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Teledyne Analytical Instruments 4060TCD Instruction, Operating And Maintenance Manual

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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
MODEL 4060TCD
P/N M82787
Date 09/16/09
Rev 3
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.

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  • Page 1 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 MODEL 4060TCD P/N M82787 Date 09/16/09 Rev 3 DANGER Toxic and/or flammable gases or liquids may be present in this monitoring system.
  • 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

    Model 4060TCD 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.
  • Page 5 Model 4060TCD CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED, UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES.

  • Page 6: Additional Safety Information

    Model 4060TCD Additional Safety Information DANGER GAS USAGE WARNING This is a general purpose instrument designed for use in a non-hazardous area. It is the customer's responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist.
  • Page 7 Model 4060TCD sample system. See the procedures for purging and leak checking this instrument on the following pages. WARNING: ELECTRICAL SHOCK HAZARD. WITH THE EXCEPTION OF OPENING THE DOOR AND ADJUSTING THE TEMPERATURE CONTROLLERS, ONLY AUTHORIZED AND SUITABLY TRAINED PERSONNEL SHOULD PERFORM WORK INSIDE OF THE INSTRUMENT.

  • Page 8: Table Of Contents

    Model 4060TCD Table of Contents Safety Messages ................iii Additional Safety Information ............v List of Figures ................x List of Tables ................xi Introduction ................. 13 1.1 Main Features of the Analyzer 1.2 Principle of Operation 1.3 Analyzer Description 1.4 Applications...
  • Page 9 Model 4060TCD 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 3.3.2.3 50-Pin Equipment Interface Connector 3.3.2.4 Analog Output 3.3.2.5 Alarm Relays 3.3.2.6 Digital Remote Cal Inputs 3.3.2.7 Range ID Relays 3.3.2.8 Network I/O 3.3.2.9 Pin Out Table...
  • Page 10 Model 4060TCD 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 4.4.9 The Alarms Function 4.4.10 The Range Function 4.4.11 Analog Output Adjustment 4.4.12 Linearization 4.4.13 Changing Stream 4.4.14 Setting up an AUTO-CAL...

  • Page 11: List Of Figures

    Figure 1-2: Model 4060TCD Temperature Controllers ....17 Figure 1-3: Model 4060TCD Rear Panel ........17 Figure 2-1: Typical Piping Diagram for Model 4060TCD ....21 Figure 2-2: Internal Temperature Controllers ........ 22 Figure 2-3: Internal Components Within Sample Chamber ... 23 Figure 2-4: Thermal Conductivity Cell Operating Principle ....
  • Page 12 Model 4060TCD List of Tables Table 3-1: Analog Output Connections ......... 35 Table 3-2: Analog Concentration Output—Example ...... 35 Table 3-3: Analog Range ID Output—Example ......36 Table 3-4: Alarm Relay Contact Pins ..........37 Table 3-5: Remote Calibration Connections ........38 Table 3-6: Range ID Relay Connections ........

  • Page 14: Introduction

    Teledyne’s highly successful Model 4000 series of gas chromatograph Aromatic Hydrocarbon Analyzers. The 4060TCD Analyzer couples a gas separation column plus sampling valve with a sensitive thermal conductivity detector to extend the range of compounds for analysis.

  • Page 15: Principle Of Operation

    Introduction Model 4060TCD • Versatile analysis with three user-definable analysis ranges. • Microprocessor based electronics: 8-bit CMOS microprocessor with 32 kB RAM and 128 kB ROM. • Manual ranging allows the user to lock onto a specific range of interest.

  • Page 16: Analyzer Description

    The Model 4060TCD uses the difference in thermal conductivity between a compound of interest and a reference gas and relates the thermal conductivity changes to the concentration of the analyte in the sample.

  • Page 17: Figure 1-1: Model 4060Tcd Front Panel Interface

    The appropriate power cord for your unit is included with this instrument. Figure 1-1 shows the Model 4060TCD front interface and Figure 1-2 shows the instrument with the front door opened revealing the three temperature controllers.

