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INSTRUCTION MANUAL
MODEL 6400A
SULFUR DIOXIDE ANALYZER
SERIAL NO. _______________
TELEDYNE ANALYTICAL INSTRUMENTS
16830 CHESTNUT STREET
CITY OF INDUSTRY, CA 91749-1020
TOLL-FREE: 888.789.8168
FAX: 626.961.2538
TEL: 626.934.1500
E-MAIL: tetci_customerservice@teledyne.com
WEB SITE: www.teledyne-ai.com
02164
REV. G
Copyright 1994
12/12/98

Summary of Contents

  • Page 1

    INSTRUCTION MANUAL MODEL 6400A SULFUR DIOXIDE ANALYZER SERIAL NO. _______________ TELEDYNE ANALYTICAL INSTRUMENTS 16830 CHESTNUT STREET CITY OF INDUSTRY, CA 91749-1020 TOLL-FREE: 888.789.8168 FAX: 626.961.2538 TEL: 626.934.1500 E-MAIL: tetci_customerservice@teledyne.com WEB SITE: www.teledyne-ai.com 02164 REV. G Copyright 1994 12/12/98...

  • Page 3: Table Of Contents

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table of Contents 1 HOW TO USE THIS MANUAL ..............1-1 1.1 S ....................1-2 AFETY ESSAGES 2 GETTING STARTED.................2-1 2.1 I ......................2-1 NSTALLATION 2.2 E ..............2-1 LECTRICAL AND...

  • Page 4: Table Of Contents

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 6 OPTIONAL HARDWARE AND SOFTWARE..........6-1 6.1 R ....................6-1 OUNT PTIONS 6.2 Z ....................6-1 ALVES 6.3 I (IZS)..................6-3 NTERNAL 6.4 A ............6-3 UTOCAL ETUP OF ALVES 6.5 P )..............

  • Page 5: Table Of Contents

    9.1.1 Fault Diagnosis with TEST Variables..............9-3 9.1.2 Fault Diagnosis with WARNING Messages ............9-9 9.1.3 Fault Diagnosis using DIAGNOSTIC Mode ............. 9-11 9.1.4 6400A Internal Variables ................. 9-18 9.1.5 Test Channel Analog Output ................9-20 9.1.6 Factory Calibration Procedure (Quick Cal) ............9-21 9.2 P...

  • Page 6: Table Of Contents

    9.5.1 Leak Check...................... 9-60 9.5.2 Pump ....................... 9-60 9.5.3 Kicker....................... 9-60 9.5.4 Z/S Valves & IZS Permeation Tube Oven ............9-62 10 TAI 6400A SPARE PARTS LIST ............10-1 APPENDIX A MAINTENANCE SCHEDULE FOR 6400A ......A-1 APPENDIX B ELECTRICAL SCHEMATICS ..........B-1...

  • Page 7

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G List of Figures 2-1: R ..............2-3 IGURE EMOVAL OF HIPPING CREWS 2-2: R ....................2-4 IGURE ANEL 2-3: R ..........2-5 IGURE ANEL NEUMATIC ECOMMENDATIONS 2-4: F ....................2-10 IGURE RONT ANEL 2-5: A ..................2-11...

  • Page 8

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G List of Tables 2-1: F ............2-12 ABLE INAL EST AND ALIBRATION ALUES 2-1: F ) ........2-13 ABLE INAL EST AND ALIBRATION ALUES ONTINUED 4-1: S ................4-6 ABLE YSTEM ODES ISPLAY...

  • Page 9

    ) ..........10-3 ABLE PARE ARTS ONTINUED 10-1: TAI 6400A S ) ..........10-4 ABLE PARE ARTS ONTINUED 10-2: TAI MODEL 6400A L ............10-4 ABLE EVEL PARES 10-3: TAI MODEL 6400A 37 ..........10-5 ABLE XPENDABLES 10-4: TAI MODEL 6400A 47 ..........10-5 ABLE...

  • Page 11: How To Use This Manual

    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.

  • Page 12: S Afety M Essages

    TAI Model 6400A SO 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.

  • Page 13: Getting Started, I Nstallation, E Lectrical And P Neumatic C Onnections

    Replace the instrument cover. When installing the 6400A, allow at least 4” (10 cm) clearance at the back and at least 1” (2.5 cm) clearance at each side for proper venting.

  • Page 14

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 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.

