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.
Series 4030 Copyright © 2004 Teledyne Analytical Instruments All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any other language or computer language in whole or in part, in any form or by any means, whether it be electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91749-1580.
Series 4030 Safety Messages Your safety and the safety of others are 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. These symbols are found in the manual and inside the instrument.
Series 4030 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. This manual provides information designed to guide you through the installation, calibration and operation of your new analyzer. Please read this manual and keep it available.
Series 4030 Additional Safety Information DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage 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. The customer should ensure that the principles of operating of this equipment are well understood by the user.
Series 4030 system. See the procedures for purging and leak checking this instrument on the following pages. If toxic gases or other hazardous materials are introduced into the sample system, the same precautions regarding leak checking and purging apply to the sample lines and sample supply or delivery lines. WARNING: ELECTRICAL SHOCK HAZARD.
Series 4030 Procedure for Removal of Internal Inaccessible Shock Hazards CAUTION: SERVICING OR MAINTENANCE OF THE ANALYZER SHOULD ONLY BE DONE BY SUITABLE TRAINED PERSONNEL. TO AVOID THESE INACCESSIBLE HAZARDOUS VOLTAGES WHEN SERVICING THE SERIES 4060, PERFORM EACH OF THE FOLLOWING STEPS, IN THE ORDER GIVEN, BEFORE SERVICING BEGINS: Switch off the power to the Analyzer and remove the main (line) power cord from the Analyzer. Remove all external voltages from the connections to the alarm contacts.
Series 4030 DEPENDING ON THE APPLICATION, MAY ALSO USE TOXIC GASES. IT IS THEREFORE, THE CUSTOMER'S RESPONSIBILITY TO ENSURE THAT PROPER TRAINING AND UNDERSTANDING OF THE 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.
Introduction Introduction Teledyne Analytical Instruments Series 4030 Total Hydrocarbon (THC) Analyzer is designed to measure the quantity of hydrocarbons present in a heated sample gas, such as gaseous mixtures or ambient air in various industrial applications. 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).
Introduction 2. High resolution, accurate readings of concentration. 3. Versatile analysis with three user-definable analysis ranges. 4. Microprocessor based electronics: 8-bit CMOS microprocessor with 32 KB RAM and 128 KB ROM. 5. Auto ranging allows analyzer to automatically select the proper preset range for a given measurement. Manual override allows the user to lock onto a specific range of interest. 6. Two adjustable concentration alarms and a system failure alarm. 7.
Introduction on the customer’s requirements. The appropriate power cord for your unit has been shipped with this instrument. 1.4 Applications . Monitoring the ambient air for Total Hydrocarbons in chemical and petrochemical plants. . Fugitive emission monitoring. . Process emission gases in the chemical industry. 2.
Introduction The Series 4030 Analyzer is composed of three subsystems: 1. Sample System 2. Detector Cell 3. Electronic Signal Processing, Display and Control 2.2 Sample System The Analyzer contains two (2) separate isothermal chambers controlled by individual PID temperature controllers, viewed just behind the Front Panel. The three chambers, ‘SAMPLE’ and ‘FID are described below. The Analyzer consists of a SAMPLE CHAMBER containing the 10port switching valve and 2 sample loops.
Introduction 2.2.2 Gas Flow Control System The Piping diagram is in the rear of this manual. A 10 port-switching valve is used to control and direct gas flows to the FID detector. The fixed volume sample loop ensures the same volume of sample injection in the Analyzer every cycle. 2.2.3 Fuel and Blanket Air Systems Stable flow is achieved by maintaining a constant pressure across restrictors upstream from the cell. Each system incorporates an adjustable pressure regulator, pressure gauge, and restrictor.
Introduction The anode-igniter, as its name implies, serves two functions. When relay K2 at PCB part number B74671 is energized, the coil becomes an electrical heating element that glows red-hot and ignites the hydrogen fuel. When relay K2 at B74671 is de-energized, the coil is connected to the +260 volt DC terminal of the anode-flame guard power supply PC board.
Introduction Figure 2-1: Flame Ionization Cell The electrode section of the cell may be removed for inspection by turning off the power, disconnecting the electrode lead plug, and removing the screws, which retain the electrode assembly in the sensor body. 2.3.1 Electrometer-Amplifier The collector cable is coupled directly to a coaxial fitting located on the electrometer-amplifier PC board. The PC board is located on the side panel next to but outside of the isothermal chamber.
