TECHNOLOGY INCORPORATED

SYSTEM INFORMATION MANUAL

Rackmount Gas Detector

Preliminary

WRITTEN BY

D. A. NORQUAY

SEP 1 2005

REV 1
 Part 1 – Hardware
Section 1: Introduction

The Rackmount version of the Datalog Total Gas Detector is a redesign of the standard
gas detector system in use for several years. We have tried to address some of the
shortcomings in the old system and update the operation and specifications, as well as
add microprocessor control. The microprocessor takes over some of the functions of
separate modules and boards from the old system, and adds functionality that was
previously not present, such as autozero, serial debug information, WITS output, etc.
Improvements have been made in the block heater control, flow control, pneumatics,
pump, and several other areas. This has resulted in a much more stable, accurate, and
repeatable system with improved specifications.

Section 2: Hardware Description

The system consists of four main blocks. These include the Power Supply, the Pneumatic
System, the Control Module, and the Gas Detector / Amplifier Board.

Power Supply

The gas detector is powered from the AC line, with an input voltage range of 100-240
VAC, 47-63 Hz, with a maximum power consumption of about 40 watts. An AC power
entry module allows the use of a standard IEC power cord, which can be supplied to fit
any country standard AC receptacle. The power inlet provides fuses to protect the
equipment. Fuse value is 3A, 250VAC, GMA style. A power filter module helps to
remove any AC noise that may be present, and an AC to DC power supply provides 12
VDC to power the electronics. A front panel switch controls the AC power to the power
supply, and thus the entire system.

Control System

The gas detector has a microprocessor at its heart that manages and monitors the entire
system as well as taking care of data and communications tasks. The microprocessor unit
is programmed with control and monitoring functions of the system. An interface board
provides I/O interfacing between the processor and the various devices. An on board
A/D converter converts the voltages from the Amplifier Board to a digital representation.
Onboard drivers control the detector cell heater, sample pump, and zero valve, all under
microprocessor supervision. A pressure sensor monitors the pneumatic system, and a
power supply module supplies additional voltages required by the Amplifier board. The
Control module also contains two electronic potentiometers used to zero the gas detector
analog signals, and interconnections for the front panel switches and indicators.

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The system uses a microprocessor-based system to monitor and control the operation of
the gas detector. The microprocessor has several functions:

• Control the gas detector cell heater to a constant temperature

• Control the operation of the gas sample pump to maintain precise gas flow
• Control and automate the zeroing of the gas sensors
• Monitor the system for problem conditions and faults, and indicate problems
with both audible and visual indicators
• Convert the analog sensor data into a digital format which can be recorded
• Control the sensor power and selection to allow a full range of measurement
capabilities
• Linearize the sensor output to improve accuracy
• Output the gas concentration information in industry standard WITS serial
data format, to allow interfacing with a wide range of 3rd party equipment
• Provide the operator with help and make calculations to provide fast, easy
calibrations and setup

The Microprocessor is connected to an Interface Board that contains control components

that interface its low-level signals to the remainder of the system. Power is supplied to
the board through two independent power connectors, TB1 and TB4A. TB1 supplies
power to the microprocessor and Gas Amplifier board. The 12V input is regulated down
to 5V via U3, which supplies this voltage to the Gas Amplifier board to run the sensor
power regulators. TB4A supplies power independently to the higher current portions of
the system, including the pump and valve via high current driver U1, and the heater
through solid state relay K1. These power supply connections are kept separated to
minimize the effects of the higher current systems on the low-level amplifiers and analog
channels.

Also on the interface board is a pressure sensor which is used to monitor the flow system
pressure. This is a 50KPa sensor that interfaces to the microprocessor A/D system, and
takes it’s power from the micro board as well. The four analog outputs from the Gas
Amplifier board enter via JP3, and are filtered with the series RC networks consisting of
R3-R6 and C9-C12. The resistors also serve to protect the microprocessor A/D inputs
from over voltage conditions possible with a fault on the amplifier board. IC U2 is a
digitally controlled electronic potentiometer chip, which has two independent channels.
These are used to adjust the zero output of the CC and TC detector channels on the
amplifier board. Separate wiring harnesses connect to JP4 and JP5 for the CC and TC
zero signals, respectively. See Photo 1 for details.

3
 SS Relay
Micro
Processor

Pressure
Sensor

Analog
Inputs

Photo 1: Control Board

Pneumatic System

The pneumatic system for the Total Gas Detector unit consists of filters, a sample pump,
some pneumatic controls and sample conditioning hardware. The incoming sample is
filtered to remove any contaminants by a pair of filter units. The first is a disposable
particulate filter that removes dust and particles. The second filter is a Teflon
hydrophobic disk filter that blocks the passage of liquid water. This filter protects the gas
detector internals from water damage. After the filters, there is a flowmeter to indicate
flow rate, after which the sample flows into the Zero valve. This valve is a selector that
can select either the Sample inlet or a Zero Gas filtering system. The Zero Gas filters
remove hydrocarbons and other impurities from the ambient air to provide a stable zero
gas for setting the zero point of the sensors. The selected input is then connected to the
sample pump, which is controlled by the Control Module. The pump speed can be
modulated to provide a stable flow for the detector cell and external Gas Chromatograph.

After the pump, the chromat output is tapped off and run to the Chromat Flow meter.
The sample then continues through a series of restrictors and pneumatic volume cylinders
that dampen pump pulsations. An adjustable needle valve controls sample flow to the
detector cell. Excess sample is vented to the exhaust through another adjustable needle
valve. This valve adjusts the system backpressure to maintain a constant sample flow
rate. Excess flow is vented through the main exhaust to maintain flow and minimize
sample lag from the trap to the instrument. See Photo 2 for details.