  • Page 15

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 2-1: Removal of Shipping Screws...

  • Page 16

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 2-2: Rear Panel...

  • Page 17

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 2-3: Rear Panel Pneumatic Recommendations...

  • Page 18: I Nitial O Peration

    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. While waiting for instrument temperatures to come up, you can check for correct operation by using some of the 6400A's diagnostic and test features.

  • Page 19

    Step Number Action Comment Press CAL-CONC This key sequence causes the 6400A to prompt for the expected SO concentration. Enter the SO span concentration value by pressing the key under each digit until the expected value is set.

  • Page 20

    Pressing ENTR actually changes the calculation equations and zeroes the instrument. Press EXIT 6400A returns to the CAL menu. Now switch gas streams to span gas. Wait 10 min Wait for reading to stabilize at the span value. (If you wait less than 10 minutes the final span value may drift.)

  • Page 21

    A value between 50mV to 250mV indicates the SO OFFSET is calibration in the optimal range. If the OFFSET value is displayed. outside this range, check Section 7.10 and 9. Step 4 - The 6400A is now ready to measure sample gas.

  • Page 22

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 2-4: Front Panel 2-10...

  • Page 23

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 2-5: Assembly Layout 2-11...

  • Page 24

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 2-1: Final Test and Calibration Values Observed TEST Values Units Nominal Range Reference Section Value RANGE 50 - 20,000 5.3.4 STABIL 0.1 - 2 5.2.1, 9.1.1, Table 9-1, 9.2.5...

  • Page 25

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 2-1: Final Test and Calibration Values (Continued) Span and Cal Values Observed Parameter Units Nominal Range Reference Section Value Span Conc 20 - 20,000 Table 7-3 Slope 1.0 ± 0.3 7.10...

  • Page 26

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G INTENTIONALLY BLANK 2-14...

  • Page 27: Specifications, Agency Approvals, Warranty, S Pecifications

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY 3.1 Specifications Ranges In 1ppb increments from 50ppb to 20,000ppb, dual ranges or autoranging Noise at Zero 0.2 ppb RMS Noise at Span <0.5% of reading (above 50 ppb) Lower Detectable Limit 0.4 ppb RMS...

  • Page 28: Epa E Quivalency D Esignation

    TAI Model 6400A SO 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.

  • Page 29: W Arranty

    TAI Model 6400A SO 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.

  • Page 30

    TAI Model 6400A SO 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...

  • Page 31: P Rinciple Of O Peration

    4 THE 6400A SO 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 SO 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.

  • Page 32

    TAI Model 6400A SO 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 SO molecules, which give off their characteristic decay radiation. A second filter allows only the decay radiation to fall on the PMT.

  • Page 33

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 4-1: 6400A Sulfur Dioxide Analyzer...

  • Page 34: I Nstrument D Escription, Sensor Module, Reaction Cell, Detector, Pneumatic Sensor Board

    This sample pressure is displayed in the test menu. A solid state flow sensor measures the sample flow. Likewise, it is displayed as a TEST function. The 6400A displays pressure in inches of mercury-absolute (in-Hg- A) and flow in cc/min.

  • Page 35: V/f Board, Front Panel

    V/F board. 4.2.5 Front Panel The front panel of the 6400A is shown in Figure 2-4. The front panel consists of a 2 line display and keyboard, 3 status LED's and power switch. Communication with the display, keyboard, and status LED's is done via the computer's on-board parallel port.

  • Page 36

    The center field displays TEST values. The TEST functions allow you to quickly access many important internal operating parameters of the 6400A. This provides a quick check on the internal health of the instrument. The right hand field shows current concentration value of SO 4.2.5.1 Front Panel Display...

  • Page 37

    TAI Model 6400A SO 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.

  • Page 38: Power Supply Module, Pneumatic System

    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.

  • Page 39: Software Features, Index To Front Panel Menu

    The next several pages contain two different styles of indexes that will allow you to navigate the 6400A software menus. The first two pages show a "tree" menu structure to let you see at a glance where each software feature is located in the menu. The second menu contains a brief description of each key mnemonic and a reference to the section of the manual that describes its purpose and function in detail.

  • Page 40

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 5-2: Setup Menu Tree...

