Teledyne 4030 Series Instruction Manual
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Teledyne 4030 Series Instruction Manual

Total hydrocarbon (thc) analyzer
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Series 4030
INSTRUCTION, OPERATING AND
MAINTENANCE MANUAL FOR
SERIES 4030 HEATED THC
TELEDYNE ANALYTICAL INSTRUMENTS
SPAN
SAMPLE
TEMP. GAUGE
SPAN GAS
BYPASS FLOW
DANGER
Toxic and/or flammable gases or liquids 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 M77216
ECO: #XX-XXXX
DATE 12/13/05
Teledyne Analytical Instruments

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  • Page 1 Series 4030 INSTRUCTION, OPERATING AND MAINTENANCE MANUAL FOR SERIES 4030 HEATED THC TELEDYNE ANALYTICAL INSTRUMENTS SPAN SAMPLE TEMP. GAUGE SPAN GAS BYPASS FLOW DANGER Toxic and/or flammable gases or liquids may be present in this monitoring system. Personal protective equipment may be required when servicing this instrument.

  • Page 2: Teledyne Analytical Instruments

    Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

  • Page 3: Safety Messages

    NOTE: Additional information and comments regarding a specific component or procedure are highlighted in the Symbol form of a note. STAND-BY: This symbol indicates that the instrument is on Stand-by but circuits are active. Teledyne Analytical Instruments...
  • Page 4 Manuals do get misplaced. Additional manuals can be obtained from Teledyne 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.

  • Page 5: Additional Safety Information

    Since the use of this instrument is beyond the control of Teledyne, no responsibility by Teledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.
  • Page 6 THIS VOLTAGE WILL REMAIN HAZARDOUS FOR MANY MINUTES AFTER THE ANALYZER HAS BEEN TURNED OFF! 3. External hazardous voltages which may be connected to the Analyzer alarm relay connections. Teledyne Analytical Instruments...

  • Page 7: Procedure For Removal Of Internal Inaccessible Shock Hazards

    THIS INSTRUMENT IS DESIGNED TO BE OPERATED IN A NONHAZARDOUS AREA. THE ANALYZER USES HYDROGEN GAS AND/OR OTHER COMBUSTIBLE GASES IN ITS OPERATION. THIS EQUIPMENT, IF NOT USED AND MAINTAINED PROPERLY CAN BE AN EXPLOSION HAZARD. THE ANALYZER, Teledyne Analytical Instruments...
  • Page 8 PRINCIPLES OF OPERATION OF THIS EQUIPMENT ARE UNDERSTOOD BY THE USER. SINCE THE USE OF THIS INSTRUMENT IS BEYOND THE CONTROL OF TELEDYNE, NO RESPONSIBILITY BY TELEDYNE, ITS AFFILIATES AND AGENTS FOR DAMAGE OR INJURY RESULTING FROM MISUSE OR NEGLECT OF THIS INSTRUMENT IS IMPLIED OR ASSUMED.

  • Page 9: Main Features Of The Analyzer

    The Analyzer is a microprocessor controlled digital instrument based on Teledyne’s highly successful Model 402R series Total Hydrocarbon Analyzer, coupled with carrier gas, a switching valve and a sample draw pump (optional). This allows...

  • Page 10: Principle Of Operation

    An RS-232 port is also available at the rear panel for connection to a remote computer or other digital communication device. The Analyzer is set up for either 120 VAC 60 Hz or 230 50/60Hz operations depending Teledyne Analytical Instruments...
  • Page 11 Series 4030 uses a Flame Ionization Detector to sense hydrocarbons. The FID was selected based on the positive performance and extensive experience in the use of this detector in other Teledyne analyzers namely Model 402R and Model 4020. The FID has proven itself to be a rugged, stable, long life sensor giving years of trouble free operation in various applications.

  • Page 12: Sample System

    The Analyzer is equipped with ports for the introduction of air, fuel, carrier gas and sample gas. It is imperative that these gases are supplied at constant pressures using two stage stainless steel diaphragm gas regulators. The recommended pressure range is 30 to 60 psig. Teledyne Analytical Instruments...

