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Teledyne Analytical Instruments 4060-PED Series Instruction, Operating And Maintenance Manual

Plasma emission detector
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Use and Disclosure of Data
Information contained herein is classified as EAR99 under the
U.S. Export Administration Regulations.
Export, reexport or diversion contrary to U.S. law is prohibited.
INSTRUCTION, OPERATING AND
MAINTENANCE MANUAL FOR
SERIES 4060-PED
PLASMA EMISSION DETECTOR
P/N M86515
DATE 04/19/12
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.
Teledyne Analytical Instruments

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  • Page 1 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. Teledyne Analytical Instruments...
  • Page 2  ...
  • Page 3 Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept responsibility for conditions beyond its knowledge and control. No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents, is to be construed as a warranty of adequate safety control under the user’s process...

  • Page 4: 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 5 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. Teledyne Analytical Instruments...

  • Page 6: Additional Safety Information

    A successful leak check was performed at TI/AI on the sample system of this instrument prior to calibration, testing and shipping. Ensure that there are no leaks in the fuel supply lines before applying power to the system. Teledyne Analytical Instruments...
  • Page 7 3. External hazardous voltages which may be connected to the Analyzer alarm relay connections. Procedure for Removal of Internal Inaccessible Shock Hazards CAUTION: SERVICING OR MAINTENANCE OF THE ANALYZER SHOULD ONLY BE DONE BY SUITABLE TRAINED Teledyne Analytical Instruments...
  • Page 8 TAMPERING WITH ITS COMPONENTS OR UNAUTHORIZED SUBSTITUTION OF ANY COMPONENT MAY ADVERSELY AFFECT THE SAFETY OF THIS INSTRUMENT. CAUTION: WHEN OPERATING THIS INSTRUMENT, THE DOORS MUST BE CLOSED AND ALL COVERS SECURELY FASTENED. THE GAUGES MUST BE IN PROPER Teledyne Analytical Instruments...
  • Page 9 Model 4060-PED WORKING ORDER. DO NOT OVERPRESSURIZE THE SYSTEM. READ THIS MANUAL BEFORE OPERATING THE INSTRUMENT AND ADHERE TO ALL WARNINGS INCLUDED IN THIS MANUAL. Teledyne Analytical Instruments viii...

  • Page 10: Table Of Contents

      Installation ................... 13   3.1 Unpacking the Analyzer   3.2 Mounting the Analyzer   3.3 User Connections   3.3.1 Electrical Power Connections   3.3.2 Electronic Connections   3.3.2.1 Primary Input Power   3.3.2.2 Fuse Installation   Teledyne Analytical Instruments...
  • Page 11 4.4.3 Navigation and Data Entry   4.4.3.1 Arrow Keys   4.4.3.2 ENTER   4.4.3.3 ESCAPE   4.4.4 Menu Structure   4.4.4.1 Main Menus   4.4.5 Span   4.4.6 ALT-SPAN   4.4.7 The Model Screen   4.4.8 System Self-Diagnostic Test   Teledyne Analytical Instruments...
  • Page 12 5.2 Temperature Control Electronic Check   5.3 Sampling System   Appendix ..................53   A.1 Specifications and Initial Settings:   A.2 Recommended Spare Parts List   A.3 Drawing List   Appendix B   B1 Addendum and Testing Results   Teledyne Analytical Instruments...

  • Page 13: List Of Figures

    Figure 2-4: Model 4060-PED Piping Diagram ......... 9   Figure 2-5: PED Diagram .............. 10   Figure 3-1: Model 4060-PED Rear Panel with Optional Gas Manifold ..............15   Figure 3-2: Equipment Interface Connector Pin Arrangement..16   Teledyne Analytical Instruments...
  • Page 14 Table 3-7: Pin out of 50 pin D-Sub Connector ....... 22   Table 3-8: Commands via RS-232 Input ........23   Table 3-9: Required RS-232 Options ..........23   Table 4-1: RS-232 Values ............. 43   Teledyne Analytical Instruments xiii...
  • Page 15 Model 4060-PED Teledyne Analytical Instruments...

  • Page 16: Introduction

    Model 4060-PED Introduction Introduction Teledyne Analytical Instruments Series 4060-PED Analyzer is a sophisticated analytical instrument designed to measure the quantity of nitrogen present in a positive pressure background of hydrogen gas. The analyzer is a microprocessor controlled digital instrument based on Teledyne’s 4060 series gas chromatograph instruments using a gas...

  • Page 17: Principle Of Operation

    120 VAC 60 Hz or 230 50/60 Hz operation depending on the customer’s requirements. The appropriate power cord for your unit has been shipped with this instrument. Figure 1-1 shows the Model 4060-PED front interface while Figure 1-2 shows the rear panel including the user connections. Teledyne Analytical Instruments...