  • Page 41: Sample Menu

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 5.1.1 Sample Menu Table 5-1: 6400A Sample Menu Structure Menu Level Reference Level 1 Level 2 Level 3 Level 4 Description Section TEST Test functions 5.2.1, Table 9-1 TST> Zero/Span calibration w/ 5.2.2.1,7.1...

  • Page 42: Set-up Menu

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 5.1.2 Set-Up Menu Table 5-2: 6400A Setup Menu Structure Setup Menu #1 Reference Level 1 Level 2 Level 3 Level 4 Description Section CFG is primarily used for 5.3.1 showing special...

  • Page 43

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 5-3: 6400A Menu Structure - Setup Menu #2 Setup Menu #2 Reference Level 1 Level 2 Level 3 Level 4 Description Section RNGE Range control menu 5.3.4 MODE Range mode select - Single, 5.3.4...

  • Page 44

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 5-4: 6400A Menu Structure - Setup Menu #3 Setup Menu #3 Reference Level 1 Level 2 Level 3 Level 4 Description Section MORE Next level of the SETUP menu...

  • Page 45: Test Functions

    RANGE1 (REC) and RANGE2 (DAS). Auto range option allows a low range and high range. The 6400A will automatically switch to the other range dynamically as concentration values require. The TEST values will show the range the instrument is currently operating in, and will dynamically display the alternate range as the range changes occur.

  • Page 46

    –50 + 200 mV. Slope The coefficient of straight line equation (y=mx + b) determines the calibration of the 6400A. The slope parameter (m) can be thought of as a gain term which determines the steepness of the calibration curve.

  • Page 47

    C. Temperatures outside this range will cause the 6400A output to drift. Box Temperature This TEST function measures the temperature inside the chassis of the 6400A. The temperature sensor is located on the Status/Temp Board. Typically it runs 2 to 10 C higher than the ambient temperature.

  • Page 48: Cal, Cals, Calz, Calibration Functions

    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.

  • Page 49

    After every zero or span calibration check the QUALITY of the calibration. The calibration of the 6400A involves balancing several sections of electronics and software to achieve an optimum balance of accuracy, noise, linearity and dynamic range. See Section 7.10 for the calibration quality check procedure.

  • Page 50: Configuration Information (cfg), Automatic Calibration (autocal), Data Acquisition System (das)

    The Data Channels can be programmed and customized from the front panel. A set of default Data Channels has been included in the Model 6400A software. These are described Section 5.3.3.1. For more information on programming custom Data Channels, a supplementary document containing this information can be requested from TAI.

  • Page 51: Range Menu

    20,000 ppb the front panel will read from 0 to 20,000 ppb. The apparently wider range of front panel readouts is because the 6400A has 2 internal hardware gain settings, namely 0-2000ppb (gain of 10) and 0-20,000ppb (gain of 1). If the physical gain changes, then the test measurement readings such as PMT, DARK PMT, and OFFSET will be adjusted accordingly.

  • Page 52

    STATUS option, see Table 6-3. If you select a Hi range that is less than Low range, the 6400A will remain locked in Low range and behave as a Single Range instrument.

  • Page 53

    6400A will calibrate RANGE #1. 5.3.4.4 Dilution Ratio The dilution feature allows the 6400A to be used with a stack dilution probe. With the Dilution feature you can select the range and display the concentration at the value and units of the un-diluted gas in the stack.

  • Page 54

    When the above selections have been made, the instrument now must be calibrated through the dilution probe. NOTE: units are now in PPM. See Section 7 for calibration methods. 5.3.4.5 Concentration Units The 6400A can display concentrations in ppb, ppm, ug/m3, mg/m3. Coefficients for mg/m3 and ug/m3 were based on 0 C (25 C for U.S.EPA), 760 mmHg.

  • Page 55: Password Enable, Time Of Day Clock, Diagnostic Mode, Communications Menu

    MORE-COMM-BAUD, select the appropriate BAUD rate, then press ENTR. The instrument ID number can also be set. This ID number is attached to every RS-232 message sent by the 6400A. To set the ID press SETUP-MORE-COMM-ID and enter a 4 digit number from 0000-9999, then press ENTR.

  • Page 56: Variables Menu (vars)

    TAI Model 6400A SO 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.

  • Page 57: Optional Hardware And Software

    TAI Model 6400A SO 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).

  • Page 58

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 6-1: Zero/Span Valve Operation Mode Description Reference Section Front panel operation via CALS and Calibration Section 7 - Manual Zero/Span CALZ buttons. Check. Automatic operation using AUTOCAL Setup and use of AUTOCAL is described in and Section 7.4.

