DONE BY SUITABLE TR AINED PERSONNEL. TO AVOID THESE INACCESSIBLE HAZARDOUS VOLTAGES WHEN SERVICING THE SERIES 4060, PERFORM EACH OF THE F O LLOWING STEPS, IN THE ORDER GIVEN, B[...]

  • Page 8

    Series 4030 Teledyne Analytical Instrument s vi DEPENDING ON THE APPLICATION, MAY ALSO USE TOXIC GASES. IT IS THEREFORE, THE CUSTOMER'S RESPONSIBILITY TO ENSURE THAT PROPER TRAINING AND UNDE RSTANDING OF THE PRINCIPLES OF OPERATION OF THIS EQUI PMENT ARE UNDERSTOOD BY THE US ER. SINCE THE USE OF THIS INSTRUMENT IS BEYOND THE CONTROL OF TELEDYN[...]

  • Page 9

    Introduction Teledyne Analytical Instrume nts 7 Introduction Teledyne Analytical Instrument s Series 4030 Total Hydrocarbon (THC) Analyzer is designed to measure the qu antity of hydrocarbons present in a heated sample gas, such as gaseous mixtures or am bient air in various industrial applications. The Analyzer is a microprocessor controlled digit[...]

  • Page 10

    Introduction Teledyne Analytical Instrume nts 8 2. High resolution, accurate readings of concentration. 3. Versatile analysis with three user-definable analysis ranges. 4. Microprocessor based electronics : 8-bit CMOS microprocessor with 32 KB RAM and 128 KB ROM. 5. Auto ranging allows analyzer to automatically select th e proper preset range for a[...]

  • Page 11

    Introduction Teledyne Analytical Instrume nts 9 on the customer’s requirements. Th e appropriate power cord for your unit has been shipped with this instrument. 1.4 Applications . Monitoring the ambient air for To tal Hydrocarbons in chem ical and petrochemical plants. . Fugitive emission monitoring. . Process emission gases in the chem ical indu[...]

  • Page 12

    Introduction Teledyne Analytical Instrument s 10 The Series 4030 Analyzer is composed of three subsystems: 1. Sample System 2. Detector Cell 3. Electronic Signal Processing, Display and Control 2.2 Sample System The Analyzer contains two (2) separate isothermal chambers controlled by individual PID temperature controller s, viewed just behind the F[...]

  • Page 13

    Introduction Teledyne Analytical Instrument s 11 2.2.2 Gas Flow Control System The Piping diagram is in the rear of this manual. A 10 port-switching valve is used to control and direct gas flows to the FID detector. The fixed volume sample loop ensures the same volum e of sample injection in the Analyzer every cycle. 2.2.3 Fuel and Blanket Air Syst[...]

  • Page 14

    Introduction Teledyne Analytical Instrument s 12 The anode-igniter, as its name imp lies, serves two functions. When relay K2 at PCB part number B74671 is energized, the coil becomes an electrical heating element that gl ows red-hot and ignites the hydrogen fuel. When relay K2 at B74671 is de-e nergized, the coil is connected to the +260 volt DC te[...]

  • Page 15

    Introduction Teledyne Analytical Instrument s 13 Figure 2-1: Flame Ionization Cell The electrode section of the cell may be rem oved for inspection by turning off the power, disconnecti ng the electrode lead plug, and removing the screws, which retain the electrode assem bly in the sensor body. 2.3.1 Electrometer-Amplifier The collector cable is co[...]

  • Page 16

    Introduction Teledyne Analytical Instrument s 14 nominally 125 volts. Output toleranc e is ±10 volts from the specified 125 volts. 2.3.3 Flame Guard Circuit A thermistor-controlled, transistor ized switching circuit is employed to operate a relay in th e event of a flameout condition. A panel indicator light and fuel shut-off solenoid valv e are o[...]

  • Page 17

    Installation Teledyne Analytical Instrument s 15 Inst allation Installation of the Series 4030 Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. Testing the system. 3.1 Unp acking the Analyzer Although the Analyzer is shipped wi th all the materials you need to install and prepare the system for operation. [...]

  • Page 18

    Installation Teledyne Analytical Instrument s 16 Regardless of configuration, the an alyzer/system must be installed on a level surface with sufficient sp ace allocated on either sid e for personnel and test equipment access. Subject to the foregoing , the Analyzer/system should be placed as close to the sam ple point as is possible. All pertinent [...]

  • Page 19

    Installation Teledyne Analytical Instrument s 17 Figure 3-1: Gas Connections Gas connections to the instrument are made at the 1/8”or 1/4” stainless steel tube fittin gs provided on the rear panel. Note that the Purge and Sensor Vent fittings are 1/4” while all other gas connections are 1/8”. If the Sample line is heat traced to avoid conde[...]