  • Page 18: Figure 1-2: Model 4060Tcd Temperature Controllers

    Model 4060TCD Introduction Figure 1-2: Model 4060TCD Temperature Controllers Figure 1-3: Model 4060TCD Rear Panel Teledyne Analytical Instruments...

  • Page 19: Applications

    Introduction Model 4060TCD 1.4 Applications • Monitoring the purity of unreactive or other stable gases. • Monitoring contamination in air liquefaction and other gas production processes. • Gas purity certification. • Detecting trace pollutants in ambient air. Teledyne Analytical Instruments...

  • Page 20: Operational Theory

    The Model 4060TCD avoids these issues by coupling the TC detector with a gas separation capability in the GC column. Therefore, even if the sample stream contains more than one compound, at any time...

  • Page 21: Modes Of Operation

    Operational Theory Model 4060TCD during analysis, only a binary mixture which includes the component of interest based on its separation properties, plus carrier gas is delivered to the detector. A suitable carrier gas can be selected that among other properties, maximizes the thermal conductivity difference for enhanced sensitivity.

  • Page 22: Figure 2-1: Typical Piping Diagram For Model 4060Tcd

    These parameters are listed for review in the Addendum and Testing Results section of Appendix B. It is important that the user does not alter or change these critical settings unless authorized from Teledyne. Figure 2-1: Typical Piping Diagram for Model 4060TCD Teledyne Analytical Instruments...

  • Page 23: Analyzer Subsystems

    Operational Theory Model 4060TCD 2.3 Analyzer Subsystems The Model 4060TCD is composed of four subsystems: 1. Sample System 2. Gas Separation 3. TC Detector 4. Electronic Signal Processing, Display and Control System 2.3.1 Sample System All components used to control the sample and supporting gases are located inside the analyzer chassis.

  • Page 24: Gas Flow Control System

    There is also a port for connecting a purge gas to purge the housing if this is necessary. The Model 4060TCD is equipped with a pressure regulator for the carrier gas however the sample and calibration gases must have their own regulators.

  • Page 25: Gas Separation System

    Operational Theory Model 4060TCD controlling the introduction of sample or calibration (zero and span) gas to the detector circuit. With the auto calibration module, calibration can be performed automatically on a programmed schedule or manually using the front panel interface.

  • Page 26: Calibration

    Model 4060TCD Operational Theory Figure 2-4: Thermal Conductivity Cell Operating Principle If the thermal conductivities of the gases in the two chambers are different, the Wheatstone bridge circuit unbalances, causing a current to flow in its detector circuit. There will be a constant current flowing as a result of the different flow rates between the reference and carrier gases, though both are the same gas.

  • Page 27: Effects Of Flowrate And Gas Density

    Thermal conductivity measurements are nonspecific by nature. This fact imposes certain limitations and requirements. In the Model 4060TCD, the thermal conductivity sensor will respond to a specific component in a sample stream as it separates and is mixed with the carrier gas.

  • Page 28: Figure 2-5: Block Diagram For Tcd Electronics

    Model 4060TCD Operational Theory CPU) with 32 kB of RAM and 128 kB of ROM to control all signal processing, input/output. The signal processing electronics including the microprocessor, analog to digital, and digital to analog converters are located on the motherboard at the bottom of the TCD case.

  • Page 29: Temperature Control

    Operational Theory Model 4060TCD The temperature control board keeps the temperature of the measuring cell regulated to within 0.1°C. A thermistor is used to measure the temperature, and a zero-crossing switch regulates the power in a cartridge-type heater. The result is a sensor output signal that is temperature independent.
  • Page 30 Model 4060TCD Operational Theory Teledyne Analytical Instruments...

  • Page 32: Installation

    3.2 Mounting the Analyzer The Model 4060TCD is a general-purpose analyzer and as such is designed with (non-sealed) enclosures. It must be installed in an area where the ambient temperature is not permitted to drop below 32ºF nor rise above 100ºF.

  • Page 33: User Connections

    BE SUPPLIED UNTIL ALL CUSTOMERS WIRING IS INSPECTED PROPERLY BY START-UP PERSONNEL. 3.3.2 Electronic Connections Figure 3-1 shows the Model 4060TCD rear panel. There are connections for power, digital communications, and both digital and analog concentration output. For safe connections, no uninsulated wiring should be able to come in contact with fingers, tools or clothing during normal operation.