  • Page 59

    The Zero/Span valves or the IZS system can be set up to operate automatically on a timed basis. The TAI model 6400A with IZS option offers capability to check any combination of zero and span points automatically on a timed basis, through remote RS-232 operation (see Section 6.8.5), or external contact closure (see Section 7.7).

  • Page 60

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 6-2: Setup Automatic Zero/Span Calibration Default Description Timer Enable 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...

  • Page 61

    TAI Model 6400A SO 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...

  • Page 62

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 6.5 Permeation Tube (used with IZS option) 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 SO...

  • Page 63

    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. Therefore you should order a permeation tube with a SPECIFIC OUTPUT of 350 to 450 ppb at 0.7 liter/minute. This will give you a IZS Span response of 80 to 90% of full scale in the 500 ppb range.

  • Page 64

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 6-1: Permeation Tube Installation...

  • Page 65: Utput

    TAI Model 6400A SO 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.

  • Page 66

    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.

  • Page 67

    Turns on quiet mode (messages suppressed) Places analyzer in computer mode (no echo of chars) Enables Security Features (Logon, Logoff) Enables RS-232 menus display on 6400A front panel display Enables alternate protocol and setup menu Enables multi-drop support for RTS...

  • Page 68

    TAI Model 6400A SO 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.

  • Page 69: Command Summary

    If you are going to be writing computer programs to communicate with the 6400A (i.e., operating the port in COMPUTER MODE) we suggest that you order a supplementary manual "The RS-232 Interface", TAI part number 01350.

  • Page 70

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 6-7: RS-232 Command Summary Commands Definition Print help screen T SET ALL Enable display of all test variables during T LIST T SET name Display only NAME during T LIST...

  • Page 71

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 6-8: RS-232 Command Summary Terminal Mode Editing Keys Definition V MODE Print current analyzer mode Backspace Erase line Recall last command Execute last command Execute command Switch to computer mode...

  • Page 72

    Variable 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.

  • Page 73: Test Commands And Messages

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 6.8.3 TEST Commands and Messages Table 6-10: RS-232 Test Messages Name Message Description RANGE RANGE=xxxxx PPB Analyzer range STABILITY STABIL=xxxx.x PPB Std. Deviation of last 25 SO concentration values SAMPPRESS PRES=xxx.x IN-HG-A...

  • Page 74: Warning Commands And Messages

    TAI Model 6400A SO 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...

  • Page 75: Calibration Commands And Messages

    TAI Model 6400A SO 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.

  • Page 76: Diagnostic Commands And Messages

    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. The C command...

  • Page 77: Das Commands And Reports

    TAI Model 6400A SO 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.

  • Page 78

    TAI Model 6400A SO 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.

  • Page 79

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Data Report Format: A data report format looks like the following: 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”).

  • Page 80: Variables Commands And Messages

    Model 6400A Internal Variables The 6400A has a number of internal setup variables. Essentially all of these are set at time of manufacture and should not need to be changed in the field. A list of user accessible variables is shown in Table 9-5.

  • Page 81

    TAI Model 6400A SO 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. The general format of the output is: name = value warning_lo warning_hi <data_lo>...

  • Page 82

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G INTENTIONALLY BLANK 6-26...

  • Page 83: Calibration And Zero/span Checks

    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.

  • Page 84

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 7-1: Types of Zero/Span Checks and Calibrations Section Type of Cal or Check Description Manual Z/S Check - Cal gas This calibration option expects the calibration gas through sample port coming in through the sample port.

  • Page 85

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 7-1: Model 6400A Calibration Setup...

  • Page 86

    Table 7-2: Manual Zero Calibration Procedure - Zero Gas Through Sample Port Step Number Action Comment Press CAL The 6400A enters the calibrate mode from sample mode. The zero gas must come in through the sample port. Wait 10 min Wait for reading to stabilize at zero value Press ZERO If you change your mind after pressing ZERO, you can still press EXIT here without zeroing the instrument.

  • Page 87

    Table 7-3: Enter Expected Span Gas Concentrations Procedure Step Number Action Comment Press CAL- This key sequence causes the 6400A to prompt for the CONC expected SO concentration. Enter the SO span concentration value by pressing the key under each digit until the expected value is set.