Introduction nominally 125 volts. Output tolerance is ±10 volts from the specified 125 volts. 2.3.3 Flame Guard Circuit A thermistor-controlled, transistorized switching circuit is employed to operate a relay in the event of a flameout condition. A panel indicator light and fuel shut-off solenoid valve are operated by the relay to alarm personnel that a flameout condition has occurred. The fuel shut-off solenoid valve stops the hydrogen flow. 2.3.
Installation Installation Installation of the Series 4030 Analyzer includes: 1. Unpacking 2. Mounting 3. Gas connections 4. Electrical connections 5. Testing the system. 3.1 Unpacking the Analyzer Although the Analyzer is shipped with all the materials you need to install and prepare the system for operation. Carefully unpack the Analyzer and inspect it for damage. Immediately report any damage or shortages to the shipping agent. 3.
Installation Regardless of configuration, the analyzer/system must be installed on a level surface with sufficient space allocated on either side for personnel and test equipment access. Subject to the foregoing, the Analyzer/system should be placed as close to the sample point as is possible. All pertinent dimensions, connecting points, and piping details can be found in the drawings section as part of the outline, input-output, and piping diagrams.
Installation Figure 3-1: 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”.
Installation Before tubing is connected to the system, it must be decontaminated to rid it of hydrocarbon deposits. Using a small torch, heat each length of tubing, while passing nitrogen through it, until it glows red. Begin at the nitrogen source end and proceed down the length of the tube, “chasing” the red glow (and hydrocarbon deposits) down to the open end of the tube. Cap tubing while not in use with suitable noncontaminating caps.
Installation THE ANALYZER WITH ITS FASTENING SCREWS. ULTIMATELY, IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI/RFI SIELDING. 3.3.3.1 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.
Installation Both the first and third set of outputs as well as the second and fourth set of outputs may be set to any of the following functions: - THC -- Total hydrocarbon as measured in the first phase of detection. The output is the percentage of the selected range. - SMP -- An alternate measurement that occurs during the second phase of detection. The output represents the percentage of the selected range. - WAVE – Analogous to the continuous output of the FID. - RID – Indicates the selected range.
Installation 3.3.3.5 ALARM RELAYS The nine alarm-circuit connector pins connect to the internal alarm relay contacts. Each set of three pins provides one set of Form C relay contacts. 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.
Installation Table 3-2: Alarm Relay Contact Pins Pin 45 28 46 42 44 43 36 20 37 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 Threshold Alarm 2, normally open contact System Alarm, normally closed contact System Alarm, moving contact System Alarm, normally open contact 3.3.3.6 RANGE ID RELAYS There are three dedicated Range ID relay contacts.
Installation 3.3.3.7 NETWORK I/O 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 (–). 3.3.3.8 Pin Out Table The following table summarizes all the outputs/inputs available in the 50-pin D-Sub connector on the back panel of the Analyzer.
Installation 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Exhaust Solenoid Hot Sample Solenoid Hot Range 4 Contact/ not used Range 4 Contact/not used Alarm 3 NC Contact Alarm 3 NO Contact Range 1 Contact Range 2 Contact Alarm 2 NC Contact Alarm 2 NO Contact Alarm 2 C Contact Alarm 1 NC Contact Alarm 1 NO Contact Exhaust Solenoid Return Sample Solenoid Return 3.3.
Installation Implementation: The RS-232 protocol allows some flexibility in its implementation. Table 3-6 lists certain RS-232 values that are required by the Model 4030 implementation. Table 3-6: Required RS-232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits Message Interval 1 Sent at the end of each cycle. 3.3.5 Supporting Gases Normally, four supporting gases of different composition (see Section 4.1: Equipment) will be required to operate the analyzer.
Installation CAUTION: THE GASES USED MUST BE OF THE HIGHEST QUALITY, ULTRA ZERO GRADES, AS SHOWN BELOW. FAILURE TO DO SO WILL RESULT IN CONTAMINATION AND FAILURE TO DETECT LOW CONCENTRATIONS OF HYDROCARBONS. AIR: USE ULTRA ZERO GRADE AIR WITH THC LESS THAN 0.1 PPM. DO NOT USE OIL PUMPED AIR UNDER ANY CIRCUMSTANCES. FUEL: USE ULTRA HIGH PURITY (UHP) GRADE HYDROGEN WITH THC LESS THAN 0.5 PPM. CARRIER GAS: USE ULTRA HIGH PURITY GRADE NITROGEN GAS, WITH THC LESS THAN 0.1 PPM. 3.3.5.