  • Page 20

    Installation Teledyne Analytical Instrument s 18 Before tubing is connected to the system, it must be decontam inated to rid it of hydrocarbon deposits. Using a small torch, heat each length of tubing, while passing nitrogen thr ough it, until it glows red. Begin at the nitrogen source end and proceed down the length of the tube, “chasing” the [...]

  • Page 21

    Installation Teledyne Analytical Instrument s 19 THE ANALYZER WITH ITS FASTENING SCREWS. ULTIMATELY, IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI/RFI SIELDING. 3.3.3.1 P RIMARY I NPUT P OWER The power cord receptacle and fuse block are located in the sam e assembly. Insert the power cord into the power cord receptacle. [...]

  • Page 22

    Installation Teledyne Analytical Instrument s 20 Both the first and third set of outputs as well as the second and fourth set of outputs may be set to any of the following functions: - THC -- Total hydrocarbon as measured in the first phase of detection. The output is th e percentage of the selected range. - SMP -- An alternate measurement that occ[...]

  • Page 23

    Installation Teledyne Analytical Instrument s 21 3.3.3.5 A LARM R ELAYS The nine alarm-circuit connector pi ns connect to the internal alarm relay contacts. Each set of three pins provides one set of Form C relay contacts. Each relay has both normally open and normally closed contact connections. The contact connections are shown in Table 3-4. They[...]

  • Page 24

    Installation Teledyne Analytical Instrument s 22 Table 3-2: Alarm Relay Contact Pins Pin Contact 45 Threshold Alarm 1, norm ally closed contact 28 Threshold Alarm 1, m oving contact 46 Threshold Alarm 1, norm ally open contact 42 Threshold Alarm 2, norm ally closed contact 44 Threshold Alarm 2, m oving contact 43 Threshold Alarm 2, norm ally open c[...]

  • Page 25

    Installation Teledyne Analytical Instrument s 23 3.3.3.7 N ETWORK I/O A serial digital input/output for local network protocol. At this printing, this port is not ye t functional. It is to be used in future options to the instrument. Pins 13 (+) and 29 (–). 3.3.3.8 Pin Out Table The following table summarizes a ll the outputs/inputs available in [...]

  • Page 26

    Installation Teledyne Analytical Instrument s 24 30 31 32 Exhaust Solenoid Hot 33 Sample Solenoid Hot 34 Range 4 Contact/ not used 35 Range 4 Contact/not used 36 Alarm 3 NC Contact 37 Alarm 3 NO Contact 38 Range 1 Contact 39 Range 2 Contact 40 41 42 Alarm 2 NC Contact 43 Alarm 2 NO Contact 44 Alarm 2 C Contact 45 Alarm 1 NC Contact 46 Alarm 1 NO Co[...]

  • Page 27

    Installation Teledyne Analytical Instrument s 25 Implementation: The RS-232 protocol allows some flexibility in its implementation. Table 3-6 lists certai n RS-232 values that are required by the Model 4030 implementation. Table 3-6: Required RS-232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 Message Interval Sent at the[...]

  • Page 28

    Installation Teledyne Analytical Instrument s 26 CAUTION : THE GASES USED MUST BE OF THE HIGHEST QUALITY, ULTRA ZERO GRADES, AS SHOWN BELOW. FAILURE TO DO SO WILL RESULT IN CONTAMINATION AND FAILURE TO DETECT LO W CONCENTRATIONS OF HYDROCARBONS. AIR: USE ULTRA ZERO GRAD E AIR WITH THC LESS THAN 0.1 PPM. DO NOT USE OIL PUMPED AIR UNDER ANY CIRCUMSTA[...]

  • Page 29

    Operation Teledyne Analytical Instrument s 27 Operation 4.1 Placing the System in Operation 1. Plug the power in the AC power inle t in the back of the Analyzer and the Sample Selector Unit. 2. Allow at least 2 hours warm-up (heat up sensor & sam ple system) after making the air ad ju stment described below. W arm up time is set by the soft war[...]

  • Page 30

    Operation Teledyne Analytical Instrument s 28 4.2.4 Fuel 1. Open the main valve on the tank and set the fuel tank pressure regulator to 30 psig. 3. Adjust the Fuel regulator until its pressure gauge reads the recommended pressure of 3.5 psig. Note: Adjust fuel settings only when the red LED (flame failure light) is off. TELEDYNE ANALYTICAL INSTRUME[...]

  • Page 31

    Operation Teledyne Analytical Instrument s 29 the temperature controller is m ainta ining the temperature se t point) and the red flame failure lamp is on. See Figure 4-1. The Series 4030 will automatically attem pt a flame ignition sequence following the warm up peri od, which has been preset at the factory. If the ignition process fails, th e ins[...]