  • Page 34: Primary Input Power

    SHIELD, AND IT MUST BE TIGHTLY FASTENED TO THE ANALYZER WITH ITS FASTENING SCREWS. ULTIMATELY, IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI/RFI SIELDING. Figure 3-1: Model 4060TCD Rear Panel 3.3.2.1 P RIMARY NPUT OWER The power cord receptacle and fuse block are located in the same assembly.

  • Page 35: 50-Pin Equipment Interface Connector

    Installation Model 4060TCD 3.3.2.3 50-P QUIPMENT NTERFACE ONNECTOR Figure 3-2 shows the pin layout of the Equipment Interface connector. The arrangement is shown as seen when the viewer faces the rear panel of the analyzer. The pin numbers for each input/output function are given where each function is described in the paragraphs below.

  • Page 36: Table 3-1: Analog Output Connections

    Model 4060TCD Installation Table 3-1: Analog Output Connections Function 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, negative ground...

  • Page 37: Alarm Relays

    Installation Model 4060TCD 10.4 12.0 13.6 15.2 16.8 18.4 20.0 Table 3-3: Analog Range ID Output—Example Range Voltage Signal Current Signal Application Output (VDC) Output (mA DC) Range 1 0.20 95–100 % Nitrogen Range 2 0.50 90–100 % Nitrogen Range 3 0.80...

  • Page 38: Table 3-4: Alarm Relay Contact Pins

    Model 4060TCD Installation Threshold Alarm 2: • Can be configured as high (actuates when concentration is above threshold), or low (actuates when concentration is below threshold). • Can be configured as failsafe or non-failsafe • Can be configured as non-latching •...

  • Page 39: Digital Remote Cal Inputs

    Cal Contact Cal Contact Remote Calibration Protocol: To properly time the Digital Remote Cal Inputs to the Model 4060TCD Analyzer, the customer's controller must monitor the Cal Relay Contact. When the contact is OPEN, the analyzer is analyzing, the Remote Cal Inputs are being polled, and a span command can be sent.

  • Page 40: Range Id Relays

    Model 4060TCD Installation 2. When the CRC closes, remove the span command. When CRC opens again, the span calibration is done, and the sample is being analyzed. 3.3.2.7 R ID R ANGE ELAYS There are three dedicated Range ID relay contacts. They are assigned to relays in ascending order—Low range is assigned to Range...

  • Page 41: Rs-232 Port

    Installation Model 4060TCD Table 3-7: Pin out of 50 pin D-Sub Connector pin # Description pin # Description + Output 4-20 ma - Channel 2 Alarm 1 C Contact - Output 4-20 ma - Channel 2 + Output 4-20 ma – Channel 1 - Output 4-20 ma –...

  • Page 42: Table 3-8: Commands Via Rs-232 Input

    Model 4060TCD Installation Table 3-8: Commands via RS-232 Input Command Description AS<enter> Immediately starts an autospan. AL<enter> Immediately revert to Analyze (CH4 Mode) RL<enter> Change to Manual Range LOW RM<enter> Change to Manual Range MEDIUM RH<enter> Change to Manual Range HIGH RA<enter>...
  • Page 43 Installation Model 4060TCD Figure 3-3: Gas Connections Gas connections to the instrument are made at the 1/8”or 1/4” stainless steel tube fittings provided on the rear panel. Note that the Purge and Sensor Vent fittings are 1/4” while all other gas connections are 1/8”.

  • Page 44: Effluent

    Model 4060TCD Installation should be left capped off, where pockets might form of material that is not representative of the current contents of the line, or which might keep contaminants from being purged out of the system. CAUTION: THE GASES USED MUST BE OF THE HIGHEST QUALITY, ULTRA ZERO GRADES, AS SHOWN BELOW.

  • Page 45: Sample Bypass Vent

    Installation Model 4060TCD If a vent line is required, the installation must include a drop-out pot to collect the water that is formed by the heated TC sensor The vent line must be constructed so that water and dirt cannot collect in it.