  • Page 13: Gas Flow Control System

    THE POWER CORD. The collector is interconnected with the electrometer-amplifier PC board by a coaxial cable. Although the cable and fittings are intended for coaxial service, the cable is actually being used as a shielded single- conductor connection. Teledyne Analytical Instruments...
  • Page 14 PC board, which will be described in a following section. The cell electrodes of both the anode-igniter and flame guard thermistor are connected to the electronics chassis by means of a plug-in cable. Teledyne Analytical Instruments...
  • Page 15 High voltage regulation is achieved through the use of series-connected zener diodes. The simplicity of this circuit’s design can be attributed to the extremely low current demand of the anode circuit. The positive output voltage is Teledyne Analytical Instruments...
  • Page 16 FID cools due to lack of flame. If automatic ignition fails five times, there will be a message that reports this, and the flame can be manually ignited by pressing simultaneously the Up and Down key. Teledyne Analytical Instruments...

  • Page 17: Installation

    Note: To completely slide the Model 4030 Analyzer out of the enclosure, pull Analyzer out until it stops, and then push down on the release levers found almost at the end of the sliders, both sides at the same time. Teledyne Analytical Instruments...

  • Page 18: User Connections

    INSPECTED PROPERLY BY START-UP PERSONNEL. 3.3.2 Gas Connections The analyzer gas connection diagram identifies the various gas connection points as to function and location. Figure 3-1 shows the gas connection points for Model 4030 and SAMPLE SELECTOR MODULE (optional). Teledyne Analytical Instruments...
  • Page 19 It is recommended that all gas tubing leading to the connections on the back of the analyzer be of the coiled type. This will facilitate sliding the unit out of the case without disconnecting the gas supply to the analyzer. Teledyne Analytical Instruments...
  • Page 20 CAUTION: USE SHIELDED CABLES. ALSO, USE PLUGS THAT PROVIDE EXCELLENT EMI/RFI PROTECTION. THE PLUG CASE MUST BE CONNECTED TO THE CABLE SHIELD, AND IT MUST BE TIGHTLY FASTENED TO Teledyne Analytical Instruments...

  • Page 21: Primary Input Power

    Table 3-1. The outputs are 0-1 VDC, 0-1 VDC, 4-20mA DC, and 4-20mA DC. The 1st and 3 outputs (0-1 VDC, and 4-20mA DC) operate analogously as do the 2 and 4 outputs (0-1 VDC, and 4-20mA DC). Teledyne Analytical Instruments...
  • Page 22 Channel 2, + 4-20 mA, floating Channel 2, – 4-20 mA, floating Channel 1, + 4-20 mA, floating Channel 1, – 4-20 mA, floating Channel 2, 0-1 VDC Channel 2, 0-1 VDC Channel 1, 0-1 VDC Channel 1, negative ground Teledyne Analytical Instruments...

  • Page 23: Alarm Relays

    However, if the condition that caused the 4030 to fail ignition is not remedied, the 4030 will likely fail to ignite again, and the System Alarm will be re-triggered. Further detail on flame ignition failure can be found in Chapter 4, Section 4.3.1. Teledyne Analytical Instruments...

  • Page 24: Range Id Relays

    4040 switches to that particular range. Table 3-3: Range ID Relay Connections Function Range 1 ID Contact Range 1 ID Contact Range 2 ID Contact Range 2 ID Contact Range 3 ID Contact Range 3 ID Contact Not Used Not Used Teledyne Analytical Instruments...

  • Page 25: Pin Out Table

    Span Solenoid Return Span Solenoid Hot Range 3 Contact Range 3 Contact Alarm 3 C Contact Range 1 Contact Range 2 Contact - Output 0-1 v (Channel 2) + Output 0-1 v (Channel 1) Alarm 1 C Contact Teledyne Analytical Instruments...
  • Page 26 AS<enter> immediately starts an auto span. AL<enter> immediately revert to Analyze (THC Phase) RL<enter> Change to Manual Range LOW RM<enter> Change to Manual Range MEDIUM RH<enter> Change to Manual Range HIGH RA<enter> Change to Manual Range AUTO Teledyne Analytical Instruments...

  • Page 27: Supporting Gases

    Be sure that all plumbing connections are free of leaks. Note: Use only stainless steel tubing throughout the system. Consult the assembly, piping, outline drawings, and any Addenda included with this manual to determine if special conditions apply. Teledyne Analytical Instruments...