Operation Operation 4.1 Placing the System in Operation 1. Plug the power in the AC power inlet in the back of the Analyzer and the Sample Selector Unit. 2. Allow at least 2 hours warm-up (heat up sensor & sample system) after making the air adjustment described below. Warm up time is set by the software at the factory but may be overridden by pressing the key. DO NOT attempt to ignite the flame during warm up countdown. Condensation will occur. 4.2 Activating the Support Gases 4.2.1 Air 1.
Operation 4.2.4 Fuel 1. Open the main valve on the tank and set the fuel tank pressure regulator to 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 BYPASS FLOW Figure 4-1: Front Panel View of Regulator and Gages 4.
Operation the temperature controller is maintaining the temperature set point) and the red flame failure lamp is on. See Figure 4-1. The Series 4030 will automatically attempt a flame ignition sequence following the warm up period, which has been preset at the factory. If the ignition process fails, the instrument will attempt to ignite the flame 4 more times. If it continues to fail after the fifth attempt, a flame failure message will appear on the display. If this occurs refer to Section 4.3.1. 4.3.
Operation Depending on the specifics of the application, this might include all or a set of the following procedures: 1. Setting system parameters 1. Establish a security password, if desired, requiring operator to log in 2. Establish and start an automatic calibration cycle (not available) 3. Choose auto ranging or select a fixed range of analysis 4. Set alarm set points and modes of alarm operation 5. Calibrate analog output, select analog output source. 2. Routine operation 1.
Operation 4.4.1 Default Parameters The versatility of this analyzer usually results in significant changes being made to parameters over the course of time to better suit a particular application. Occasionally processes change requiring alteration to alarms, ranges etc. At some time, it may be beneficial to reset the analyzer to the default conditions as it was when shipped from the factory.
Operation Screen Modes: Screen Readout: particular key it will be typed as text using all caps. Example: this is the ENTER key. Times New Roman 12 pt. italic. Example: Analysis Mode or Setup Mode. Arial Narrow, 12 pt bold. Example: AUTOCAL or Zero in 12 days. 4.4.
Operation - Dynamic (real time) FID input level - Time spent in mode - Range - Activity indicator LINE 2 display mode 2 data: - Current analysis mode - Analysis TOTAL AREA from most recent pass of current mode. - Time spent in mode - Range - Activity Indicator 3. 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.
Operation saving the value. The value will revert to the original before modification (if any). 4.4.4 Menu Structure The 4030 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.
Operation 11. MODIFIABLE ITEM screens have a flashing value somewhere in the line. 4.4.4.1 MAIN MENUS The MAIN MENU consists of 13 functions you can use to customize and check the operation of the analyzer. They are listed here with brief descriptions: 1. AUTO-CAL: Used to define and/or start an automatic calibration sequence. AUTOCAL is not available for standard configurations of the 4030. 2. GAIN: Used to change the amplification of the incoming signal. This is factory set, and should not change. 3.
Operation ENTER it. The analyzer will immediately start that function, unless password restrictions have been assigned. (Password assignment is explained in Section 4.4.10). 4.4.4.2 EXPANDED MENUS An exhaustive list of menu messages is provided as follows. AUTOCAL ----------------------AUTO SPAN NOT AVAILABLE ----------------------- AUTOCAL is not available for standard configurations of the 4030.
Operation Password Mismatch ----------------------Password Changed! ----------------------LOGOUT ----------------------Restrict Access? ENTER-YES ESCAPE-NO ----------------------MODEL ----------------------4030 THC Monitor V1.
Operation SPAN ----------------------THC Span ?: Yes SMP Span ?: No THC Sp: 8.00 ppm SMP Sp: 0.00 ppm Span Begin --------------------------------------------Begin Span? ENTER-YES ESCAPE-NO ----------------------ALARMS ----------------------AL-1 DEFEATED AL-1 HIGH AL-1 NON-FAILSAFE AL-1 NON-LATCHING 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.
Operation ----------------------ANALOG-OUT ADJUST ----------------------CH1 mA Offset: 0 CH1 mA Gain: 0 CH1 Select: THC CH2 Select: WAVE ----------------------CHANGE STREAM ----------------------CHANGE STREAM NOT AVAILABLE ----------------------TIMING ----------------------THC I/P: 100%/00% THC TIME: 05m00s THC I Begin: 00m05s THC I End: 00m05s 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
Operation ----------------------STANDBY Switch to Sleep Mode ENTER-YES ESCAPE-NO notification if logged out ----------------------Access Restricted Re-enter Password ----------------------- 4.4.5 Setting up an AUTO-CAL AUTOCAL is not available for standard configurations of the 4040. 4.4.6 Adjusting the GAIN The output of the FID is conditioned by an amplification circuit with 3 user-adjustable settings: 0) x1 1) x10 2) x100 The resulting signal is converted to a number.