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 Photo 2 – Pneumatic Assembly

Zero
Filters
Block
Flow Adj.
Pump

Exhaust Flow
Adjust
Zero
Valve

Gas Detector / Amplifier

The Gas Detector / Amplifier module is an analog signal conditioning circuit which
provides a stable power supply for the detector elements, and amplifies the signal from
those detectors to a useable level. It also contains signal conditioning circuitry and a
temperature sensor and heater which keeps the detector cell at a constant temperature,
thus minimizing zero drift of the sensors. A Catalytic Combustion Pellistor sensor
measures low gas concentrations in the range of 0-5% Methane Equivalent by volume,
and a Thermal Conductivity Pellistor sensor measures in the range of 5% to 100% by
volume.

Power input connector PL4 brings 12V and 5V to power the internal circuitry. 12V
powers all of the analog circuits, and the 5V is used for sensor power. U7 regulates the
incoming 5V down to 2V for the CC detectors, adjusted by R44 VBR ADJ CC. U6
regulates the incoming 5V down to 3.25V for the TC detector, adjusted by R41, VBR
ADJ TC. A negative voltage supply is generated by U8 and its associated components.
This is used for a negative reference for the zero adjustments, along with a negative
supply for the operational and instrumentation amplifiers

Each gas detector channel has a bridge balancing pot (R3 for CC and R13 for TC), which
allows the bridge to be balanced at the zero point for each sensor. Each sensor signal is
then amplified by instrumentation amplifiers U1 and U2. Additional gain and offset
adjustments for each channel are provided by U5 and its associated circuitry. Span for

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the CC channel is adjusted by R10, and for the TC channel is adjusted by R20. Final
zeroing for the two channels is provided off board via connectors JP4 and JP14.

A third channel on the amplifier board is dedicated to signal conditioning for the block
temperature sensor. This sensor is located under the sensor block, and the signal is
amplified by instrumentation amplifier U4. Additional amplification is provided in U5,
and span and zero settings are done by R40 and R34, respectively. A fourth signal
conditioning channel is provided on the board for an additional H2S sensor, but is not
currently implemented.

All output voltages can be monitored on test points at the front of the board. Power
supply voltages can be monitored at color-coded test points around the board. See Photo
3 for details.
Photo 3 – Amplifier Board

Detector
Cell

CC Volt TC Volt
Adjust Adjust

Bridge
Zero CC TC T.P. Bridge
CC T.P. Volts Zero TC
Volts

Bridge
Zero CC
U4 Pin 8
TC Span
Temp Span CC Span
And Zero
R37

Temp
T.P.
CC T.P.

TC T.P.

6
Section 3: Theory of Operation

Detector Operation

Catalytic Combustion and Thermal Conductivity sensors have been used for decades in
the detection of combustible gasses. Catalytic sensors have a limited range, but high
sensitivity for low concentrations (under 100% LEL Methane, or 5% by volume) and are
very stable. They can be damaged by high concentrations of gas, however. Thermal
detectors can detect concentrations of up to 100% by volume Methane, but have poor
low-end sensitivity and somewhat greater drift. Datalog originally designed a system that
combined both these detector types in a single cell, and used a separate computer to
control the detectors and switch between them based on the gas concentration. This
system was used in several products, and worked well for many years, but it was
recognized that it needed to be updated. Thus, the stand-alone system for use with
Mudlogging units was born, as a standby to the Gas Chromatograph.

The system monitors the gas concentration from the CC sensor at first, for low
concentrations. In this way, maximum resolution is obtained for low gas concentrations,
which is where the gas detector spends most of its time. As the gas concentration rises, a
point is reached above which the CC can no longer read reliably. At this point, the CC
detector is powered off to prevent damage. If the CC detector is exposed to gas
concentrations much above LEL, but below UEL, the lack of oxygen in the mixture can
cause incomplete combustion of the gas products. This incomplete combustion produces
soot on the detector bead, plugging the porous bead structure. This causes a permanent
calibration shift, a phenomenon known as coking. The crossover point for this gas
detector is in the range of 4.5% by volume methane.

As the gas concentration passes the crossover point, as mentioned earlier, the power is
shut off to the CC detector. The signal from the TC detector is now used from this point
as the gas concentration continues to increase. If the gas concentration subsequently
decreases, the system will switch back to reading the CC detector when the concentration
falls below about 2.5%. This hysteresis between the upward crossover and the downward
crossover prevents rapid switching about the crossover point. When the CC sensor is
powered up, it takes 45-60 seconds to stabilize. There is a software time delay in the
switching algorithm to allow for this warm-up time. This warm-up time is required on
system power up as well. In addition, on power up, the CC is automatically shut off until
the TCD sensor warms up and gas concentration is determined to be low enough to
switch on the CC detector. This prevents CC sensor damage in case the system is
powered up with a high concentration of gas already present in the sample lines.

Flow System and Pump Control

The sensors, being somewhat sensitive to flow through the detector cell, have a
controlled flow arrangement. This consists of a pump, whose speed can be varied under
software control, connected to a system of orifices. Each orifice controls the flow
through a particular channel. One channel is the detector cell itself; another is the flow of

7
sample to the gas chromatograph, which is a separate unit. The third channel is the
exhaust of the sample to the outside world. Each of these channels has a needle valve
that can be adjusted to give the desired flow through the channel.

The objective is to maintain a constant pressure ahead of the exhaust flow control. Each
channel is adjusted to its flow requirements, and then the exhaust flow control is adjusted
to create a stable backpressure in the system. This pressure is measured by a pressure
sensor, and a PWM control routine in the microprocessor uses this information to adjust
pump speed. Allowing most of the available flow to exit out the exhaust provides a
means of reducing the sample lag time with long tubing runs. Controlling a constant
pressure against the orifice flow controls provides a constant flow across the sensors.
Using a series of restrictors and volume chambers in the system provides a cushion
against pressure spikes and filters pump pressure pulsations.