  • Page 28: Sample Bypass Vent

    The compressed air, ultra zero gas quality with THC less than 0.1 ppm should be used at a controlled pressure of 30 psig Connect the fuel and air sources to the instrument according to the gas connection diagram included at the back of this manual. Teledyne Analytical Instruments...

  • Page 29: Placing The System In Operation

    The Span gas containing certified mixture of methane in air, recommended range 6 to 8 ppm methane in zero grade air, may be connected to the Span Manifold or the ¼ inch connection on the back of the Sample Selector Module. Teledyne Analytical Instruments...

  • Page 30: Flame Ignition

    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 INSTRUMENTS SPAN SAMPLE TEMP. GAUGE SPAN GAS...

  • Page 31: Verification Of The Flame Guard Circuit

    1200 cc/minute using the Front Panel FLOW CONTROL valve (clockwise increases flow). 4.4 Analyzer Operation Although the Model 4030 has been programmed for your application at the factory, it can be further configured at the operator level. Teledyne Analytical Instruments...
  • Page 32 The only exception to this is when the instrument is powered up. It will go through a warm-up period, followed by a diagnostic self-test routine. Teledyne Analytical Instruments...
  • Page 33 < and >. Example: <enter> or <escape> or <▲> (UP key) or <▼> (DOWN key. Only when the keystroke is to be entered will it be placed between the brackets. If discussing a Teledyne Analytical Instruments...

  • Page 34: Arrow Keys

    ENABLE/DISABLE type values. 4.4.3.2 ENTER The ENTER key is used in several context-sensitive ways. 2. When showing the THC analysis mode, the ENTER key toggles the LINE 2 display. LINE 2 display mode 1 data: - Current analysis mode Teledyne Analytical Instruments...
  • Page 35 ESCAPE key is used to return to the parent menu finally returning to the ANALYSIS SCREEN the function. 9. If the selected option is a modifiable item (value is flashing), The ESCAPE key is used to escape to the parent menu without Teledyne Analytical Instruments...

  • Page 36: Menu Structure

    TOTAL AREA is shown while the ESCAPE key is held down). Time spent in mode Range Activity Indicator 10. The MAIN MENU and SUB MENU screens have a flashing arrow on the left side indicating which item is being pointed Teledyne Analytical Instruments...

  • Page 37: Main Menus

    Factory set. Do not change these. 13. STANDBY: Removes power to outputs and displays, but maintains power to internal circuitry. Any function can be selected at anytime. Just scroll through the MAIN MENU with the DOWN/UP keys to the appropriate function, and Teledyne Analytical Instruments...

  • Page 38: Expanded Menus

    PASSWORD ----------------------- Enter Password 'T' 'A' 'I' ----------------------- GAIN ADJUST ----------------------- GAIN 0 ----------------------- ----------------------- Password Incorrect Change Password ----------------------- ----------------------- Enter New Password 'T' 'A' 'I' ----------------------- ----------------------- Reenter New Password 'A' 'A' 'A' ----------------------- ----------------------- Teledyne Analytical Instruments...
  • Page 39 Begin Self-Test? ENTER-YES ESCAPE-NO ----------------------- ----------------------- Running Diagnostic - Test - Test DAC A - Test DAC B - Test ----------------------- ----------------------- Diagnostic Result - GOOD - GOOD DAC A - GOOD DAC B - GOOD ----------------------- Teledyne Analytical Instruments...
  • Page 40 AL-1 20.00 ppm AL-1 SOURCE THC AL-2 DEFEATED AL-2 HIGH AL-2 NON-FAILSAFE AL-2 NON-LATCHING AL-2 50.00 ppm AL-2 SOURCE THC ----------------------- RANGE ----------------------- Range Select: Auto AutoRange Src: THC Man Rng: R1: 0-10.00ppm R2: 0-100.00ppm R3: 0-1000.00ppm Teledyne Analytical Instruments...
  • Page 41 AIR I Begin: 00m05s AIR I End: 00m05s THC Base 1: 00m03s THC Base 2: 00m03s SMP I/P: 100%/00% SMP TIME: 05m00s SMP I Begin: 00m05s SMP I End: 00m30s SMP Base 1: 00m03s SMP Base 2: 00m03s Teledyne Analytical Instruments...

  • Page 42: Setting Up An Auto-Cal

    The gain has been set at the factory such that the analyzer will work reliably within the prescribed range of operation. The user may change the gain when a different level of sample is to be analyzed. Teledyne Analytical Instruments...