  • Page 18: Figure 1-1: Model 4060-Ped Front Panel Interface

    Model 4060-PED Introduction Figure 1-1: Model 4060-PED Front Panel Interface Figure 1-2: Model 4060-PED Rear Panel Teledyne Analytical Instruments...

  • Page 19: Applications

    The Model 4060-PED Analyzer is used in a wide range of applications including:  Gas purity certification.  Specialty Gas Laboratories  Specialty Steel Manufacturing  Gas Management/Monitoring Systems  Process Control  New Line Certification  Chemical Plants  Semiconductor Manufacturing Teledyne Analytical Instruments...

  • Page 20: Operational Theory

    During the analysis the column is back flushed to accept the fresh sample for the next cycle. Actual separating and detecting sequence may vary depending on how the analyzer is configured for your specific application. Figure 2-1: Major Internal Components Teledyne Analytical Instruments...

  • Page 21: Modes Of Operation

    The analyzer has 2 modes of operation depending on the position of the GC Sampling Valve (See Piping Diagram in Figure 2-2). They are: Sample Mode (position A) and Analysis Mode (position B). 1. Valve Position A—Sampling Mode In this mode the analyzer configures the operational valve to Teledyne Analytical Instruments...

  • Page 22: Analyzer Subsystems

    The Model Analyzer is composed of four subsystems: Sample System GC Column PED Detector Electronic Signal Processing, Display and Control 2.3.1 Sample System All components used to control the sample and support gases, are located on the front door or inside the analyzer chassis. Teledyne Analytical Instruments...

  • Page 23: Figure 2-3: Internal Temperature Controllers

    It is imperative that these gases are supplied at constant pressures. The recommended pressure is 20 psig, more importantly, however, the sample and span gases must be supplied at the same pressure. Teledyne Analytical Instruments...

  • Page 24: Gc Column

    The residence time in the column is a function of the gases present and the temperature. This Model 4060- PED is specifically set up for analyzing nitrogen in hydrogen however Teledyne Analytical Instruments...

  • Page 25: Plasma Emission Detector Cell

    The specific line energy is identified for nitrogen and a custom blocking filter is selectively chosen and installed in the optic circuit at Teledyne Analytical Instruments...

  • Page 26: Electronic Signal Processing, Display And Control

    The detector lifetime is enhanced using a “Duty Cycle Controlled System” by reducing the coating inside the cell. This also results in an increase in sensitivity. Teledyne Analytical Instruments...

  • Page 28: Installation

    Refer to the system/analyzer outline drawings for dimensions. Note: To completely slide the analyzer out of the enclosure, pull Analyzer out until it stops, then push down on the release Teledyne Analytical Instruments...

  • Page 29: User Connections

    PRIMARY POWER TO THE SYSTEM SHOULD NOT BE SUPPLIED UNTIL ALL CUSTOMERS WIRING IS INSPECTED PROPERLY BY START-UP PERSONNEL. 3.3.2 Electronic Connections Figure 3-1 shows the 4060-PED rear panel. There are connections for power, digital communications, and both digital and analog concentration output. Teledyne Analytical Instruments...

  • Page 30: Primary Input Power

    The power cord receptacle and fuse block are located in the same assembly. Insert the power cord into the power cord receptacle. CAUTION: POWER IS APPLIED TO THE INSTRUMENT'S CIRCUITRY AS LONG AS THE INSTRUMENT IS CONNECTED TO THE POWER SOURCE. Teledyne Analytical Instruments...

  • Page 31: Fuse Installation

    0.5 V = Medium Range 0.80 V = High Range 4–20 mA DC % Range: Current increases linearly with concentration, from 4 mA at 0 concentration to 20 mA at full scale. (Full scale = 100% of programmable range.) Teledyne Analytical Instruments...

  • Page 32: Table 3-1: Analog Output Connections

    To provide an indication of the range, the Range ID analog outputs are used. They generate a steady preset voltage (or current when using the current outputs) to represent a particular range. Table 3-3 gives the range ID output for each analysis range. Teledyne Analytical Instruments...

  • Page 33: Alarm Relays

    Each relay has both normally open and normally closed contact connections. The contact connections are shown in Table 3-4. They are capable of switching up to 3 amperes at 250 VAC into a resistive load. The connectors are: Teledyne Analytical Instruments...

  • Page 34: Table 3-4: Alarm Relay Contact Pins

    Chapter 4, Section 4.4.20. Table 3-4: Alarm Relay Contact Pins Contact Threshold Alarm 1, normally closed contact Threshold Alarm 1, moving contact Threshold Alarm 1, normally open contact Threshold Alarm 2, normally closed contact Threshold Alarm 2, moving contact Teledyne Analytical Instruments...

  • Page 35: Digital Remote Cal Inputs

    Remote Cal Inputs are being polled, and a span command can be sent. When the contact is CLOSED, the analyzer is already calibrating. It will ignore your request to calibrate, and it will not remember that request. Teledyne Analytical Instruments...