  • Page 46: Operation

    Operation This section of the manual describes how to setup and operate the Model 4060TCD Analyzer. Sections 4.1 through 4.3 describe preliminary steps and equipment needed to operate the analyzer. Beginning with Section 4.4, the actual operation of the analyzer is described along with descriptions of the display prompts, messages and options available to the user within a menu or sub menu.

  • Page 47: Preliminary Power-Off Check List

    Operation Model 4060TCD CONTAMINATION AND FAILURE TO DETECT AT THE REQUIRED ACCURACY. CARRIER GAS: ULTRA ZERO GRADE WITH LESS THAN 0.1 PPM ANALYTE. 4.2 Preliminary Power-Off Check List Make the following checks of the installation before proceeding further into the start-up procedure: 1.

  • Page 48: Analyzer Operation

    3. Turn off span gas and repeat the above for zero gas. 4.4 Analyzer Operation Although the Model 4060TCD has been programmed for your application at the factory, it can be further configured at the operator level. Depending on the specifics of the application, this might include all or a set of the following procedures: 1.

  • Page 49: Default Parameters

    Below is a listing of the default parameters used in configuring the typical Model 4060TCD instrument. Your specific application may require different settings. Refer to the Addendum and Testing Results section of Appendix B for any specific changes or recommendations that apply to your application.

  • Page 50: Navigation And Data Entry

    Model 4060TCD Operation Screens: Arial 12 pt. type in capital letters. Example: ANALYZE or MAIN screen or menu. Key Presses: <key> The particular keystroke to enter is placed between < and >. Example: <enter> or <escape> or <▲> (UP key) or <▼> (DOWN key.

  • Page 51: Enter

    Operation Model 4060TCD 2. When the selected option is a function on the MAIN MENU or any SUB MENU screen, the ARROW KEYS move to the next lower or upper menu. 3. If the selected option is a MODIFIABLE ITEM (value is...

  • Page 52: Menu Structure

    The value will revert to the original before modification (if any). 4.4.4 Menu Structure The 4060TCD screen setup consists of several classes of screens and items. No item occupies more than 1 line. It is important to read and understand the NAVIGATION AND DATA ENTRY section to fully understand the menu structure.

  • Page 53: Span

    • Used to define and/or start an automatic AUTO-CAL: calibration sequence. AUTOCAL is an optional feature not included in the standard configurations of the 4060TCD. • : Low level application specific timing parameters. TIMING Factory set. Do not change these values.

  • Page 54: Alt-Span

    Analysis Phase. The difference is that, at the end, the analyzer calculates the calibration constants rather than the standard concentration calculation. After both Sampling Phase and Analysis Phase are complete, the calculation is performed and the 4060TCD re- enters Analysis Mode. 4.4.6 ALT-SPAN...

  • Page 55: The Model Screen

    <UP/DOWN > keys to scroll to MODEL and pressing <Enter>. 4.4.8 System Self-Diagnostic Test The Model 4060TCD has a built-in self-diagnostic testing routine. Preprogramming signals are sent through the power supply, output board, preamp board and sensor circuit. The return signal is analyzed, and at the end of the test the status of each function is displayed on the screen, either as GOOD or BAD.

  • Page 56: The Alarms Function

    Analyze Mode. 4.4.9 The Alarms Function The Model 4060TCD is equipped with two alarms and a system failure alarm relay. Each alarm relay has a set of form "C" contacts rated for 3 amperes resistive load at 250 VAC. See the Interconnection Diagram included at the back of this manual for relay terminal connections.
  • Page 57 Operation Model 4060TCD be taken such as correcting the alarm or the analysis concentration. If an active (not defeated) alarm has been set to HIGH at 20.0 %, and the analysis concentration is above that level, then the 'alarm condition' is occurring.

  • Page 58: The Range Function

    Model 4060TCD Operation 20.00 %, then when the analysis concentration is at or above 20.00 % an alarm condition is initiated or maintained. CAUTION: IT IS NOT GOOD PRACTICE TO SILENCE AN EXISTING ALARM BY SETTING THE ALARM ATTRIBUTE TO ‘DEFEAT”. THE ALARM WILL NOT AUTOMATICALLY RETURN TO “ACTIVE”...