  • Page 43: Password Protection

    'A' 'A' 'A', and the correct letters must be input. If user has LOGGED OUT, then only the following SUB MENU procedures may be executed: 14. PASSWORD 15. LOGOUT (which only repeats the logout) 16. MODEL Teledyne Analytical Instruments...

  • Page 44: Entering A Password

    ENTER PASSWORD SCREEN ________________________________________________ Enter a Password 'T' 'A' 'I' ________________________________________________ <▲▼> Use the ▲▼ keys to change the letters to the proper password. <Enter> Press <Enter> to advance to the next letter Teledyne Analytical Instruments...

  • Page 45: Change Password Screen

    Press <Enter> to advance to the next letter <Enter> The last <Enter> moves to the REPEAT PASSWORD ENTRY screen. <Escape> Steps back to the previously entered letter or, if on the first letter, returns to the CHANGE PASSWORD menu. REPEAT PASSWORD ENTRY SCREEN Teledyne Analytical Instruments...

  • Page 46: Logging Out

    The system will continue analysis, however. To log out: <▲▼> From the MAIN MENU scroll to field of LOGOUT function. <Enter> Press <Enter> to logout . The screen will display the message: ________________________________________________ Restrict Access? ENTER=Yes ESCAPE=NO ________________________________________________ Teledyne Analytical Instruments...
  • Page 47 Note: The self diagnostics will interrupt analysis temporarily. To initiate a self-test: <▲▼> From the MAIN MENU scroll to the SELF-TEST function. <Enter> Activate the SELF-TEST function by pressing <Enter>. This brings up the SELF-TEST initialization screen. ________________________________________________ BeginSelf-Test? ENTER=Yes ESCAPE=NO Teledyne Analytical Instruments...
  • Page 48 To initiate a pan calibration: <▲▼> From the MAIN MENU, scroll down to the SPAN function. <Enter> Press <Enter> to activate the SPAN function. ________________________________________________ -> THC Span? SMP Span? THC Sp: 8.00 ppm SMP Sp: 0.00 ppm Span Begin ________________________________________________ Teledyne Analytical Instruments...

  • Page 49: The Alarms Function

    50-pin Equipment Interface connector. The system failure alarm has a fixed configuration described in Chapter 3 Installation. The concentration alarms can be configured from the ALARM function screen as follows: ________________________________________________ -> AL-1 DEFEATED AL-1 HIGH AL-1 NON-FAILSAFE AL-1 NON-LATCHING Teledyne Analytical Instruments...
  • Page 50 So, if an alarm is NON-LATCHING, and the analysis concentration temporarily drifts above the trip point of a HIGH alarm, the alarm condition occurs Teledyne Analytical Instruments...

  • Page 51: The Range Function

    RESET, YOUR PROCESS WILL BE RUNNING WITHOUT SAFEGUARDS THIS INSTRUMENT IS DESIGNED TO PROVIDE. 4.4.12 The Range Function ________________________________________________ -> Range Select: Man Autorange Src: Man Rng: R1: 0-10.0 ppm R2: 0-100.0 ppm R3: 0-1000.0 ppm ________________________________________________ Teledyne Analytical Instruments...

  • Page 52: Changing Stream

    During a span calibration, the span stream is activated. After a span calibration, the stream reverts to whatever was set before the span. This value is not remembered if the power in cycled on the unit, the analyzer will default to the analyze stream. Teledyne Analytical Instruments...

  • Page 53: Analog Output Adjustment

    'Offset:' That number may be modified –500 to 500. When the arrow is on the Gain, or when the user presses <Enter> to modify the gain, the output is 20mA scaled by the value to the right of Teledyne Analytical Instruments...

  • Page 54: Advanced User Functions

    These functions include: 20. Timing 4.5.1 Timing Timing controls the parameters of the valve and data acquisition. It is specific to the setup of the instrument and must be determined at the factory or TAI trained personnel. Teledyne Analytical Instruments...

  • Page 55: Recommended Spare Parts List

    A minimum charge of US $20.00 is applicable to spare parts orders. IMPORTANT: Orders for replacement parts should include the part number and the model and serial number of the system for which the parts are intended. Teledyne Analytical Instruments...

  • Page 56: Drawing List

    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 diagram (Rev. 2) Teledyne Analytical Instruments...

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