The system is calibrated by invoking a mode in the software for pump calibration. The
pump is adjusted to maximum speed, and the backpressure control is then adjusted to
provide a pressure slightly above the standard system 3.0 PSI setpoint. This allows the
pump some dynamic headroom to adjust its output to maintain a constant system pressure
of 3 PSI. This setup must be done with all sample lines, dryers, filters, etc connected to
the system, and with the chromat and detector cell flows set to their correct values. This
is easily accomplished under normal operating conditions at wellsite, after the system has
been completely rigged up. In this way, any site-specific peculiarities can be
accommodated, and the system will function normally.

The pump operation is monitored, and if the system detects an out of specification
condition the pump will automatically shut down and an alarm will sound. If the Sample
inlet becomes blocked, due to a clogged filter or blocked calcium chloride dryer, for
instance, the pump will speed up in an attempt to maintain flow rates. If it reaches
maximum speed and the system pressure is still below the setpoint, the pump will shut
down and an alarm will sound. This protects the system from drawing mud into the
sample lines should the trap gas inlet become submerged. Conversely, if the exhaust
outlet becomes blocked due to freezing or other cause, the pressure will exceed the
setpoint, and the pump will attempt to throttle down to compensate. If it reaches a
minimum setting without being able to reduce the pressure sufficiently (the pump will not
stall), the pump will shut down and an alarm will sound.

Since the viscosity of Methane is much lower than the viscosity of air, the system reacts
much differently when the sample contains large percentages of Methane. The apparent
restriction of each orifice becomes less, the pump efficiency increases, and generally,
flows increase through the different channels. This affects the operation of the system, so
a control algorithm was developed to compensate. As the percentage of Methane
increases (as measured by the TC Detector), the pressure setpoint of the system is
lowered based on the results of an empirically derived equation. The pump speed is
lowered, and the system pressure setpoint falls. This has the net effect of keeping the
flow relatively constant even with the lowered viscosity of the gas mixture. In addition,

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this also has the effect of reducing flow at the trap end of the system, reducing dilution of
the gas in the trap, and resulting in more consistent gas readings.

Detector Limitations

The gas detector overall is fairly accurate, but there are some shortcomings of the CC and
TCD detectors that limit accuracy in some circumstances. The CC detector is slightly
nonlinear, but in this case the linearity error is within a few percent of full scale, making
it much less than 1% overall and thus it can be ignored. The TCD shows much more
nonlinearity, and is a significant percentage of its full-scale reading especially at
midspan. For this reason, Datalog has developed a linearization equation for the sensors
based on a zero/full scale calibration. This equation was developed using a representative
response curve for the TCD detectors as a group, and is not optimized for individual
sensors, other than by the individual calibration of those sensors in the system. TCD
sensors overall, however, show a very good correlation from one sensor to the next, and
so the approximation used provides good linearity correction. Linearity using this
correction approach is within a few percent of flat over the entire 5-100% by volume
range.

The CC detector shows varying sensitivities to other flammable gasses that may be in the
sample stream, including ethane, propane, butanes, and pentanes. Usually, the higher the
“C” number, the greater the response of a CC type detector. For this reason, the gas
detector specifications are always quoted in “Methane Equivalent”, which is the signal
level that the gas would have if it was composed of only Methane. The gas detector
specifications and accuracy quoted are for a gas consisting only of Methane and air or
Methane and nitrogen mixtures. Air must be present in the gas mixture used to calibrate
the CC sensor, since it relies on combustion for its operation.

The TC sensor also shows varying sensitivities to other gas components, and its response
is also quoted only for Methane. Unlike the CC detector, its sensitivity to other
flammable components of a gas mixture may be less than that of Methane, and these
mixtures may have a damping effect on the overall reading if present in large quantities.
Fortunately, in oil and gas reservoirs, Methane usually dominates the gas composition by
an order of magnitude over the heavier gasses, and so this effect is minimized.
Additionally, non-flammable gasses such as Carbon Dioxide may also have a damping
effect, reducing the apparent response to methane. Generally, a chromatograph should be
calibrated to indicate CO2 concentration to alert the operator to the presence of damping
gasses. The mixture used to calibrate the TCD sensor is typically 100% Methane.

These shortcomings are generally minor, especially since the Total Gas Detector is
mainly used as a backup or adjunct to a Gas Chromatograph. If the exact composition of
the gas is required, a GC is the only reliable method of determining it. A total gas
detector, because of it’s limitations, generally cannot be used to QA a chromatograph, or
vice versa. No combination of Total Gas Detector and Chromatograph can be expected
to produce identical readings for the exact same gas concentration, since they use widely
separate and different measurement techniques. The best that can be hoped for is a

9
qualitative agreement in trends showing gas increases and decreases and not quantitative
comparisons between the two.

10
Section 4: Installation

Installation of the gas detector is straightforward. The unit should be installed in the
equipment rack somewhere around countertop height. It should be installed on full
extension slides, to allow easy access and make it simple to calibrate or work on. Ensure
that the rack mounts are properly installed, and all screws are in the proper places.
Ensure that the slides function properly and the rack chassis does not interfere with any
other equipment mounted in the rack. Allow space for air circulation at the top of the
chassis if possible. Also, check to see that the back panel has full access for the
connection of hoses and electrical connectors. Find a source of 120 or 240 VAC to plug
the AC power cord.