  • Page 88

    Action Comment Press CALS The 6400A enters the calibrate mode from sample mode. This operates the sample/cal and zero/span valves to allow span gas to come in through the cal gas inlet port or the rear panel. Wait 10 min Wait for reading to stabilize at span value.

  • Page 89

    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 SO span gas to be input into the instrument.

  • Page 90

    7.6 Calibrate on SO 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 SO gas is routed through the permeation tube.

  • Page 91

    * Calibrate only if Dynamic Calibration is enabled (see Table 9-5). 7.8 EPA Protocol Calibration If the 6400A is to be used for EPA SLAMS monitoring, it must be calibrated in accordance with the instructions in this section. In order to insure that high quality, accurate measurements are obtained at all times, the 6400A must be calibrated prior to use.

  • Page 92: Calibration Gas Sources

    (preferably overnight) before calibration so that it is fully warmed up and its operation has stabilized. During the calibration, the 6400A should be in the CAL mode, and therefore sample the test atmosphere through all components used during normal ambient sampling and through as much of the ambient air inlet system as is practicable.

  • Page 93

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 7-8: Activity Matrix for Calibration Equipment & Supplies Frequency and method Action if requirements Equipment/supplies Acceptance limits of measurement are not met Recorder Compatible with Check upon receipt Return equipment to...

  • Page 94: Data Recording Device, Dynamic Multipoint Span Calibration

    Either a strip chart recorder, data acquisition system, digital data acquisition system should be used to record the data from the 6400A RS-232 port or analog outputs. If analog readings are being used, the response of that system should be checked against a NIST referenced voltage source or meter.

  • Page 95

    All operational adjustments to the 6400A should be completed prior to the calibration. The following software features must be set into the desired state before calibration.

  • Page 96

    Table 7-10: EPA Zero Calibration Procedure Step Number Action Comment Press CAL The 6400A enters the calibrate mode from sample mode. Allow the zero gas through the sample port. Wait 10 min Wait for reading to stabilize at the zero value. Press ZERO To select a zero calibration.

  • Page 97

    Figure 7-2: Diagram Of Calibration System Table 7-11: EPA Expected Span Gas Concentration Procedure Step Number Action Comment Press CAL- This key sequence causes the 6400A to prompt for the CONC expected SO concentration. Enter the SO span concentration value by pressing the key under each digit until the expected value is set.

  • Page 98

    Table 7-12: EPA Span Calibration Procedure Step Number Action Comment Press CAL The 6400A enters the calibrate mode from sample mode. Wait 10 min Wait for readings to stabilize at span values. Press SPAN If you change your mind after pressing SPAN, you can still press EXIT here without spanning the instrument.

  • Page 99

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 1. Zero calibration procedure is identical to Table 7-11. 2. Generate the SO concentration to approximately 80% of the URL of the range. Calculate the expected concentration as follows. ×...

  • Page 100

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G By rearranging Equation 7.2 it is possible to calculate total air flow which is sum of F and F total × − × × 382 10 Equation 7.3 total Total air flow rate should exceed the analyzer's sample flow rate demand by margin of 10% to 50%.

  • Page 101: Calibration Frequency, Other Quality Assurance Procedures

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 7.8.6 Calibration Frequency To ensure accurate measurements of the SO 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.

  • Page 102

    TAI Model 6400A SO 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...

  • Page 103: Summary Of Quality Assurance Checks

    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.

  • Page 104: Zero And Span Checks

    TAI Model 6400A SO 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.

  • Page 105: Recommended Standards For Establishing Traceability

    TAI Model 6400A SO 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 SO concentration between 0.08 and...

  • Page 106

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 7-15: NIST-SRM's Available for Traceability of Calibration and Audit Gas Standards NIST-SRM Type Nominal concentration 1693 in N 50 ppm 1694 in N 100 ppm Permeation Tubes Permeation rate,...

  • Page 107

    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.

  • Page 108

    TAI Model 6400A SO 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.

  • Page 109: Maintenance

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G 8 MAINTENANCE NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only. 8.1 Maintenance Schedule Table 8-1: Preventative Maintenance Schedule Item Maintenance Interval Reference Section...

  • Page 110

    To check and change the filter (refer Figure 8-1): 1. Fold down the 6400A front panel. 2. Locate the filter on the left side of the analyzer front panel and visually inspect the filter through the glass window.

  • Page 111

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 8-1: Replacing the Particulate Filter...