Operation To setup the GAIN: 1) From the Analysis Screen, press an arrow key to enter the Setup Mode. The VFD will display the first 2 lines of functions available. ________________________________________________ -> GAIN ADJUST PASSWORD ________________________________________________ <▲▼> If the arrow is not adjacent to the GAIN ADJUST menu item, use the ▲▼ keys to move the arrow to the proper position. Press to activate the function and move you to the next screen.
Operation Note however, that the instrument can still be used for analysis without entering the password. To defeat security the password must be entered. Note: If you use password security, it is strongly advised to keep a copy of the password in a separate, safe location. If the password is lost and security is enabled, the analyzer must be cold-booted. Cold booting invalidates parameters necessary for correct operation so they must be reentered.
Operation The last enters the password. Steps back to the previously entered letter or, if on the first letter, returns to the MAIN MENU. If the correct password has been entered the 4040 now allows access to all the SUBMENU items. The 4040 next presents the CHANGE PASSWORD screen.
Operation ________________________________________________ Reenter a new Password 'A' 'A' 'A' ________________________________________________ Note that the new password has been replaced by 'A' as placeholder characters. This is to ensure that the wrong password is not mistakenly entered. <▲▼> Use the ▲▼ keys to reenter the letters of the new password.
Operation Pressing 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: 17. PASSWORD 18. LOGOUT (which only repeats the logout) 19. MODEL Note however, that the instrument can still be used for analysis without entering the password. To defeat security the password must be entered. 4.4.8 The Model Screen The MODEL screen displays the model, and software version information.
Operation ________________________________________________ Start the diagnostic testing routine by pressing or cancel out by pressing . If you pressed the self-test routine will begin and after a few moments the results will appear onscreen. The module is functioning properly if it is followed by OK otherwise it is followed by BAD. In this case, please contact TAI Customer Service for an explanation of the problem.
Operation The first line determines whether a span calculation will be performed for THC. The second line determines whether a span calculation will be preformed for SMP. The third line allows the user to modify the span target value for THC calibration. The fourth line allows the user to modify the span target value for SMP.
Operation AL-1 AL-1 AL-2 AL-2 AL-2 AL-2 AL-2 AL-2 20.00 ppb SOURCE THC ACTIVE LOW FAILSAFE LATCHING 50.00 ppb SOURCE SMP ________________________________________________ Note: For the purpose of example, Alarm 2 has been set differently than Alarm 1. Note: An alarm in 'alarm condition' is signaling that action must be taken such as correcting the alarm or the analysis concentration. If an active (not defeated) alarm has been set to HIGH at 20.
Operation only during the time the concentration is above the trip point. If that alarm were 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 of the following messages: 'AL1-', 'AL-2', 'AL12'.
Operation The value of the upper limit of the currently selected range (AUTO or MANUAL) affects the voltage and current of the analog outputs on the rear of the analyzer as well as contact closures indicating which range is current. The Analog outputs on the rear of the analyzer represent the proportion of the analysis concentration to the currently selected range limit.
Operation 4.4.14 Analog output Adjustment The software in this instrument provides a way to enter to manage the analog output of the analyzer FOR ANALOG CHANNEL 1 ONLY. To access the offset function: <▲▼> From the MAIN MENU, scroll to the ANALOG ADJUST function using the UP/DOWN keys. Pressing activates the function and takes you to the next screen.
Operation 'Gain: ' plus the Offset value plus a value that is proportionate to the number indicated to the right of 'GAIN:'. If these 2 values are modified and entered and accepted, then the analog output will be affected in like manner in ANALYSIS MODE. That is, it will be scaled by the gain value, then summed with the offset value. The analog output for each channel may be set to source THC, SMP, AVG, WAVE, or R-ID.
Appendix Recommended Spare Parts List Qty. P/N Description 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 B74671 B74677 B30927 C75825A A46128 B-13207 C62371A B74674A C65507A B74677A L79 F77 L156 L154 A33748 V825 CP2408 PC board, Flame guard & anode power supply PC board, Electrometer-amplifier PC board, Temperature control Micro-processor PC board Coaxial cable Sensor Assy. Display PCB Assy. Interface to Motherboard PCB Assy. Backpanel/Power Supply PCB Assy. Electrometer PCB Assy. Lamp, neon Fuse, 6.
Appendix Send orders to: 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 D77215 Model 4030 Outline diagram Wiring diagram (Rev.