User ManualTable of ContentsPART I –GENERAL INFORMATION231. INTRODUCTION251.1. M300E FAMILY OVERVIEW251.2. ADDITIONAL DOCUMENTATION261.2.1. USING THIS MANUAL272. SPECIFICATIONS AND APPROVALS292.1. SPECIFICATIONS292.2. EPA EQUIVALENCY DESIGNATION302.3. TUV DESIGNATION312.4. CE MARK COMPLIANCE312.4.1. EMISSIONS COMPLIANCE312.4.2. SAFETY COMPLIANCE313. GETTING STARTED333.1. M300E/EM ANALYZER LAYOUT333.2. UNPACKING THE M300E/EM ANALYZER393.2.1. VENTILATION CLEARANCE403.3. ELECTRICAL CONNECTIONS403.3.1. POWER CONNECTION403.3.2. ANALOG OUTPUT CONNECTIONS413.3.3. CONNECTING THE STATUS OUTPUTS413.3.4. CONNECTING THE CONTROL INPUTS433.3.5. CONNECTING THE SERIAL PORTS443.3.6. CONNECTING TO A LAN OR THE INTERNET443.3.7. CONNECTING TO A MULTIDROP NETWORK443.4. PNEUMATIC CONNECTIONS443.4.1. CALIBRATION GASES443.4.1.1. Zero Air443.4.1.2. Span Gas453.4.2. PNEUMATIC CONNECTIONS TO M300E/EM BASIC CONFIGURATION463.4.2.1. Sample Gas Source473.4.2.2. Calibration Gas Sources473.4.2.3. Input Gas Venting483.4.2.4. Exhaust Outlet483.5. INITIAL OPERATION483.5.1. STARTUP493.5.2. WARM UP503.5.3. WARNING MESSAGES503.5.4. FUNCTIONAL CHECK523.6. INITIAL CALIBRATION OF THE M300E/EM533.6.1. INTERFERENTS FOR CO2 MEASUREMENTS533.6.2. INITIAL CALIBRATION PROCEDURE FOR M300E/EM ANALYZERS WITHOUT OPTIONS533.6.2.1. Verifying the M300E/EM Reporting Range Settings543.6.2.2. Dilution Ratio Set Up553.6.2.3. Set CO Span Gas Concentration563.6.2.4. Zero/Span Calibration573.6.3. O2 SENSOR CALIBRATION PROCEDURE583.6.4. CO2 SENSOR CALIBRATION PROCEDURE584. FREQUENTLY ASKED QUESTIONS594.1. FAQ’S594.2. GLOSSARY605. OPTIONAL HARDWARE AND SOFTWARE635.1. EXTERNAL PUMPS (OPTIONS 10A-10E, 11, 13)635.2. RACK MOUNT KITS (OPT 20 TO OPT 23)635.3. CARRYING STRAP/HANDLE (OPT 29)645.4. CURRENT LOOP ANALOG OUTPUTS (OPTION 41)645.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS655.5. EXPENDABLES AND SPARES KITS (OPTIONS 42A, 45)665.6. CALIBRATION VALVES (OPTIONS 50A, 50B, 50E, 50H)665.6.1. GENERAL INFORMATION RELATED TO ALL VALVE OPTIONS665.6.1.1. Gas Flow Rate665.6.1.2. Valve Control665.6.2. ZERO/SPAN VALVE (OPTION 50A)665.6.2.1. Internal Pneumatics (OPT 50A)675.6.2.2. Pneumatic Set Up (OPT 50A)685.6.2.3. Input Gas Venting685.6.2.4. Exhaust Outlet685.6.3. ZERO/SPAN/SHUTOFF VALVE (OPTION 50B)695.6.3.1. Internal Pneumatics (OPT 50B)695.6.3.2. Pneumatic Set Up (OPT 50B)705.6.4. ZERO/SPAN VALVE WITH INTERNAL CO SCRUBBER (OPTION 50H)715.6.4.1. Internal Pneumatics (OPT 50H)715.6.4.2. Pneumatic Set Up (OPT 50H)725.6.5. ZERO/SPAN/SHUTOFF WITH INTERNAL ZERO AIR SCRUBBER (OPTION 50E)735.6.5.1. Internal Pneumatics (OPT 50E)735.6.5.2. Pneumatic Set Up (OPT 50E)745.7. COMMUNICATION OPTIONS755.7.1. RS-232 MODEM CABLE (OPTION 60A)755.7.2. RS-232 MULTIDROP (OPTION 62)755.7.3. ETHERNET (OPTION 63A)765.7.4. ETHERNET + MULTIDROP (OPT 63C)775.8. SECOND GAS SENSORS775.8.1. OXYGEN SENSOR (OPTION 65A)775.8.1.1. Theory of Operation - Paramagnetic measurement of O2775.8.1.2. Operation within the M300E/EM Analyzer785.8.1.3. Pneumatic Operation of the O2 Sensor785.9. CARBON DIOXIDE SENSOR (OPTION 67A)795.9.1. CO2 SENSOR RANGES AND SPECIFICATIONS795.9.2. THEORY OF OPERATION795.9.2.1. NDIR measurement of CO2795.9.2.2. Operation within the M300E/EM Analyzer805.9.2.3. Pneumatic Operation of the CO2 Sensor805.9.2.4. Electronic Operation of the CO2 Sensor815.10. CONCENTRATION ALARM RELAY (OPTION 61)825.11. SPECIAL FEATURES845.11.1. DILUTION RATIO OPTION845.11.2. MAINTENANCE MODE SWITCH845.11.3. SECOND LANGUAGE SWITCH84PART II –OPERATING INSTRUCTIONS856. BASIC OPERATION876.1. OVERVIEW OF OPERATING MODES876.2. SAMPLE MODE886.3. WARNING MESSAGES906.4. CALIBRATION MODE916.5. SETUP MODE926.5.1. SETUP ( CFG: CONFIGURATION INFORMATION936.5.2. SETUP ( ACAL: AUTOMATIC CALIBRATION936.5.3. SETUP ( PASS: PASSWORD FEATURE946.5.4. SETUP ( CLK: SETTING THE M300E/EM ANALYZER’S INTERNAL CLOCK976.5.4.1. Setting the internal Clock’s Time and Day976.5.4.2. Adjusting the Internal Clock’s Speed986.6. SETUP ( RNGE: ANALOG OUTPUT REPORTING RANGE CONFIGURATION996.6.1. PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING RANGES996.6.2. ANALOG OUTPUT RANGES FOR CO CONCENTRATION1006.6.3. REPORTING RANGE MODES1016.6.3.1. RNGE ( MODE ( SNGL: Configuring the M300E/EM Analyzer for SINGLE Range Mode1026.6.3.2. RNGE ( MODE ( DUAL: Configuring the M300E/EM Analyzer for DUAL Range Mode1036.6.3.3. RNGE ( MODE ( AUTO: Configuring the M300E/EM Analyzer for AUTO Range Mode1056.6.4. SETUP ( RNGE ( UNIT: SETTING THE REPORTING RANGE UNITS OF MEASURE1066.6.5. SETUP (RNGE ( DIL: USING THE OPTIONAL DILUTION RATIO FEATURE1077. ADVANCED FEATURES1097.1. SETUP ( IDAS: USING THE DATA ACQUISITION SYSTEM (IDAS)1097.1.1. IDAS STATUS1097.1.2. IDAS STRUCTURE1107.1.2.1. iDAS Channels1107.1.3. DEFAULT IDAS CHANNELS1117.1.4. SETUP (DAS (VIEW: VIEWING IDAS CHANNELS AND INDIVIDUAL RECORDS1137.1.5. SETUP (DAS (EDIT: ACCESSING THE IDAS EDIT MODE1147.1.5.1. Editing iDAS Data Channel Names1157.1.5.2. Editing iDAS Triggering Events1167.1.5.3. Editing iDAS Parameters1177.1.5.4. Editing Sample Period and Report Period1197.1.5.5. Report Periods in Progress When Instrument Is Powered Off1207.1.5.6. Editing the Number of Records1217.1.5.7. RS-232 Report Function1227.1.5.8. Enabling/Disabling the HOLDOFF Feature1237.1.5.9. The Compact Report Feature1247.1.5.10. The Starting Date Feature1247.1.6. DISABLING/ENABLING DATA CHANNELS1247.1.7. REMOTE IDAS