  • Page 112: R Eplacing The P Ermeation T Ube ( Option )

    TAI Model 6400A SO 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.

  • Page 113: C Leaning O Rifice And O Rifice F Ilter

    TAI Model 6400A SO 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.

  • Page 114: C Leaning The R Eaction C Ell, P Neumatic L Ine I Nspection

    TAI Model 6400A SO 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.

  • Page 115

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 8-2: Reaction Cell...

  • Page 116

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 8-3: Pneumatic Diagram...

  • Page 117: Leak Check Procedure

    TAI Model 6400A SO 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.

  • Page 118: Light Leak Check Procedure, Eprom R Eplacement P Rocedure

    5. Re-attach the CPU board to the V/F board, and re-attach the assembly to the motherboard. 6. Turn the 6400A ON and observe the front panel display. As the machine goes through the setup the version number will be displayed on the front panel. It should read the same as the version number printed on the prom.

  • Page 119: Diagnostic, Troubleshooting

    TAI Model 6400A SO 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.

  • Page 120

    Incorrect zero gas Incorrect span gas concentration - this could come either from the calibrator or entering the expected span gas concentration in the 6400A incorrectly, see Table 7-3. If the instrument does not respond to span gas check Section 9.2.3.

  • Page 121: O Peration V Erification - 6400a D Iagnostic T Echniques, Fault Diagnosis With Test Variables

    TAI Model 6400A SO 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.

  • Page 122

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment PRES Check value in Reaction cell pressure is measured to monitor sample pressure Final Test and to compensate any sample pressure variation. Reaction cell...

  • Page 123

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment 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.

  • Page 124

    TAI Model 6400A SO 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.

  • Page 125

    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.

  • Page 126

    The Box Temp is read from a thermistor on the Status/Temp board (01086). It should usually read about 5C above room temp. The 6400A is designed to operate from 5 to 40 ambient. Therefore the box temperature should be in the range of about 10 to 50 C.

  • Page 127: Fault Diagnosis With Warning Messages

    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.

  • Page 128

    TAI Model 6400A SO 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.

  • Page 129: Fault Diagnosis Using Diagnostic Mode

    TAI Model 6400A SO 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.

  • Page 130

    This selection starts a procedure to calibrate these outputs. Refer to Section 9.3.3.1 for a detailed procedure. OPTICAL TEST Sets the 6400A into a known state and turns on an LED near the PMT to test the instrument signal path. See Section 9.1.3.3 for details on using this test.

  • Page 131

    The CPU reads this and generates the BROWNOUT_RST signal described below. EXT_ZERO_CAL Shows state of status input bit to cause the 6400A to enter Zero Calibration mode. Use to check external contact closure circuitry. EXT_SPAN_CAL Shows state of status input bit to cause the 6400A to enter the Span Calibration mode.

  • Page 132

    ST_HIGH_RANGE Status Bit - Autorange High Range Logic High = 6400A in high range of autorange mode Logic Low = 6400A in low range of autorange mode ST_SHUT_ALARM Status Bit - Shutter alarm Logic High = Shutter not working Logic Low = Shutter working properly PRMP_RNG_HI Switches the preamp (01105A) hardware range.

  • Page 133

    Signal Control Description ST_DIAG_MODE Status Bit - In Diagnostic mode Logic High = 6400A in Diagnostic mode Logic Low = Not in Diagnostic mode ST_POWER_OK Status Bit - Power OK Logic High = Instrument power is on Logic Low = Instrument power is off...

  • Page 134

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 9-4: Diagnostic Mode - Signal I/O (Continued) Signal Control Description DAC_CHAN_2 Output of spare (DAC2) channel in mV. DAC_CHAN_3 Test Channel (DAC3) output. UVLAMP_SIGNAL Current UV lamp signal voltage in mV. Same as UV LAMP in TEST menu.

  • Page 135

    The implementation of OT involves several changes to the instrument operating conditions. The 6400A does the following when switching to optic test: 1. Save the current instrument setup as to autorange, dual range, current range. D/A analog output is set at 2000 ppb range and auto-ranging is disabled.

  • Page 136: A Internal Variables

    DVM. A detailed procedure is given in the Troubleshooting Section 9.3.2. 9.1.4 6400A Internal Variables The 6400A software contains many adjustable parameters. Many of the parameters are set at time of manufacture and do not need to be adjusted for the lifetime of the instrument. It is possible to change these variables either through the RS-232 port or the front panel.