Connect the AC power to the mains, and the WITS serial output to the data acquisition
server with an RS232 NULL cable. It is important to use the supplied NULL cable or a
standard cable with Null Modem adapter with the system, as communications cannot be
established over an ordinary cable. Ensure that the data acquisition server has the port
configured properly to receive WITS gas information. See the WW MLS Software
section in the manual for details.

Connect the sample inlet fitting to the incoming sample line. It is recommended that a
20-30 micron filter in conjunction with a Teflon water stop filter or water trap be used
ahead of the gas detector. All possible precautions should be made to eliminate the
possibility of getting water into the sample inlet of the gas detector, as this will cause
extensive damage to the instrument. Ensure that all connections are tight and leak free.
Connect the two exhaust fittings via separate hoses plumbed to the outside of the unit.

Warning: It is possible to build up a flammable or explosive gas mixture inside the

building housing the equipment if the exhausts are not properly plumbed to the
outside.

Caution: The two exhaust hoses must NOT be connected together. SEPARATE lines for
each exhaust connection must be run outside the building.

Once the system has been installed, power it up and follow the instructions in Appendix
1: Routine Calibration to calibrate the unit with appropriate gasses. If any Warning or
Error Codes are displayed, got to Appendix 2: Calibration and Alarm Codes.

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Section 5: Operation
Controls and Indicators

The Total Gas Detector has very few operating controls. All are located on the front
panel. These include:

• Power Switch – This controls power to the unit. The bar depressed indicates the
switch is in the on position, the circle depressed indicates off, in the standard
international convention. Note that there is also a switch located on the power entry
module in the rear of the unit, this switch is not connected and has no function.
• Autozero Switch – This is a momentary switch that causes the system to zero both
sensor channels automatically when pressed. To initiate an Autozero cycle, the
switch must be pressed and held for approximately 2.5 seconds, until a short beep is
heard from the speaker. To cancel an Autozero cycle, the button can be pressed and
held for approximately 5 seconds, or until two short beeps are heard from the speaker.
The Autozero switch can also be used to silence audible alarms by pushing it
momentarily, or cancel alarm blink codes if pressed and held for 2.5 seconds
(assuming an Autozero cycle is not in progress).
• Pump Switch – The Pump switch controls the operation of the pump. Pressing and
holding the switch for 2.5 seconds will toggle the pump from on to off or vice-versa.
Turning the pump off essentially places the gas detector in standby mode, when it is
not needed. It can also be used to allow servicing filters, chemicals, etc in the sample
line. As with the Autozero switch, it can also be used to silence audible alarms by
pushing it momentarily, or cancel alarm blink codes if pressed and held for 2.5
seconds.

There are also a few indicators located on the front panel of the TGD. These include:

• Sample Flow Indicator – This is a rotameter style indicator that displays the flow of
sample from the trap into the TGD. Normally this indicator will be near the top of its
range, or >5 SCFH. Long sample lines or clogged filters may cause this reading to
drop. If the reading drops below about 3 SCFH, the system should be checked for
blockages or clogged filters, or the pump output should be recalibrated to bring the
flow back to normal range.
• Status Light – This is a multifunction light that indicates the status of the TGD’s
various subsystems. It can indicate stabilizing, pending operations, and low and high
alarms, as well as some special modes. See Appendix 2 – Blink Codes for a detailed
explanation of the Status Light function.
• Alarm Speaker – The alarm speaker is located directly above the Status light. It is a
small piezo sounder that is activated if an alarm condition occurs. The Audible alarm
can be cancelled by momentarily depressing either the Pump or Autozero switch.
• Chromat Flowmeter/Control – The Chromat flowmeter is used to adjust the flow of
sample to the Chromat sample inlet port. Although this is adjustable from the front
panel, adjustment during TGD operation is neither required nor recommended. The

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 flow rate should be set for 0.5 SCFH and left at this setting. The gas outlet for the
Chromat is located immediately adjacent to the Flowmeter.

There is one other connection on the front panel that does not fit into either the control or
indicator category. This is a serial port marked Console. This serial port is used to
connect a serial terminal or computer running a terminal program to the TGD in order to
evaluate problems or perform calibrations and setup. Note that either a NULL cable, or
standard cable and Null Modem Adapter must be used to connect this port to another
computer. Communication parameters for this port are fixed at 19200/N/8/1, with no
handshaking enabled. A laptop or desktop computer running Hyperterminal, TeraTerm
Pro, or some other equivalent terminal emulator program is required to connect to this
port. A real hardware serial port is preferred, but a USB serial adapter may be used if it
is properly configured.

The rear panel contains only power inlet, gas ports and another serial connection for
WITS gas data out. See the installation section for details of the gas connections. The
serial WITS output port is normally connected to the Data Acquisition server to supply
gas data to the system. Note that either a NULL cable (supplied), or standard cable and
Null Modem Adapter must be used to connect this port to another computer.
Communication parameters for this port are fixed at 9600/N/8/1, with no handshaking
enabled.

Autozero Operation

As described under Controls and Indicators above, pressing and holding the Autozero
button for 2.5 seconds will initiate an autozero cycle. The autozero can also be initiated
by pressing the “A” key if the terminal emulator is connected to the console port. The
autozero cycle will only occur if certain conditions are met:

• The autozero is not currently running or pending

• The pump pressure is stable and within tolerance
• Heater temperature is stable and within tolerance
• CC sensor power has to be on and the output stable

The cycle will proceed by opening the zero valve and waiting for the readings to
stabilize. It is not necessary to disconnect the sample inlet line during Autozeroing. The
microprocessor will then adjust the electronic pots for both the CC and TC zeros until the
output of the amp board is correct. The Status LED blinks two long green blinks
repeatedly until the autozero cycle is complete. If the Autozero cycle was successful, the
system will return to normal operation. If not, an error code indicating the failure will
appear. Refer to Appendix 2 – Blink Codes if this happens.