CONFIGURATION1257.1.7.1. iDAS Configuration Using APICOM1257.1.7.2. iDAS Configuration Using Terminal Emulation Programs1267.2. SETUP ( MORE ( VARS: INTERNAL VARIABLES (VARS)1277.3. SETUP ( MORE ( DIAG: USING THE DIAGNOSTICS FUNCTIONS1297.3.1. ACCESSING THE DIAGNOSTIC FEATURES1307.4. USING THE M300E/EM ANALYZER’S ANALOG OUTPUTS.1317.4.1. ACCESSING THE ANALOG OUTPUT SIGNAL CONFIGURATION SUBMENU1317.4.2. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION1337.4.3. CALIBRATION OF THE ANALOG OUTPUTS1357.4.3.1. Enabling or Disabling the AutoCal for an Individual Analog Output1357.4.3.2. Automatic Calibration of the Analog Outputs1367.4.3.3. Individual Calibration of the Analog Outputs1387.4.3.4. Manual Calibration of the Analog Outputs Configured for Voltage Ranges1397.4.3.5. Manual Adjustment of Current Loop Output Span and Offset1417.4.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE ON/OFF1447.4.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT1457.4.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A41467.4.7. AIN CALIBRATION1487.5. SETUP (MORE ( ALRM: USING THE GAS CONCENTRATION ALARMS1497.5.1. SETTING THE M300E CONCENTRATION ALARM LIMITS1498. REMOTE OPERATION1518.1. SETUP ( MORE( COMM: USING THE ANALYSER’S COMMUNICATION PORTS1518.1.1. RS-232 DTE AND DCE COMMUNICATION1518.1.2. COMM PORT DEFAULT SETTINGS1518.1.3. COMM PORT BAUD RATE1538.1.4. COMM PORT COMMUNICATION MODES1548.1.5. COMM PORT TESTING1568.1.6. MACHINE ID1578.1.7. TERMINAL OPERATING MODES1588.1.7.1. Help Commands in Terminal Mode1588.1.7.2. Command Syntax1598.1.7.3. Data Types1598.1.7.4. Status Reporting1608.1.7.5. COMM Port Password Security1618.2. MULTIDROP RS-232 SET UP1628.3. RS-485 CONFIGURATION OF COM21648.4. REMOTE ACCESS VIA THE ETHERNET1668.4.1. ETHERNET CARD COM2 COMMUNICATION MODES AND BAUD RATE1668.4.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP1678.4.3. MANUALLY CONFIGURING THE NETWORK IP ADDRESSES1698.4.4. CHANGING THE ANALYZER’S HOSTNAME1728.5. MODBUS SETUP1738.5.1. REMOTE ACCESS BY MODEM1748.6. USING THE M300E/EM WITH A HESSEN PROTOCOL NETWORK1778.6.1. GENERAL OVERVIEW OF HESSEN PROTOCOL1778.6.2. HESSEN COMM PORT CONFIGURATION1778.6.3. ACTIVATING HESSEN PROTOCOL1788.6.4. SELECTING A HESSEN PROTOCOL TYPE1798.6.5. SETTING THE HESSEN PROTOCOL RESPONSE MODE1808.6.6. HESSEN PROTOCOL GAS LIST ENTRIES1818.6.6.1. Gas List Entry Format and Definitions1818.6.6.2. Editing or Adding HESSEN Gas List Entries1828.6.6.3. Deleting HESSEN Gas List Entries1838.6.7. SETTING HESSEN PROTOCOL STATUS FLAGS1848.6.8. INSTRUMENT ID CODE1858.7. APICOM REMOTE CONTROL PROGRAM1869. CALIBRATION PROCEDURES1879.1. BEFORE CALIBRATION1889.