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Technical Support FAQ

4020 - Total Hydrocarbon Analyzer

What modifications are required to run a 4020 on H2 as fuel rather than 40% H2 / 60% N2?
How do I bypass the warm up time when I start up the 4020?
How do I reignite the flame when the flame failure message is displayed on the 4020?
On the 4020, is there a flame out alarm to indicate the analyzer has power and is working, but the flame has gone?
On the 4020, when will the system failure alarm de-energize?
When (what kind of application, background gas) should the 40% H2 / 60% N2 fuel be selected?
When (what kind of application, background gas) should the 100% H2 fuel be selected?
When (what kind of application, background gas) should the 100% N2 fuel be selected?
I have an instrument using 40% H2/60% N2 fuel, but I would like to substitute 40/60% of H2/HE. What modifications to the unit are required?
When I change the fuel gas on the unit, the readings change dramatically and take time to come back up. Why is this?
How do I "cold start" the 4020 (i.e. return all parameters to factory default settings)?
Can you give me information about gas consumption? Air and fuel consumption?
If I change the background gas of the unit from Argon to N2 or CO2 or vice versa, do I need to optimize the pressure setttings of the unit for maximum signal?
We have a 4020 currently setup for ranges 0-1, 0-10, 0-100 ppm. How can we reset the ranges for 0-10, 0-100, 0-1000 ppm?
If I have a 4020 with 0 to 10, 100, 1000 ppm ranges, do I have to adjust the ranges in decades?
How can I use one 4020 analyzer for two background gases? (Air and N2)
How do I calibrate the analog outputs?
What is the max inlet pressure the sample regulator can handle? What is the output range of the sample regulator?
Where can I find the 4-20 mA output modules on the computer motherboard?
What is the effect on sample pressure changes to the unit?
Can plant air be used for the air supply for these units?
How do you cold-start the 4020 unit?
Do you have anything that explains the profibus interface for the 4020 and K2001?
What is the average power consumption of the 4020 FID?
We have a model 4020 unit that we need to modify for range and power. The range needs to be 0/1/10/100 ppm instead of 30/300/3000 ppm and power needs to be 220VAC from 110VAC. Please advise how to do this and let us know of precautionary steps to take, if any.
What is the maximum power consumption of the Model 4020 at 110VAC power?
Is the unit reading sensitive to changes in bypass flow rate?
We have two analyzers which do not provide +15V at valve outputs 49/15 and 17/16. Is the 4020 generally supplied with the outputs at the 50 pole d-sub (even the version without cal valves) and can I assume that in my case the transistor outputs are defective?
What's the procedure to perform zero adjustment on the 4020 analyzer?
With a 4020R, when there is no sample in the sensor chamber is there no ignition and flame? Can it be used for discrete measurings when customer will do a few series of measurings per day?
What do the error codes on the 4020 analyzer mean?
Which fuel gas is the best to use for the following application:
Samples include Pure Oxygen, Pure N2O, Pure He, Pure N2. (No H2 samples)
Fuel Gas: 40% H2 / 60% N2, or 40% H2 / 60% H2 or 100% H2
If one calibrates the analyzer in air and then measures THC in bulk N2, how does the accuracy change?
The customer intends to purchase 4020 FID to measure Total Hydrocarbons in CO2.

The pressure is 26 bars and the distance between the take off point and the cabinet of the FID is 100 meters.

1) In the document attached with the piping diagram of 4020, there is a bypass. Regarding the distance of 100 meters, does the customer have to install an external bypass with purge or will the internal bypass be sufficient?

2) What is the response time with 100 meters and internal bypass?
We have some 4020 problems: The fuel valve will not open. There is 30 volt to the valve, should it be 110 volt? The solenoid is 1.6kOhms. The fuses are checked and ok. If a new electronic board is needed what is the part number?
Is there memory in the analyser that can store the user settings on the analyser? After a power loss today the user had to change the settings.

Also, we run calibration gas on a regular bases and they always have to calibrate the analyser. Is there a reason for this variance?


What modifications are required to run a 4020 on H2 as fuel rather than 40% H2 / 60% N2?

Replace the 200cc fuel restrictor with a 30cc, p/n R-598.


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How do I bypass the warm up time when I start up the 4020?

Press the Enter Key


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How do I reignite the flame when the flame failure message is displayed on the 4020?

Press both the Up and Down keys at the same time.


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On the 4020, is there a flame out alarm to indicate the analyzer has power and is working, but the flame has gone?

When the flame goes out, the unit tries to reignite and does not give any system failure alarm. After 5 tries, the system failure alarm will activate. The system alarm is failsafe..