  • Page 36: Range Id Relays

    3.3.2.8 N ETWORK A serial digital input/output for local network protocol. At this printing, this port is not yet functional. It is to be used in future options to the instrument. Pins 13 (+) and 29 (–). Teledyne Analytical Instruments...

  • Page 37: Pin Out Table

    It requires a standard 9-pin D connector. Input: The input functions using RS-232 that have been implemented to date are described in Table 3-8. Teledyne Analytical Instruments...

  • Page 38: Gas Connections

    Sent at the end of each cycle. 3.3.3 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 instruments fitted with the optional auto cal module. Teledyne Analytical Instruments...
  • Page 39 Cap the tubing while not in use with suitable non- contaminating caps. All sample, calibration, and supporting gas lines, which deliver gas to the analyzer, must be decontaminated before connection; vent lines do not. Teledyne Analytical Instruments...
  • Page 40 HYDROGEN IS A FLAMMABLE AND EXPLOSIVE GAS. MAKE SURE THERE ARE ABSOLUTELY NO LEAKS IN THE SAMPLE LINES. PERFORM LEAK CHECKS REGULARLY ON ALL LINES. ALWAYS PERFORM A LEAK CHECK WHENEVER A FITTING HAS BEEN LOOSENED AND/OR RE-TIGHTENED FOR ANY REASON. Teledyne Analytical Instruments...

  • Page 41: Effluent

    See Section 4 for information on starting the analyzer for the first time. Makes sure that all electrical connections have been made correctly and all connectors are fully seated. Make sure all gas connections are correct and leak–free. Teledyne Analytical Instruments...

  • Page 42: Operation

    4. Sample Pressure Regulation: An oil-free, metallic diaphragm regulator must be installed at the sample point when possible; see Section 3.3.3 Gas Connections. CAUTION: THE GASES USED MUST BE OF THE HIGHEST QUALITY, ULTRA ZERO GRADES. FAILURE TO DO SO WILL RESULT IN CONTAMINATION. Teledyne Analytical Instruments...

  • Page 43: Preliminary Power-Off Check List

    Shut off the span gas. The analyzer is now ready to be configured for your application. 4.4 Analyzer Operation Although the Model 4060-PED has been programmed for your application at the factory, it can be further configured at the operator Teledyne Analytical Instruments...
  • Page 44 This can result in a condition where the screen may be reporting a value that should cause an alarm, but until the analyzer again enters SAMPLE MODE, no alarm condition will reoccur. Teledyne Analytical Instruments...

  • Page 45: Default Parameters

    < 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 46: Navigation And Data Entry

    The ENTER key is used in several context-sensitive ways. 1. When the selected option is a function on the MAIN MENU or any SUB MENU screen, the function name appears with an arrow next to it. In some cases, the item in the menu is Teledyne Analytical Instruments...

  • Page 47: Escape

    (if any) and some information about what phase of analysis is occurring. 2. 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 48: Main Menus

    : Low level application specific timing parameters. TIMING Factory set. Do not change these.  : Determines compound names, associated GROUP SETUP timing and measurement ranges. Do not change these.  Used to establish password protection or change the PSWD: existing password. Teledyne Analytical Instruments...

  • Page 49: Span

    The second line commences the span after the following query: ________________________________________________ Begin Span: ENTER-YES ESCAPE-NO ________________________________________________ Pressing <Enter> enters the SPAN mode in the Sampling Phase. This is similar to the Analysis Mode both in the Sampling Phase and Teledyne Analytical Instruments...

  • Page 50: Alt-Span

    Note: The self diagnostics will interrupt analysis temporarily. To initiate a self-test: <UP/DOWN >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. ________________________________________________ Begin Self-Test? ENTER=Yes ESCAPE=NO Teledyne Analytical Instruments...

  • Page 51: The Alarms Function

    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 AL-1 20.00 ppm AL-2 ACTIVE AL-2 LOW Teledyne Analytical Instruments...
  • Page 52 LATCHING, the alarm condition 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 screen will have one or both of the following Teledyne Analytical Instruments...

  • Page 53: The Range Function

    The analog outputs from the 50 –pin Equipment connector (see Section 3.3.2.4 and Table 3-1) represent the proportion of the analysis concentration to the currently selected range limit. Teledyne Analytical Instruments...

  • Page 54: Analog Output Adjustment

    ______________________________________________ -> CH1 Offset CH1 Gain CH1 (Wave, Id for Ch2, or Group Output) CH1 (Select Groups) CH2 (Wave, Id for Ch2, or Group Output) CH2 (Select Groups) ______________________________________________ 4.4.12 Linearization Not applicable to the 4060-PED configuration. Teledyne Analytical Instruments...