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES1889.1.2. CALIBRATION GASES1889.1.2.1. Zero Air1889.1.2.2. Span Gas1899.1.2.3. Traceability1899.1.3. DATA RECORDING DEVICES1899.2. MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE M300E/EM ANALYZER IN ITS BASE CONFIGURATION1909.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION1909.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK1929.2.3. PERFORMING A BASIC MANUAL CALIBRATION1939.2.3.1. Setting the Expected Span Gas Concentration1939.2.3.2. Zero/Span Point Calibration Procedure1949.3. MANUAL CALIBRATION WITH ZERO/SPAN VALVES1959.3.1. SETUP FOR CALIBRATION USING VALVE OPTIONS1959.3.2. MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS INSTALLED1979.3.3. MANUAL CALIBRATION USING VALVE OPTIONS1989.3.3.1. Setting the Expected Span Gas Concentration1989.3.3.2. Zero/Span Point Calibration Procedure1999.3.3.3. Use of Zero/Span Valve with Remote Contact Closure2009.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL)2009.4.1. SETUP ( ACAL: PROGRAMMING AND AUTO CAL SEQUENCE2039.4.1.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected2059.5. CO CALIBRATION QUALITY2069.6. CALIBRATION OF THE M300E/EM’S ELECTRONIC SUBSYSTEMS2079.6.1. DARK CALIBRATION TEST2079.6.2. PRESSURE CALIBRATION2089.6.3. FLOW CALIBRATION2099.6.4. ELECTRICAL TEST CALIBRATION2109.7. CALIBRATION OF OPTIONAL SENSORS2119.7.1. O2 SENSOR CALIBRATION PROCEDURE2119.7.1.1. O2 Calibration Setup2119.7.1.2. Set O2 Span Gas Concentration2129.7.1.3. Activate O2 Sensor Stability Function2139.7.1.4. O2ZERO/SPAN CALIBRATION2149.7.2. CO2 SENSOR CALIBRATION PROCEDURE2159.7.2.1. CO2 Calibration Setup2159.7.2.2. Set CO2 Span Gas Concentration:2159.7.2.3. Activate CO2 Sensor Stability Function2169.7.2.4. CO2 Zero/Span Calibration21710. EPA CALIBRATION PROTOCOL21910.1. CALIBRATION REQUIREMENTS21910.1.1. CALIBRATION OF EQUIPMENT - GENERAL GUIDELINES21910.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES22010.1.2.1. Data Recording Device22010.1.2.2. Spare Parts and Expendable Supplies22010.1.3. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY22110.1.4. CALIBRATION FREQUENCY22210.1.5. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS22210.2. ZERO AND SPAN CHECKS22310.2.1. ZERO/SPAN CHECK PROCEDURES22410.2.2. PRECISION CHECK22410.3. PRECISIONS CALIBRATION22410.3.1. PRECISION CALIBRATION PROCEDURES22510.4. AUDITING PROCEDURE22510.4.1. CALIBRATION AUDIT22510.4.2. DATA REDUCTION AUDIT22510.4.3. SYSTEM AUDIT/VALIDATION22610.5. DYNAMIC MULTIPOINT CALIBRATION PROCEDURE22610.5.1. LINEARITY TEST22610.6. REFERENCES228PART III –TECHNICAL INFORMATION22911. THEORY OF OPERATION23111.1. MEASUREMENT METHOD23111.1.1. BEER’S LAW23111.2. MEASUREMENT FUNDAMENTALS23111.2.1. GAS