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On the 4020, when will the system failure alarm de-energize?

System failure alarm is de-energized under 3 circumstances; inability to re-ignite, when performing a zero calibration and the signal is too high, or if the system loses power.


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When (what kind of application, background gas) should the 40% H2 / 60% N2 fuel be selected?

The oxygen background must use 40% H2 / 60% N2; all others applications are optional to use this fuel, and H2 does not require this fuel.


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When (what kind of application, background gas) should the 100% H2 fuel be selected?

All applications except O2 and H2.


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When (what kind of application, background gas) should the 100% N2 fuel be selected?

When the background is H2, then we use the sample, span, and zero gases as fuel and the N2 connecting to the fuel port to dilute the H2.


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I have an instrument using 40% H2/60% N2 fuel, but I would like to substitute 40/60% of H2/HE. What modifications to the unit are required?

No modifications are needed. You only need to recalibrate the unit.


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When I change the fuel gas on the unit, the readings change dramatically and take time to come back up. Why is this?

It is always necessary to Recalibrate / Re-standardize the analyzer when the fuel or air supply gases are changed. Refer to your manual for specifics.


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How do I "cold start" the 4020 (i.e. return all parameters to factory default settings)?

Cold start procedures can be found here.

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Can you give me information about gas consumption? Air and fuel consumption?

1) 4020 with H2 fuel coming from sample:
Air: approximately 300ccm
N2: 30 ccm

2) 4020 using 60/40 fuel:
Fuel: 200ccm
Air: aproximatly 300ccm

3) 4020 using H2 fuel:
Fuel: 30 ccm
Air: approximately 300ccm


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If I change the background gas of the unit from Argon to N2 or CO2 or vice versa, do I need to optimize the pressure setttings of the unit for maximum signal?

No. Only a re-calibration on a standard is required (standard cylinders of span and zero gases).


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We have a 4020 currently setup for ranges 0-1, 0-10, 0-100 ppm. How can we reset the ranges for 0-10, 0-100, 0-1000 ppm?

To change the range from 0-1, 0-10, 0-100 to 0-10, 0-100, 0-1000 ppm, you must change out the electrometer board.


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If I have a 4020 with 0 to 10, 100, 1000 ppm ranges, do I have to adjust the ranges in decades?

No, the range doesn't have to be in decades as long as the minimum range is 10 and the maximum is 1000. For example, the low range can be adjusted anywhere from 10 to 90 and the next range can be 0 to 100 and tje highest range can be 0 to 500.


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How can I use one 4020 analyzer for two background gases? (Air and N2)

The operator must manually change the pressure setting when backgrounds are changed.

1. Introduce the span gas with an Air background,
2. Increase the fuel 2 psig over the setting specified in the manual.
3. Increase the fuel 3 psig over the setting specified in the manual.
4. Let it run for 20 minutes, then span the analyzer.
5. After the span gas, introduce zero gas (Air) and let it run for 15 minutes to zero the analyzer.
6. Record the air, fuel, and sample pressure for future use.
7. Introduce zero gas (N2) and let it run for 15 to 20 minutes. When the reading stabilizes, select the zero menu and enter the zero value's opposite with the value display.
example: if the reading is -1ppm then enter the zero value is +1ppm
8. Introduce span gas with N2 background and let it run for 15 to 20 minutes. Then increase the sample pressure until the reading displays span gas value. Record the fuel and pressure value for future use. With this method, the operator will have to calibrate zero and span on one background Air and need to change the pressure when backgrounds are changed.


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How do I calibrate the analog outputs?

The 4020 has a function called 'ANALOG - OUT ADJUST' that lets you calibrate the 4 - 20 maDC output.

- Connect a DVM configured as an ammeter to the output of the analyzer.

- Use the Up/Down keys to bring up the main menu. Use the Up/Down key to navigate and find the 'ANALOG-OUT ADJUST' function and press the Enter key. You should see the following screen:
-> 4-20 ma Offset: 0
4-20 ma Gain: 0

- The arrow should be pointing to the Offset setting. The number on the right represents the position of the slider of a digital potentiometer. Zero indicates the slider is in the middle of this digital potentiometer. The number can be adjusted up and down from -500 to 500 by pressing the Enter key and the using the Up and Down keys. This will have an effect on the 4-20 maDC output. Adjust until the reading on the DVM is as close to 4.00 maDC as possible. When done, press the enter key one more time.

- Use the Down arrow key to select the Gain adjustment, then press the Enter key. The number on the right again represents the slider of a digital potentiometer. Adjust this number using the Up/Down keys till the output of the DVM reads 20.00 maDC. Press Enter one more time when done.