  • Page 137

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 9-5: Model 6400A Variables Default Value Name Units Description Value Range DAS_HOLD_OFF 15.0 0.5-20.0 Hold off duration after calibration or diagnostic mode. TPC_ENABLE ON-OFF Temp/Pres compensation enable RCELL_SET 30-70...

  • Page 138: Test Channel Analog Output

    TAI Model 6400A SO 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).

  • Page 139: Factory Calibration Procedure (quick Cal)

    TAI Model 6400A SO 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.

  • Page 140

    TAI Model 6400A SO 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.

  • Page 141: P Erformance P Roblems, Ac Power Check

    TAI Model 6400A SO 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:...

  • Page 142: Flow Check, No Response To Sample Gas

    C. Check if UV LAMP reading of TEST function is greater than 350mV. If the 6400A passes ET and OT that means the instrument is capable of detecting light and processing the signal to produce a reading. Therefore, the problem is most likely in the pneumatics.

  • Page 143: Negative Concentration Display, Excessive Noise

    TAI Model 6400A SO 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 SO gas - that is it had more SO gas than that of the sample air. May also be caused by doing a zero calibration using ambient air.

  • Page 144: Unstable Span

    TAI Model 6400A SO 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.

  • Page 145: Unstable Zero, Inability To Span

    TAI Model 6400A SO 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.

  • Page 146: Inability To Zero, Non-linear Response

    TAI Model 6400A SO 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.

  • Page 147: Slow Response, Analog Output Doesn't Agree With Display Concentration

    TAI Model 6400A SO 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.

  • Page 148: Computer, Display, Keyboard

    It contains a self test feature. To test the display: 1. Turn off the power to the instrument. 2. Fold down the 6400A front panel. 3. Disconnect the 24 line flat ribbon cable (J2) that connects the computer parallel port to the keyboard.

  • Page 149

    TAI Model 6400A SO 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.

  • Page 150

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-1: CPU Board Jumper Settings 9-32...

  • Page 151: Rs-232 Communications

    1 sec. If all the LED's are observed to light, they are working properly. 9.3.2 RS-232 Communications The 6400A uses the RS-232 communications protocol to allow the instrument to be connected to a variety of computer based equipment. RS-232 has been used for many years and is well documented.

  • Page 152

    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.

  • Page 153

    TAI Model 6400A SO 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.

  • Page 154: Voltage/frequency (v/f) Board

    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. When data is transmitted by the 6400A the red LED will flicker, indicating data present on this line. When the 6400A is running, the LED will normally be ON, indicating logic low.

  • Page 155

    B. Enter the SETUP-MORE-DIAG menu. C. Scroll to select the ANALOG OUTPUT test. This causes the 6400A to output a 5 step voltage pattern to the 4 analog outputs on the rear panel. The status of the test is shown on the front panel display.

  • Page 156

    Put the probe of a voltmeter (recommend to use 4 1/2 digits meter) on the recorder output terminals 1 and 2 on the 6400A rear panel. The value displayed on the front panel and the voltmeter reading should be the same (± 3 mV). If they are not, adjust the zero pot (R27) on the V/F board until the two values are the same (±...

  • Page 157

    4. The 6400A display will now show "x)CONC_OUT_X,CURR,GAIN". As before, press the up/down buttons on the 6400A front panel until the current meter reads 20.0 ± 0.1 mA. 5. Repeat step 1 through 4 for additional current channel output calibration. Each current channel must be calibrated separately.

  • Page 158

    TAI Model 6400A SO 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.

  • Page 159

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-3: V/F Board Dip Switch Settings 9-41...

  • Page 160: Status/temp Board

    TAI Model 6400A SO 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.

  • Page 161

    TAI Model 6400A SO 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.

  • Page 162

    TAI Model 6400A SO 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...

  • Page 163

    Power Transformers There are potentially 2 input power transformers in the instrument. The multitap transformer T1 is in every 6400A and supplies input power for the Linear Power Supply board described above. A second transformer T2 is added if 220 or 240 VAC input is required. Input power selection is done via a programming connector P2 which provides the proper connections for either foreign or domestic power.

  • Page 164

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-4: Power Supply Module Layout 9-46...

  • Page 165

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-5: Electrical Block Diagram 9-47...