  • Page 32

    Operation Teledyne Analytical Instrument s 30 Depending on the specifics of the applic ation, this might include all or a set of the following procedures: 1. Setting system parameters 1. Establish a security password, if desired, requ iring operato r to log in 2. Establish and start an automatic calibration cycle (not available) 3. Choose auto rang[...]

  • Page 33

    Operation Teledyne Analytical Instrument s 31 4.4.1 Default Parameters The versatility of this analyzer usually results in significant changes being made to parameters over the course of time to better suit a particular application. Occasiona lly processes ch ange requiring alteration to alarms, ranges etc. At some tim e, it may be beneficial to re[...]

  • Page 34

    Operation Teledyne Analytical Instrument s 32 particular key it will be typed as text using all caps. Example: this is the ENTER key. Screen Modes: Times Ne w Roman 12 pt. italic. Example: Analysis Mode or Setup Mode. Screen Readout: Arial Narrow, 12 pt bold. Example: AUTOCAL or Zero in 12 days. 4.4.3 Navigation and Data Entry Note: All menus time [...]

  • Page 35

    Operation Teledyne Analytical Instrument s 33 - Dynamic (real time) FID input level - Time spent in mode - Range - Activity indicator LINE 2 display mode 2 data: - Current analysis mode - Analysis TOTAL AREA from most recent pass o f current mode. - Time spent in mode - Range - Activit y Indica tor 3. When the selected option is a function on the M[...]

  • Page 36

    Operation Teledyne Analytical Instrument s 34 saving the value . The value will revert to the origin al before modification (if any). 4.4.4 Menu Structure The 4030 screen setup consists of several classes of screens and items. No item occupies m ore than 1 line. It is important to read and understand the NAVIGATION AND DATA ENTRY section to fully u[...]

  • Page 37

    Operation Teledyne Analytical Instrument s 35 11. MODIFIABLE ITEM screens have a flashing value somewhere in the line. 4.4.4.1 MAIN M ENUS The MAIN MENU consists of 13 functions you can use to customize and check the operation of the analyzer . They are listed here with brief descriptions: 1. AUTO-CAL: Used to define and/or st art an automatic cali[...]

  • Page 38

    Operation Teledyne Analytical Instrument s 36 ENTER it. The analyzer will immedi ately start that function , unless password restrictions have been assigned. (Password assignment is explained in Section 4.4.10). 4.4.4.2 E XPANDED MENUS An exhaustive list of menu messages is provided as follows. AUTOCAL ----------------------- AUTO SPAN NOT AVAILABL[...]

  • Page 39

    Operation Teledyne Analytical Instrument s 37 Password Mismatch ----------------------- Password Changed! ----------------------- LOGOUT ----------------------- Restrict Access? ENTER-YES ESCAPE-NO ----------------------- MODEL ----------------------- 4030 THC Monitor V1.0 ----------------------- SELF TEST ----------------------- Begin Self-Test? E[...]

  • Page 40

    Operation Teledyne Analytical Instrument s 38 SPAN ----------------------- THC Span ?: Yes SMP Span ?: No THC Sp: 8.00 ppm SMP Sp: 0.00 ppm Span Begin ----------------------- ----------------------- Begin Span? ENTER-YES ESCAPE-NO ----------------------- ALARMS ----------------------- AL-1 DEFEATED AL-1 HIGH AL-1 NON-FAILSAFE AL-1 NON-LATCHING AL-1[...]

  • Page 41

    Operation Teledyne Analytical Instrument s 39 ----------------------- ANALOG-OUT ADJUST ----------------------- CH1 mA Offset: 0 CH1 mA Gain: 0 CH1 Select: THC CH2 Select: WAVE ----------------------- CHANGE STREAM ----------------------- CHANGE STREAM NOT AVAILABLE ----------------------- TIMING ----------------------- THC I/P: 100%/00% THC TIME: [...]

  • Page 42

    Operation Teledyne Analytical Instrument s 40 ----------------------- STANDBY Switch to Sleep Mode ENTER-YES ESCAPE-NO notification if logged out ----------------------- Access Restricted Re-enter Password ----------------------- 4.4.5 Setting up an AUTO-CAL AUTOCAL is not available for st andard configurations of the 4040. 4.4.6 Adjusting the GAIN[...]

  • Page 43

    Operation Teledyne Analytical Instrument s 41 To setup the GAIN : 1) From the Analysis Screen, press an arrow key to enter the Setup Mode . The VFD will display the first 2 lines of f unctions available. ________________________________________________ -> GAIN ADJUST PASSWORD ________________________________________________ < ▲▼ > If t[...]