FILTER CORRELATION23211.2.1.1. The GFC Wheel23311.2.1.2. The Measure Reference Ratio23411.2.1.3. Summary Interference Rejection23511.3. PNEUMATIC OPERATION23611.4. FLOW RATE CONTROL23711.4.1.1. Critical Flow Orifice23711.4.2. PARTICULATE FILTER23811.4.3. PNEUMATIC SENSORS23811.4.3.1. Sample Pressure Sensor23811.4.3.2. Sample Flow Sensor23811.5. ELECTRONIC OPERATION23911.5.1. OVERVIEW23911.5.2. CENTRAL PROCESSING UNIT (CPU)24111.5.3. OPTICAL BENCH & GFC WHEEL24211.5.3.1. Temperature Control24211.5.3.2. IR Source24211.5.3.3. GFC Wheel24211.5.3.4. IR Photo-Detector24411.5.4. SYNCHRONOUS DEMODULATOR (SYNC/DEMOD) ASSEMBLY24411.5.4.1. Overview24411.5.4.2. Signal Synchronization and Demodulation24511.5.4.3. Sync/Demod Status LED’s24611.5.4.4. Photo-Detector Temperature Control24611.5.4.5. Dark Calibration Switch24611.5.4.6. Electric Test Switch24711.5.5. RELAY BOARD24711.5.5.1. Heater Control24711.5.5.2. GFC Wheel Motor Control:24711.5.5.3. Zero/Span Valve Options24711.5.5.4. IR Source24711.5.5.5. Status LED’s24811.5.5.6. I2C Watch Dog Circuitry24811.5.6. MOTHERBOARD24911.5.6.1. A to D Conversion24911.5.6.2. Sensor Inputs24911.5.6.3. Thermistor Interface24911.5.6.4. Analog Outputs25011.5.6.5. Internal Digital I/O25011.5.6.6. External Digital I/O25011.5.7. I2C DATA BUS25111.5.8. POWER SUPPLY/ CIRCUIT BREAKER25111.5.9. COMMUNICATION INTERFACE25311.5.10. FRONT PANEL INTERFACE25411.5.10.1. Analyzer Status LED’s25411.5.10.2. Keyboard25411.5.10.3. Display25511.5.10.4. Keyboard/Display Interface Electronics25511.5.11. SOFTWARE OPERATION25811.5.12. ADAPTIVE FILTER25811.5.13. CALIBRATION - SLOPE AND OFFSET25911.5.14. MEASUREMENT ALGORITHM25911.5.15. TEMPERATURE AND PRESSURE COMPENSATION25911.5.16. INTERNAL DATA ACQUISITION SYSTEM (IDAS)25912. MAINTENANCE SCHEDULE & PROCEDURES26112.1. MAINTENANCE SCHEDULE26112.2. PREDICTING FAILURES USING THE TEST FUNCTIONS26512.3. MAINTENANCE PROCEDURES26612.3.1. REPLACING THE SAMPLE PARTICULATE FILTER26612.3.2. REBUILDING THE SAMPLE PUMP26612.3.3. PERFORMING LEAK CHECKS26712.3.3.1. Vacuum Leak Check and Pump Check26712.3.3.2. Pressure Leak Check26712.3.4. PERFORMING A SAMPLE FLOW CHECK26812.3.5. CLEANING THE OPTICAL BENCH26812.3.6. CLEANING EXTERIOR SURFACES OF THE M300E/EM26813. TROUBLESHOOTING & REPAIR26913.1. GENERAL TROUBLESHOOTING26913.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES27013.