  • Page 166

    TAI Model 6400A SO 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.

  • Page 167: Flow/pressure Sensor

    TAI Model 6400A SO 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.

  • Page 168

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-6: Flow/Pressure Sensor 9-50...

  • Page 169

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-7: SO Sensor Module 9-51...

  • Page 170

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-8: SO Sensor Module 9-52...

  • Page 171: Reaction Cell Temp, Preamp Board, Pmt Cooler

    TAI Model 6400A SO 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.

  • Page 172

    TAI Model 6400A SO 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.

  • Page 173

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-9: PMT Cooler Subsystem 9-55...

  • Page 174: Hvps (high Voltage Power Supply)

    TAI Model 6400A SO 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.

  • Page 175

    TAI Model 6400A SO 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.

  • Page 176: Uv Lamp Adjust Or Replacement

    TAI Model 6400A SO 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 SO 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.

  • Page 177: Uv Filter Replacement, Shutter System

    TAI Model 6400A SO 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.

  • Page 178: Leak Check, Pump, Kicker

    9.5.1 Leak Check CAUTION When doing a leak check do not pressurize the 6400A to greater than 15psig. Damage to internal components will occur at higher pressures. Many performance problems cause is a leak. Refer to Section 8.8 for the leak check procedure.

  • Page 179

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Figure 9-11: Kicker Leak Check 9-61...

  • Page 180: Z/s Valves & Izs Permeation Tube Oven

    TAI Model 6400A SO 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 sub- assembly, check that the options were ordered, and that they are enabled in the software (if not call factory).

  • Page 181: Tai 6400a Spare Parts List

    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 non- compliance with European Standard EN61010-1. Table 10-1: TAI 6400A Spare Parts List PART NO DESCRIPTION 000940100A...

  • Page 182

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 10-1: TAI 6400A Spare Parts List (Continued) PART NO DESCRIPTION 011390200A Assembly, Power Supply Module - 220V/50Hz 011390400A Assembly, Power Supply Module - 240V/50Hz 011900000A 37 mm Sample Filter Assembly...

  • Page 183

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 10-1: TAI 6400A Spare Parts List (Continued) PART NO DESCRIPTION 024720000A Tubing: 6’, 1/8” BLK 024750000A Tubing: 6’, 1/4” TYGON FL0000001A Sintered Filter (002-024900) FL0000003A Filter, DFU (036-040180) FM0000004A...

  • Page 184

    Solid State Relay, 115 Vac SW0000006A Overheat SW, Cell/Oven SW0000008A Pressure Sensor VA0000033A 3-Way Solenoid Valve, Teflon, 12V Table 10-2: TAI MODEL 6400A Level 1 Spares Kit PART NO. DESCRIPTION 014760000A 6400A LEVEL 1 SPARES KIT INCLUDES:` 002620100A UV Lamp Assembly...

  • Page 185

    TAI Model 6400A SO 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:` 003690100A Filter, TFE, 37 mm, Qty. 25 (872-006300) FL0000001A Sintered Filter (002-024900)

  • Page 186

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G Table 10-6: TAI MODEL 6400A Spares Kit For 1 Unit PART NO. DESCRIPTION 014760100A 6400A Spares Kit for 1 Unit INCLUDES:` 003290000A Thermistor Assembly (885-071600) 012360000A Fan, Power Supply Module...

  • Page 187: Appendix A Maintenance Schedule For 6400a

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G APPENDIX A MAINTENANCE SCHEDULE FOR 6400A DATE INSTRUMENT RECEIVED _____________ JUNE JULY SEPT PARTICULATE REPLACE WEEKLY AS NEEDED. FILTER ELEMENT CHARCOAL ZERO REPLACE QUARTERLY. AIR SCRUBBER REPLACE ANNUALLY. PARTICULATE FILTER FOR ZERO...

  • Page 188

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G INTENTIONALLY BLANK...

  • Page 189: Appendix B Electrical Schematics

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G APPENDIX B ELECTRICAL SCHEMATICS Part Number Name 00402I Sensor Board Assembly 00403I Sensor Board Schematic 00514I V/F Board Assembly 00515I V/F Board Schematic 00704I Keyboard, non CE 00705I Keyboard Schematic, non CE...

  • Page 190

    TAI Model 6400A SO Analyzer Operator Manual, 02164, Rev. G INTENTIONALLY BLANK...

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