  • Page 44

    Operation Teledyne Analytical Instrument s 42 Note however, that the instrument can still be used for analysis without entering the password. To def eat security the password must be entered. Note: If you use password security, it is strongly advised to keep a copy of the password in a separ ate, safe location. If the password is lost and security [...]

  • Page 45

    Operation Teledyne Analytical Instrument s 43 < Enter > The last <Enter> enters the password. < Escape > Steps back to the previously entered letter or, if on the first letter, returns to the MAIN MENU. If the correct password has been entered the 4040 now allows access to all the SUBMENU items. The 4040 next presents the CHANGE P[...]

  • Page 46

    Operation Teledyne Analytical Instrument s 44 ________________________________________________ Reenter a new Password 'A' 'A' 'A' ________________________________________________ Note that the new password has been replaced by 'A' as placeholder characters. This is to ensure that the wrong password is not mis[...]

  • Page 47

    Operation Teledyne Analytical Instrument s 45 Pressing <Enter> will logout the curr ent user and protect the system from unauthorized changes to parameters. If user has LOGGED OUT, then only the following SUB MENU procedures may be executed: 17. PASSWORD 18. LOGOUT (which only repeats the logout) 19. MODEL Note however, that the instrument ca[...]

  • Page 48

    Operation Teledyne Analytical Instrument s 46 ________________________________________________ < Enter or Escape > Start the diagnostic test ing routine by pressing <Enter> or cancel out by pressing <Escape>. If you pressed <Enter> the se lf-test routine will begin and after a few moments the results will appear onscreen. Th[...]

  • Page 49

    Operation Teledyne Analytical Instrument s 47 The first line determ ines whether a span calculation will be perform ed for THC. The second line determines whether a span calculation will be preformed for SMP. The third line a llows the user to modify the span target value for THC calibration. Th e fourth line allows the user to modify the span targ[...]

  • Page 50

    Operation Teledyne Analytical Instrument s 48 AL-1 20.00 ppb AL-1 SOURCE THC AL-2 ACTIVE AL-2 LOW AL-2 FAILSAFE AL-2 LATCHING AL-2 50.00 ppb AL-2 SOURCE SMP ________________________________________________ Note: For the purpose of example, Alarm 2 has been set differently than Alarm 1. Note: An alarm in 'alarm condition' is signaling that[...]

  • Page 51

    Operation Teledyne Analytical Instrument s 49 only during the time the concentration is above the trip point. If that alarm were LATCHING, the alarm c ondition would persist (even though the concentration is no longer above the trip point), until the user released it. RELEASING A LATCHED ALARM: When alarm conditions are present, the main analysis s[...]

  • Page 52

    Operation Teledyne Analytical Instrument s 50 The value of the upper limit of th e currently selected range (A UTO or MANUAL) affects the voltage and current of the analog outputs on the rear of the analyzer as well as contact closures indicating which range is current. The Analog outpu ts on the rear of the analyzer represent the proportion of the[...]

  • Page 53

    Operation Teledyne Analytical Instrument s 51 4.4.14 Analog output Adjustment The software in this instrument provides a way to enter to manage the analog output of the analyzer FOR ANALOG CHANNEL 1 ONLY . To access the offset function: < ▲▼ > From the MAIN MENU, scroll to the ANALOG ADJUST function using the UP/DOWN keys. < Enter >[...]

  • Page 54

    Operation Teledyne Analytical Instrument s 52 'Gain: ' plus the Offset value plus a value that is proportionate to the number indicated to th e right of 'GAIN:' . If these 2 values are modified and entered and accepted, then the analog output will be affected in like manner in ANALYSIS MODE. That is, it will be scaled by the gai[...]

  • Page 55

    Appendix Teledyne Analytical Instrument s 53 Recommended Sp are Part s List Qty. P/N Description 1 B74671 PC board, Flame guard & anode power supply 1 B74677 PC board, Electrometer-amplifier 1 B30927 PC board, Temperature control 1 C75825A Micro-processor PC board 1 A46128 Coaxial cable 1 B-13207 Sensor Assy. 1 C62371A Display PCB Assy. 1 B7467[...]

  • Page 56

    Appendix Teledyne Analytical Instrument s 54 Send orders to: TELEDYNE INSTRUMENTS Analytical Instruments 16830 Chestnut Street City of Industry, CA 91749-1580 Telephone: (626) 934-1500 Fax: (626) 961-2538 Web: www.teledyne-ai.com or your local representative. Email: ask_tai@teledyne.com Drawing List D77214 Model 4030 Outline diagram D77215 Wiring d[...]