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS27213.1.3. DIAG ( SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O FUNCTION27513.1.4. INTERNAL ELECTRONIC STATUS LED’S27613.1.4.1. CPU Status Indicator27613.1.4.2. Sync Demodulator Status LED’s27713.1.4.3. Relay Board Status LED’s27813.2. GAS FLOW PROBLEMS28013.2.1. M300E/EM INTERNAL GAS FLOW DIAGRAMS28013.2.2. TYPICAL SAMPLE GAS FLOW PROBLEMS28413.2.2.1. Flow is Zero28413.2.2.2. Low Flow28413.2.2.3. High Flow28413.2.2.4. Displayed Flow = “Warnings”28513.2.2.5. Actual Flow Does Not Match Displayed Flow28513.2.2.6. Sample Pump28513.3. CALIBRATION PROBLEMS28513.3.1. MISCALIBRATED28513.3.2. NON-REPEATABLE ZERO AND SPAN28613.3.3. INABILITY TO SPAN – NO SPAN KEY28613.3.4. INABILITY TO ZERO – NO ZERO KEY28613.4. OTHER PERFORMANCE PROBLEMS28713.4.1. TEMPERATURE PROBLEMS28713.4.1.1. Box or Sample Temperature28713.4.1.2. Bench Temperature28713.4.1.3. GFC Wheel Temperature28813.4.1.4. IR Photo-Detector TEC Temperature28813.4.2. EXCESSIVE NOISE28913.5. SUBSYSTEM CHECKOUT29013.5.1. AC MAINS CONFIGURATION29013.5.2. DC POWER SUPPLY29013.5.3. I2C BUS29113.5.4. KEYBOARD/DISPLAY INTERFACE29113.5.5. RELAY BOARD29213.5.6. SENSOR ASSEMBLY29313.5.6.1. Sync/Demodulator Assembly29313.5.6.2. Electrical Test29313.5.6.3. Opto Pickup Assembly29413.5.6.4. GFC Wheel Drive29413.5.6.5. IR Source29413.5.6.6. Pressure/Flow Sensor Assembly29513.5.7. MOTHERBOARD29613.5.7.1. A/D Functions29613.5.7.2. Test Channel / Analog Outputs Voltage29613.5.7.3. Analog Outputs: Current Loop29713.5.7.4. Status Outputs29813.5.7.5. Control Inputs – Remote Zero, Span29913.5.8. CPU29913.5.9. RS-232 COMMUNICATIONS29913.5.9.1. General RS-232 Troubleshooting29913.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation30013.5.10. THE OPTIONAL CO2 SENSOR30013.6. REPAIR PROCEDURES30113.6.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY30113.6.2. REMOVING/REPLACING THE GFC WHEEL30213.6.3. CHECKING AND ADJUSTING THE SYNC/DEMODULATOR, CIRCUIT GAIN (CO MEAS)30413.6.3.1. Checking the Sync/Demodulator Circuit Gain30413.6.3.2. Adjusting the Sync/Demodulator, Circuit Gain30513.6.4. DISK-ON-MODULE REPLACEMENT PROCEDURE30613.7. TECHNICAL ASSISTANCE30614. A PRIMER ON ELECTRO-STATIC DISCHARGE30714.1. HOW STATIC CHARGES ARE CREATED30714.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE30814.3. COMMON MYTHS ABOUT ESD DAMAGE30914.4. BASIC PRINCIPLES OF STATIC CONTROL30914.4.1. GENERAL RULES30914.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE31114.4.2.1. Working at the Instrument Rack31114.4.2.2. Working at an Anti-ESD Work Bench31114.4.2.3. Transferring Components from Rack to Bench and Back31214.4.2.4. Opening Shipments from Teledyne API’ Customer Service31214.4.2.5. Packing Components for Return to Teledyne API’s Customer Service313M300E Spare Parts List363M300EM Spare Parts List365300EM Recom Spares Stkng Levl367Indented Bill Of Material Costs368M300E-M300EU Rec Sp Pt Stk Lvl370Indented Bill Of Material Costs369Sheet1375Size: 11.9 MBPages: 398Language: EnglishOpen manual