In some cases, an autozero cycle can not start immediately, for instance on power-up. In
this case, two short green blinks indicate that an autozero cycle is pending, and will start
as soon as the system stabilizes. An autozero cycle is always automatically performed on
power-up of the system, after the above conditions are met. An autozero cycle can be

13
cancelled by pressing and holding the Autozero button for about 5 seconds. This will
cancel a cycle in progress, or a pending cycle.

If the Autozero cycle fails, it will blink either 2 short red or 2 long red blinks on the status
LED, depending on the failure mode. Two short blinks indicates a zero pot reached its
minimum setting without being able to zero the sensor output. Two long blinks indicates a
zero pot reached its maximum setting without being able to zero the sensor output. These
errors could occur with either sensor channel. It will be necessary to connect a terminal
emulator to the Console Port on the front of the machine to determine which sensor has
gone awry. The sensor channel that triggered the alarm will indicate a 0 for the DPOT if
the failure was a minimum value failure (2 short red blinks). This channel will also show
a CDl or TCl flag set in the Alarms section of the Display command. The sensor channel
that triggered the alarm will indicate a 255 for the DPOT if the failure was a maximum
value failure (2 long red blinks). This channel will also show a CDh or TCh flag set in
the Alarms section of the Display command.

This alarm is not catastrophic, in that the machine will still operate after the alarm has
been cleared (by holding either button for 2.5 seconds), but the affected sensor will still
require attention. The zero point for the affected sensor will not be within its required
range, and therefore the sensor output cannot be trusted. In its simplest form, the zero pot
could have simply run out of range due to normal sensor zero drift. This can be remedied
by performing the Sensor Zero procedure in Appendix 1: Routine Calibration section of
this manual. If the sensor cannot be zeroed by this procedure, it will likely have to be
replaced. If the zero can be restored, the system will continue to operate normally after
the alarm has been dealt with. In the worst case, the sensor could have failed completely
and will need to be replaced before normal operation can be resumed. In this case, a CC
or TC low or high failure alarm (See Appendix 2: Blink Codes for more details) will take
place immediately after the autozero alarm has been cleared.

Console Commands

As mentioned earlier, the console port is a serial communications link that displays
various operating parameters and allows access to internal calibration routines and other
system functions and overrides. Most of the detailed information on calibration
procedures and debug information is contained in the Appendices. This description is
intended as a quick reference guide to console commands. There are only a few
commands that the console recognizes:

D - This is the basic display mode for all of the parameters of interest to the user. When
this key is pressed (note that it is Upper Case, as are all commands) the cursor will scroll
to the bottom of the screen and display:

Time sec|Press PSI|Temp C|CC %|TC %|Flags

|Alarms
187 |06710 2.99|13099 40.01|02223 0.57|00683
1.26|PHC____|

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This display shows the time in seconds since last power on, Pump Pressure, Block
Temperature, CC Detector value, TC Detector value, a Flag area and an Alarm area. The
bottom line of this display is refreshed with real time data several times a second. The
analog values are shown in both Decimal A/D counts, and Engineering Units for each
device. The Flags and Alarm areas will be described later. The D command is also used
to exit any other command mode.

C – This is the command prefix for Calibration Mode. It must be followed by two
additional characters that specify the type of calibration to be performed. The options for
the other calibration modes are:

CC – CC sensor calibration mode

TC – TC sensor calibration mode
PU –Pump calibration mode

Example displays for these modes are shown in the relevant appendices. Each mode
shows a set of instructions for completing the calibration, as well as a real time display
line at the bottom of the screen which shows information relevant to the device being
calibrated. As mentioned, pressing the D key will exit any of these calibration modes.

V – This command toggles the Autozero valve independently of what state the autozero
routine may be in at the time.

Z – This toggles the autozero routine. It has essentially the same effect as pressing the
Autozero Button on the front panel. Pressing it while the autozero routine is not running
will start it, pressing it while the routine is running will abort. In the console mode,
additional information is displayed as own below:

Press PSI|Temp C|CC Cnts|CC DPOT|TC Cnts|TC DPOT|Tgt

Cnt|Zero Valve
3.00| 40.02| 2214| 0| 680| 0| 368|
On

There are some additional commands that are only active in the calibration modes. These
include:

M – resets the DPOT for the current channel to midpoint (128)(CC and TC only)
(+) - Increments the DPOT setting by 1 for the current channel (CC and TC only)
(-) - Decrements the DPOT setting by 1 for the current channel (CC and TC only)
R – Places the Pump in Restrictor calibration mode (PU only)

( ) Numeric or Alpha pad both work

? - A help screen can be invoked with a quick reference guide to these commands by
typing the ? key.

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16
 WITS Data Stream

The TGD module uses industry standard serial WITS (Wellsite Information Transfer
Standard) output format, which is easily read and interpreted by our WellWizard
software, and in fact, many other systems as well. Using this ASCII data format makes it
easily transmitted and shared by several systems at once. Information on the WITS
standard transmission protocol can be found by visiting www.witsml.org and clicking on
the WITS link near the bottom left hand side.

The TGD system sends the following WITS data string. Note that the descriptions after
the “;” are NOT part of the information sent, they are included as descriptors only:

&& ; start of WITS packet (CRLF)

01400000.06 ; gas value in percent (CRLF)
015003.00 ; pump pressure in PSI (CRLF)
015140.07 ; temperature of block in ° C (CRLF)
015200.00 ; CC detector raw output in percent (CRLF)
01530000.06 ; TC detector raw output in percent (CRLF)
0154065 ; pump related flags (CRLF)
0155000 ; autozero related flags (CRLF)
0156004 ; CC detector related flags (CRLF)
0157001 ; TC detector related flags (CRLF)
0158001 ; heater related flags (CRLF)
!! ; end of WITS packet (CRLF)

The (CRLF) in the above records indicates that a carriage return and a line feed character
are appended to the end of each record/field string. These characters are non-printing and
will not actually be seen on a terminal emulator program.