- The output is now calibrated. Use Escape to return to the analyzer screen.


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What is the max inlet pressure the sample regulator can handle? What is the output range of the sample regulator?

Maximum pressure for the regulator in a Model 4020 are 50PSIG inlet


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Where can I find the 4-20 mA output modules on the computer motherboard?

The 4-20ma modules are supplied on of two ways:



as a component from Analog Device, Part Number 1b-22 AN
(device with the white label) or



as a separate circuit board mounted on the top.


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What is the effect on sample pressure changes to the unit?

These have been supplied in two main versions -- a low pressure version in which the sample pressure applied to the unit must be over 5psi, and a normal unit in which the sample pressure applied ot the unit must be over 10psi. Internal at the detector, sample pressure must be controlled tightly due to the effect of flow and pressure changes on the output of the FID detector.

It is for this reason that TAI has supplied this unit with pressure regulators inside the unit for Air, Fuel and Sample. Small changes above the minimum pressure required for regulation have a negligible effect on the reading of the unit. If the pressure falls under the minimum required, readings can change quite a bit as the sample regulator in the unit will not have sufficient headroom to operate and therefore will not regulate properly.

Data was taken on quantity four units set up to measure THC in O2 and is shown in the table below :

Pressure to analyzer Unit One Data
(ppm reading / sample pressure gauge reading)
Unit Two Data Unit Three Data Unit Four Data
30 psi 0.07 ppm / 4 psi 1.19 / 5.6 psi 1.02 / 4 psi 0.25 / 5 psi
28 psi 0.07 ppm / 4 psi 1.1 / 5.6 psi 1.02 / 4 psi 0.24 / 5 psi
25 psi 0.06 ppm / 4 psi 1.21 / 5.6 psi 1.01 / 4 psi 0.24 / 5 psi
20 psi 0.06 ppm / 4 psi 1.21 / 5.6 psi 1.01 / 4 psi 0.25 / 5 psi
15 psi 0.03 ppm / 3.8 psi 1.22 / 5.6 psi 1.01 / 4 psi 0.26 / 5 psi
12 psi 0.01 ppm / 3.5 psi 1.32 / 3.8 psi .73 / 3 psi 0.28 / 5 psi



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Can plant air be used for the air supply for these units?

Absolutely not. Plant air is never sufficiently hydrocarbon or contaminent free to be used in the FID. Never use it. Only use air from a zero air generator or a certified hydrocarbon free cylinder.


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How do you cold-start the 4020 unit?

When the analyzer starts and is showing the version, press the UP & DOWN keys at the same time. The analyzer will prompt you to confirm the cold start. Press ENTER to continue.


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Do you have anything that explains the profibus interface for the 4020 and K2001?

All the commands are the same for each unit but there are a couple of unique items. For 4020 there is special message: the third least significant bit of byte in address 27 (0x1B) is used to indicate that the analyzer flame is out and unit is re-starting the flame. It flame does not ignite after 5 tries, you get the regular second LSBt in address 30 to indicate analyzer failure.

There is a similar warning on the GFC7000. Any warning from the GFC7000 (you will note the red light on the front of the GFC7000 and a message on the display) will trigger the same bit in address 27 as an indication of a warning. It is not a failure. We decided not to treat the warnings as failure because these warnings may not stop the unit from working. For example, after power up, you get a warning just because the unit was just powered up. Somebody is got to come and reset the warning and do correction if needed.

For example the power up warning, only requires people to come and reset the fault. But other warnings such as low purge pressure, may need attention. Analyzer is working fine, it only needs somebody to adjust the purge pressure.


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What is the average power consumption of the 4020 FID?

Per testing on a sample unit the average power consumption is 113 VAC x 0.93 A = 106 W


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We have a model 4020 unit that we need to modify for range and power. The range needs to be 0/1/10/100 ppm instead of 30/300/3000 ppm and power needs to be 220VAC from 110VAC. Please advise how to do this and let us know of precautionary steps to take, if any.

Please see attached drawing to modify for 220VAC.

C81366-0-P2.pdf

The modification kit is our p/n C-81366.


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What is the maximum power consumption of the Model 4020 at 110VAC power?

The power consumption is 2 Amps, however normally about 1 Amp


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Is the unit reading sensitive to changes in bypass flow rate?

Yes it is. All readings and zero and spanning should be done at the same bypass flow rate


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We have two analyzers which do not provide +15V at valve outputs 49/15 and 17/16. Is the 4020 generally supplied with the outputs at the 50 pole d-sub (even the version without cal valves) and can I assume that in my case the transistor outputs are defective?