  • Page 59: Analog Output Adjustment

    Operation Model 4060TCD connector (see Section 3.3.2.4 and Table 3-1) represent the proportion of the analysis concentration to the currently selected range limit. MANUAL/AUTO RANGE SELECT: In Manual Range Select, the range indicated on the second line 'Man Rng:' is maintained as the current range of operation.

  • Page 60: Linearization

    • Adjust up or down to set the meter to 20.0 mA. Disconnect the meter. The 4-20 mA analog output is now calibrated. 4.4.12 Linearization Not applicable to the 4060TCD configuration. 4.4.13 Changing Stream This function affects the relay on the rear panel that controls which gas is allowed to flow to the column and detector.

  • Page 61: Setting Up An Auto-Cal

    Operation Model 4060TCD 4.4.14 Setting up an AUTO-CAL The Model 4060TCD Analyzer can be fitted with an external auto calibration module as an option. This feature provides automatic switching of sample and calibration gases and allows the operator to program calibration events to occur automatically...

  • Page 62: Timing

    Model 4060TCD Operation Here are the autocal parameters (with an example of data). The underlined items are modifiable (but not underlined in the actual display): ________________________________________________ -> AS:3d 20h AUTO SPAN Enabled Span in 11 days Span in 6 hours...

  • Page 63: Group Setup

    Operation Model 4060TCD directed by Customer Service at TAI. For further information please contact TAI Customer Service. 4.4.16 Group Setup Group Setup assigns to each compound a name, a range given in Range settings and an associated peak window that is determined in Timing settings.

  • Page 64: Entering A Password

    Model 4060TCD Operation ENTERING A PASSWORD To install a new password or change a previously installed password, you must key in and ENTER the old password first. If the default password is in effect it will be displayed as the default gausses for each letter, pressing <Enter>...

  • Page 65: Change Password Screen

    Operation Model 4060TCD If the correct password has been entered the 4060TCD now allows access to all the SUBMENU items. The 4060TCD next presents the CHANGE PASSWORD screen. CHANGE PASSWORD SCREEN ________________________________________________ -> Change Password ________________________________________________ <Escape> Press to return to the MAIN MENU, you are now <Escape>...

  • Page 66: Logging Out

    <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 4060TCD resumes the ANALYSIS SCREEN after displaying a brief message 'Password Changed'. <Escape> Steps back to the previously entered letter or, if on the first letter, returns to the CHANGE PASSWORD menu.

  • Page 67: Standby

    Operation Model 4060TCD 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.

  • Page 68: Appendix

    Model 4060TCD Appendix Appendix A.1 Specifications and Initial Settings: Range(s): Refer to Addendum and Testing Results in Appendix B. Power Requirements: Refer to Addendum and Testing Results in Appendix B. Signal Output: Two analog channels: Channel 1: 0-1 VDC and isolated 4-20...

  • Page 69: Recommended Spare Parts List

    Appendix Model 4060TCD A.2 Recommended Spare Parts List Qty. Description C82893 PC board, Electrometer-amplifier C75825A Micro-processor PC board B82773 TCD Sensor assembly C62371A Display PCB Assy. B74674A Interface to Motherboard PCB Assy. C65507A Back panel/Power Supply PCB Assy. Fuse, 2A (220V uses F9)

  • Page 70: Drawing List

    Model 4060TCD Appendix A.3 Drawing List (Refer to the Addendum and Testing Results section of Appendix B for actual drawing list for your application.) D-82770 Outline Diagram D-83119 Wiring Diagram C-82772 Piping Diagram B-74678 Schematic, Electrometer PCB D-65506 Schematic, Back Panel/Power Supply PCB...
  • Page 71 Appendix Model 4060TCD Teledyne Analytical Instruments...

  • Page 72: B1 Addendum And Testing Results

    Model 4060TCD Appendix Appendix B B1 Addendum and Testing Results Teledyne Analytical Instruments...
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