Note that the first record only is standard for use with Total Gas detectors. All other
records are not specifically defined in the WITS standard, but available for use as extra or
user-defined parameters. Datalog uses these record numbers 0150-60 as extra records for
Debug data that can be used for troubleshooting and diagnosis of the TGD operation.
WellWizard software allows these values to be placed in the database for later use in
case of trouble or device failure. These codes are proprietary to Datalog, and are not to
be used for any other purpose.

17
 Section 6: Maintenance
System Maintenance is minimal. There are no required maintenance issues except for
replacement of filters on a regular basis.

1. Main Inlet Filters – These filters should be replaced as a unit every 6 months of
operation, or if they appear to be clogged or wet. Inlet flow will drop significantly if
these filters are plugged. The DFU filter unit is there to remove particulate matter from
the sample stream, while the Teflon Disk filter blocks the passage of liquid water into the
sampling system.

2. Autozero Filters – These filters are used to remove hydrocarbons, water vapor, and
other contaminants from the air used to autozero the instrument. These filters should be
replaced at least every 6 months and more if frequent autozeroing operations are done.
The Molecular Sieve filter has an indicator chemical which turns from blue to pink when
it is saturated with water vapor. This does not necessarily mean that the filter needs
replacement, since water vapor does not affect the reading. The Mol Sieve filter will
continue to remove large molecule contaminants even if it is saturated with water vapor.
The Activated Charcoal filter may become saturated, but only after a significant amount
of hydrocarbons have been trapped.

3. Chromatograph Outlet Filter – This is another Teflon Disk filter, which is a last line of
defense against liquid water getting to the Gas Chromatograph. It should be replaced
only when the Chromat Flow cannot be set to 0.5 SCFH.

18
 Appendix 1
ROUTINE CALIBRATION

From time to time, the autozero routine may fail to adequately zero the sensor value. In
most cases, this is simply due to normal drift of the sensor as it ages. Full adjustability of
the sensor DPOT’s may be restored by adjustment of the Bridge Zero Pot for the sensor
in question. Note that a Pump Calibration procedure should be performed before doing
the Zero procedure.

A. Sensor Zeroing

1. Once communications have been established with the console port, type the command
“CCC” in the terminal window. This should cause the TGD to go into CC Sensor
Calibration mode. There will be a numerical display at the bottom of the terminal
screen similar to:

(note that the actual numbers and status on the bottom line may vary)

Pwr| Cnts |CC Gas|Cal Gas|Span Cnts|Set Cnts|DPOT|Zero

Valve|Entry
On| 02240| 0.58| 2.50| 8000| 8368| 128|
On|_

2. Press the “V” key to open the Zero Valve. Zero Valve status on the above lines
should now read “On”.
3. Press the “M” key to reset the DPOT value to 128.
4. Wait for the reading to stabilize.
5. Adjust the Bridge Zero Pot for the CC channel until the CNTS value = 00368, and the
CC gas reads 0.00.
6. Zeroing for CC sensor is now complete, press “D” to return to display mode.
7. Return to Step 1, but instead of “CCC” press “CTC”.

(note that the actual numbers and status on the bottom line may vary)

Pwr| Cnts |TC Gas|Cal Gas|Span Cnts|Set Cnts|DPOT|Zero

Valve|Entry
On| 01202| 1.62| 100.00| 15633| 16001| 128|
On|_

8. Follow steps 3 through 6, (the Zero Valve should already be open) but adjust the TC
Bridge Zero Pot instead of the CC BZP, until the TC counts value reads 00368, and
the TC gas reads 0.00.
9. Zeroing for TC sensor is now complete, press “D” to return to display mode.
10. Both sensors have now had full-range autozero capability restored.

19
11. If either of these steps is not possible because the associated Bridge Zero Pot has run
out of adjustment range, replacement of the sensor assembly is indicated.

20
There are three additional steps required for calibration of the Total Gas Detector system.
In order to do these steps, the system Console port must be connected to a PC running a
terminal emulator program with the communication parameters set to 19200-N-8-1, with
hardware handshaking disabled. The steps are outlined below.

B. Pump Calibration

Pump calibration may be required from time to time, especially if the flow system
changes, i.e. filters are replaced, additional sample tubing is added, etc. Fortunately,
calibration is quick, simple, and requires adjustment of only one control. Pump
calibration is also a good idea before performing a Sensor Zero adjust procedure or
before Calibration of the system.

1. Assuming communications have been established, type the command “CPU” in the
terminal window. This should cause the TGD to go into Pump Calibration mode.
There will be a numerical display at the bottom of the terminal screen similar to:
(note that the actual numbers and status on the bottom line may vary)

Note: All commands sent to the TGD via serial port must be Upper Case (Capital)
characters. The system will not recognize lower case characters.

PWM %|PWM Cnts|Target PSI|Press PSI|Pump RPM|Zero Valve

23.3| 10427| 3.00| 06774 3.02| 2529| On

The PWM % and PWM Cnts values indicate the current PWM values applied to the pump motor.
Target PSI and Press PSI indicate the setpoint and actual pressure at the pump output,
respectively. The Pump RPM is derived from the pulsations caused by the pump on the pressure
sensor. The Zero Valve status indicator shows the current state of the zero valve.