The analyzers ship from here without auto-cal valves, the valve selection is set for defeated in the software

To control the valves externally use down key. Scroll down to VALVE SELECTION, press ENTER then the UP key to change from DEFEAT to DEFAULT then press ENTER, then press ESCAPE a couple of times to go back to analyze mode.


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What's the procedure to perform zero adjustment on the 4020 analyzer?

Please refer to the following document:

4020_electronic_zero_adjust small.doc


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With a 4020R, when there is no sample in the sensor chamber is there no ignition and flame? Can it be used for discrete measurings when customer will do a few series of measurings per day?

With no sample, the flame is still on, and the reading is zero due to no sample, unless the fuel also is off during this time. You can leave the analyzer running with all support gases on, and the analyzer will read zero until the sample is introduced.


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What do the error codes on the 4020 analyzer mean?

The following is an explanation of the error codes for the self-test:

4020_4080_error_codes.pdf

Please note the comment that the preamp results for the self-test are only valid at startup, before the FID has been actuated. It is possible to manually deplete the fuel to the FID, allow it to cool and perform a self-test during run time however.


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Which fuel gas is the best to use for the following application:
Samples include Pure Oxygen, Pure N2O, Pure He, Pure N2. (No H2 samples)
Fuel Gas: 40% H2 / 60% N2, or 40% H2 / 60% H2 or 100% H2


Generally we recommend a 40 60 mix of H2 and N2, except for pure O2

In pure O2 excess water will be formed if H2 fuel is used and the flame will go out frequently, the output will be noisy, etc.

The unit must be set up for the individual background gases, however, properly. You can't calibrate the unit for instance on pure O2 and then THC span gas in O2, and then inject a sample of He or N2O or N2 and expect accurate results.


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If one calibrates the analyzer in air and then measures THC in bulk N2, how does the accuracy change?

Here is some test data. The analyzer was not fully warmed up, so the analyzer is drifting somewhat.

The analyzer is calibrated with Air background.

Gases used:

80.04ppm CH4 balance N2
80.41ppm CH4 balance Air

Ultra- high purity grade N2
Zero-grade Air
Zero reading:

Air: 3.6ppm
N2: 1.5ppm

Zero reading difference : 2.1ppm
Span reading:
Air: 77.8ppm
N2: 66,8ppm
Span reading difference : 9.2ppm


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The customer intends to purchase 4020 FID to measure Total Hydrocarbons in CO2.

The pressure is 26 bars and the distance between the take off point and the cabinet of the FID is 100 meters.

1) In the document attached with the piping diagram of 4020, there is a bypass. Regarding the distance of 100 meters, does the customer have to install an external bypass with purge or will the internal bypass be sufficient?

2) What is the response time with 100 meters and internal bypass?


If we assume tubing from the process to the analyzer (best case), the sample travel time is:

100 m * [3.28 ft/m] * [5 cc/ft tube] * [26 cc @ 1 bar/cc @ 26 bar] / [1000 cc/min bypass] = 42.65 min.

This unacceptably long transport time is why we never transport high pressure samples. The proper solution is to drop the sample pressure with a regulator at the takeoff to ~1 bar g. This will decrease the sample travel time to 1-2 min.


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We have some 4020 problems: The fuel valve will not open. There is 30 volt to the valve, should it be 110 volt? The solenoid is 1.6kOhms. The fuses are checked and ok. If a new electronic board is needed what is the part number?

The fuel solenoid valve needs 110vac. The problem is most likely a failure in the flame guard/ ignition circuit board. You will need to replace the p.c.b. The part number is B74671 (Anode power supply, flame guard pcb).

4020 electrical drawings are available here:

http://www.teledyne-ai.com/techsupport/schematics.asp


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Is there memory in the analyser that can store the user settings on the analyser? After a power loss today the user had to change the settings.

Also, we run calibration gas on a regular bases and they always have to calibrate the analyser. Is there a reason for this variance?


The settings are stored in the EEprom on the main cpu board. This memory is retained after power loss.

Unless the "cold start" procedure was done, which will cause the analyzer to return to factory.default setting. Cold start is done by pressing both up&down Keys at power-up. This procedure is useful to clear garbage from memory, and zero preamp circuit. But when done the settings must be re-entered., And will be retained even after power loss.

Regarding the drift, this can occur if the flame need to be adjusted. This is done by adjusting the fuel and sample gas pressure settings. Monitor the output while on zero gas to check stability. Drift should not exceed 2% of the full-scale range. Note the recomended start-up pressure settings are on a sticker in the analyzer and written in the manual.

Other reason for drift is temerature control.

Problem. Is the amber lamp on the analyzer. blinking? The lamp should be blinking on and off when the temp is being controlled.


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