  • Page 55: Changing Stream

    To setup an auto cal cycle for a span event to occur in a certain number of days/hours: From the Analysis Screen, press the UP or DOWN key to enter the Setup Mode. The VFD will display the first 2 lines of functions available. ______________________________________________ -> AUTO CAL Teledyne Analytical Instruments...
  • Page 56 The 3rd and 4th lines modify the days and hours until the next Auto Span occurs. When these are changed and <Enter> is pressed, the Auto Span is re-set to occur according to the number of Days/Hours set. The first line will reflect the new count down. Teledyne Analytical Instruments...

  • Page 57: Timing

     Profi  Query 4.4.17.1 STD This is the standard message format and is emitted once every two seconds. The following is an example of this format: ************************************* PRO 5.4ppm R1 AL-2 BNZ 15.42% R3 AL-2 ************************************* Teledyne Analytical Instruments...

  • Page 58: Detct

    PC board. For 9600 baud, move dipswitch 1 to ON and dipswitch 2 to OFF. 4.4.17.4 Q UERY This format is selected when sending out specific commands from a computer to extract information. Contact TAI for more information on these alternative communication modes Teledyne Analytical Instruments...

  • Page 59: Password Protection

    <Enter> for each letter of the password will enter the default password for you. To enter a password: <any key> From the ANALYSIS SCREEN Enter MAIN MENU setup by pressing an UP/DOWN KEY. <UP/DOWN >Use the UP or DOWN key to scroll to Teledyne Analytical Instruments...
  • Page 60 MAIN MENU. If the correct password has been entered the 4060-PED now allows access to all the SUBMENU items. The 4060-PED next presents the CHANGE PASSWORD screen. CHANGE PASSWORD SCREEN ________________________________________________ -> Change Password ________________________________________________ Teledyne Analytical Instruments...
  • Page 61 <UP/DOWN >Use the UP/DOWN keys to reenter the letters of the new password. <Enter> Press <Enter> to advance to the next letter <Enter> If the repeated password matches the previously entered new password, the new password is set, the 4060-PED Teledyne Analytical Instruments...

  • Page 62: Logging Out

    Pressing <Enter> will logout the current 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: 1. PASSWORD 2. LOGOUT (which only repeats the logout) 3. MODEL Teledyne Analytical Instruments...

  • Page 63: Standby

    To place the instrument in STANDBY status: <UP/DOWN >From the MAIN MENU, scroll to the STANDBY function using the UP/DOWN keys. <Enter> Pressing <Enter> places the instrument in STANDBY. To exit STANDBY, scroll again to the STANDBY function and press <Enter> again. Teledyne Analytical Instruments...

  • Page 64: Maintenance & Troubleshooting

    ANALYZER ARE SUSCEPTIBLE TO DAMAGE FROM ELECTROSTATIC DISCHARGE (ESD). USE ESD SAFE PROCEDURES WHEN HANDLING OR WORKING WITH ELECTRONIC COMPONENTS If the analyzer is suspected of incorrect operation, always evaluate performance with zero (pure hydrogen) or span gas flowing in the Teledyne Analytical Instruments...

  • Page 65: Temperature Control Electronic Check

    P/N B30927, the wires out of the thermistor are yellow, and measure resistance between that wire and the remaining undisturbed terminal. Resistance of the thermistor varies with its surrounding temperature. A reading of between 10KOhms and Teledyne Analytical Instruments...

  • Page 66: Sampling System

    Plugged or faulty regulators, plugged restrictors, or leaks within the system can cause erratic performance. TAI recommends that the factory or an authorized representative be contacted before attempting any repairs to the sample or supporting gas systems within the analyzer. Teledyne Analytical Instruments...
  • Page 67 Maintenance Model 4060-PED Teledyne Analytical Instruments...

  • Page 68: Appendix

    One System Alarm for AC power failure and flame out, fail safe, ‘C’ type relay contacts. Calibration Contact, ‘A’ Type Relay Calibration Contact: contact for span mode indication. Provided RS-232 Output: 0 – 40º C. Install in a well ventilated Ambient Temp: area Teledyne Analytical Instruments...

  • Page 69: Recommended Spare Parts List

    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. Send orders to: TELEDYNE Analytical Instruments 16830 Chestnut Street City of Industry, CA 91748 Telephone: (626) 934-1500...

  • Page 70: Drawing List

    Model 4060-PED Appendix A.3 Drawing List (Refer to the Addendum and Testing Results section of Appendix B for actual drawing list for your application.) D88791 Outline Diagram C86472 Piping Diagram Teledyne Analytical Instruments...
  • Page 71 Appendix Model 4060-PED Teledyne Analytical Instruments...

  • Page 72: B1 Addendum And Testing Results

    Model 4060-PED Appendix Appendix B B1 Addendum and Testing Results Teledyne Analytical Instruments...
  • Page 74  ...

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