2. Also on the screen, immediately above the numerical display, will be a set of
instructions. Follow these instructions in the order listed to do the calibration of the
System Pressure using the Exhaust Flow Adjust needle valve. (The control locations
are shown in Photo 2) Make sure that the system is set up with all sample tubing,
trap, filters, dryers etc. attached and in good condition (i.e. filters clean and not
blocked, tubing is dry, etc.
3. Once the steps have been completed, press “D” to return to the main display screen.

21
B. CC Detector Calibration

1. Ensure that a good supply of low concentration (4% Methane in air or less)
calibration gas is available. Disconnect the sample line from the Sample Inlet and
connect the red Luer connector of the Calibration Adapter in its place. A flowmeter
should be attached to the outlet of the calibration adapter to monitor gas flow. This
exhaust flow must be kept above zero to ensure that the gas detector has enough flow
to calibrate the sensor without the possibility of sucking air in through the calibration
adapter exhaust.
2. Once communications have been established with the console port, type the command
“CCC” in the terminal window. This should cause the TGD to go into CC Sensor
Calibration mode. There will be a numerical display at the bottom of the terminal
screen similar to:

(note that the actual numbers and status on the bottom line may vary)

Pwr| Cnts |CC Gas|Cal Gas|Span Cnts|Set Cnts|DPOT|Zero

Valve|Entry
On| 02240| 0.58| 2.50| 8000| 8368| 0|
On|_

The Pwr indicator shows whether sensor power is on or off. Cnts shows the current sensor voltage
in A/D counts. CC Gas shows the current calculated gas value in %. Cal Gas is the entered gas
concentration for the calibration gas. Span Cnts is the target number of counts for full scale with
gas applied, and is adjusted using the CC Span pot. Offset Cnts is an additional zero offset value
adjusted after the Span Cnts, and is set using the CC Bridge Zero pot. The DPOT value is the
current setting of the electronic Zero pot, Zero Valve shows the valve status, and Entry is used to
enter the cal gas value if different than 2.5%.

3. Connect the gas cylinder to the inlet of the calibration adapter, and turn on the gas
supply. Ensure that the Zero Valve in the TGD is off, and that there is excess flow
going out the exhaust port of the calibration adapter. The rotameter should read at
least 1-2 SCFH with the Zero Valve off.
4. On the screen, immediately above the numerical display, will be a set of instructions.
Follow these instructions in the order listed to do the calibration of the amplifier
board pots and control settings related to the CC detector. This calibration procedure
sets the values of the Bridge Zero Pot, the CC Span Pot, and the electronic Zero Pot
for the CC detector channel in order to calibrate the sensor to a known gas
concentration range. The system allows the user to enter the actual analyzed
concentration of the calibration gas used, this should be done first to allow the system
to calculate actual settings.
5. Recheck zero once more by turning the Zero Valve on (“V” command). Recheck the
span by turning off the Zero Valve. Once the steps have been completed, turn off the
calibration gas supply, disconnect the low value gas cylinder, and press “D” to return
to the main display screen.

22
C. TC Detector Calibration

1. Ensure that a good supply of high concentration (100% Methane) calibration gas is
available. Disconnect the sample line from the Sample Inlet and connect the red Luer
connector of the Calibration Adapter in its place. A flowmeter should be attached to
the outlet of the calibration adapter to monitor gas flow. This exhaust flow must be
kept above zero to ensure that the gas detector has enough flow to calibrate the sensor
without the possibility of sucking air in through the calibration adapter exhaust.
2. Once communications have been established with the console port, type the command
“CTC” in the terminal window. This should cause the TGD to go into TC Sensor
Calibration mode. There will be a numerical display at the bottom of the terminal
screen similar to:

(note that the actual numbers and status on the bottom line may vary)

Pwr| Cnts |TC Gas|Cal Gas|Span Cnts|Offset Cnts|DPOT|Zero

Valve|Entry
On| 00687| 1.28| 100.00| 15633| 16001| 128|
On|_

The Pwr indicator shows whether sensor power is on or off. Cnts shows the current sensor voltage
in A/D counts. TC Gas shows the current calculated gas value in %. Cal Gas is the entered gas
concentration for the calibration gas. Span Cnts is the target number of counts for full scale with
gas applied, and is adjusted using the CC Span pot. Offset Cnts is an additional zero offset value
adjusted after the Span Cnts, and is set using the CC Bridge Zero pot. The DPOT value is the
current setting of the electronic Zero pot, Zero Valve shows the valve status, and Entry is used to
enter the cal gas value if different than 2.5%.

3. Connect the gas cylinder to the inlet of the calibration adapter, and turn on the gas
supply. Ensure that the Zero Valve in the TGD is off, and that there is excess flow
going out the exhaust port of the calibration adapter. The rotameter should read at
least 1-2 SCFH with the Zero Valve off.
4. On the screen, immediately above the numerical display, will be a set of instructions.
Follow these instructions in the order listed to do the calibration of the amplifier
board pots and control settings related to the TC detector. This calibration procedure
sets the values of the Bridge Zero Pot, the TC Span Pot, and the electronic Zero Pot
for the TC detector channel in order to calibrate the sensor to a known gas
concentration range. The system allows the user to enter the actual analyzed
concentration of the calibration gas used, this should be done first to allow the system
to calculate actual settings.
5. Recheck zero once more by turning the Zero Valve on (“V” command). Recheck the
span by turning off the Zero Valve. Once the steps have been completed, turn off the
calibration gas supply, disconnect the high value gas cylinder, and press “D” to return
to the main display screen.

23
 Appendix 2
BLINK CODES

There is a single multifunction status light on the front of the Total Gas Detector module
that indicates system status via combinations of red and green and short and long blinks.
Basically, the blink codes are separated into number of blinks representing the subsystem
which is has a problem or status indication, and the length and color of blinks which
indicate the nature of the problem or status.

Subsystem Definitions

Each subsystem has a basic number of blinks that is indicated below:

1. Pump System – 1 blink

2. Autozero System – 2 blinks
3. CC Detector - 3 blinks
4. TC Detector - 4 blinks
5. Heater - 5 blinks

Blink Codes

For each subsystem, there are 4 possible combinations of blink speed/color that indicate
different status/alarm indications for each subsystem:

1. Stabilizing/Pending - short blink green ο

This indicates that a particular subsystem is currently stabilizing its controlled
variable, i.e. the pump pressure is stabilizing at the setpoint.
2. Calibration Mode - long blink green ⊂⊃
This indicates that the particular subsystem is currently in calibration mode as
invoked from the terminal program attached to Console Port.
3. Error Low - short blink red ο
This indicates that the subsystem has a low alarm condition, i.e. temperature
below setpoint, or pump pressure below setpoint.
4. Error High - long blink red ⊂⊃
This indicates that the subsystem has a high alarm condition, i.e. the CC
sensor is pegged at the maximum value, or the Autozero failed high on a
channel.

24
In addition, there are a couple of extra codes that do not specifically fit into a subsystem
category:

1. Zero Valve On (manual) - 6 short blinks (green only) οοοοοο

2. Pump Off (manual) - 2 short blinks (1 green/1 red) οο
3. Normal Operating - 1 long blink/ 1 long space (green only) ⊂⊃

These are fixed codes and do not change.

Putting it all Together

These codes are combined to indicate the status and any errors in the form of blink codes
for each subsystem. Probably the best way to describe the result is to give some
examples:

• Pump Pressure Stabilizing - 1 short green ο

• Heater Temperature Stabilizing - 5 short greens οοοοο
• Calibrating CC Sensor - 3 long greens ⊂⊃⊂⊃⊂⊃
• Heater Temperature Low Alarm - 5 short reds οοοοο
• TC Detector Overrange - 4 long reds ⊂⊃⊂⊃⊂⊃⊂⊃

Blink codes automatically repeat as long as the condition that causes them still exists.
There is a long space between each set of codes. Multiple codes can exist at the same
time, in which case they are presented in order, starting with the highest priority:

• Pump Pressure stabilizing, heater stabilizing, CC detector warm-up:

ο ο ο ο ο ο ο ο ο …Repeats

Heater
Warm-up
CC
Warm-up
Pump
Stabilizing

Generally, green blink codes indicate system status and indicate only that a subsystem is
stabilizing or in a calibration mode. Green blink codes may occur from time to time
during normal operation, such as when switching from TC sensor back to CC sensor, or if
a front panel button is pushed. Red blink codes generally indicate an error or problem
with the system, and are usually accompanied by an audible alarm to draw attention.
Audible alarms can be cancelled by momentarily pushing either the Pump or Autozero
button on the front panel. This action does not clear the blink code, but only cancels the
audible alarm.

25
Usually if an alarm condition occurs, it is prudent to connect a terminal to the Console
Port using a NULL serial cable, and see what caused the problem. The Display mode can
be used to see the status of the two detectors, pump pressure, and block temperature. The
blink code will indicate in a general way where the problem lies with the system. If the
problem was temporary or is repaired, the blink code can be cancelled by holding down
either front panel button until a short beep is heard. Blink codes can only be cancelled if
the underlying cause has been remedied. Pushing and holding a front panel button will
cancel all pending alarm codes. Codes will re-appear if the underlying problem has not
been repaired.

A Blink code Matrix following lists all blink codes and their causes. All code blinks for
the same subsystem are separated by a short space approximately equal in length to the
blink. Blink codes from separate subsystems or repeating blink codes are separated by
long spaces. The green blink for normal operation is an extra long blink followed by an
extra long space. The Pump Off indicator is one short green followed by one short red
blink.

Blink Code Matrix

Stabilizing Calibrating Error Low Error High

No. Subsystem
Green Green Red Red
1 Pump 1 short 1 long 1 short 1 long

2 Autozero 2 short 2 long 2 short 2 long

3 CC 3 short 3 long 3 short 3 long

4 TC 4 short 4 long 4 short 4 long

5 Heater 5 short 5 long 5 short 5 long

6 Zero Valve 6 short

7 Pump Off 1 short 1 short

8 Normal 1 X long
(long space)

26
 Appendix 3
INITIAL COMMISSIONING AND CALIBRATION

There are three steps to initial commissioning of the Total Gas Detector system. This
does not include basic calibration of the CC and TC sensors. These steps are outlined
below. Note that all of the adjustments below are performed while the system is in
Override Mode:

A. Voltage and Power Supply Checks

1. Install fuses in the power entry module (3A, 250VAC).

2. Visually check all AC wiring.
3. Ensure power switch is in the off position, and install an AC power cord
4. Unplug all terminal block connectors from the Control Module, including the valve
(TB3), pump (TB2), heater (TB4B), and the two 12V (TB1 and TB4A) input
connectors. Remove P1 power connector to the amplifier board as well as the power
connection to the CPU module (JP1)
5. Turn the power switch to the On position
6. Check the voltage at the DC output terminals on the power supply. Ensure that the
green LED in the supply is on, and set the pot to adjust the output voltage to 13.2V.
7. Reconnect TB1 12v plug, and test voltages on P1 connector on the circuit board.
Center 2 pins are ground, left-hand pin should be 13.2v, and right-hand pin should be
5.00v.
8. Plug in the CPU module power (JP1). The green LED on the CPU board should light
up and the red LED should begin to blink.
9. Assuming these checks are all OK, turn off the AC power switch and reconnect all
other terminations except for the heater (TB4B).
10. Voltage checks are now complete. Proceed to Startup Tests.

B. Pre-calibration Adjustments

6. Press and hold the Pump switch, and turn on the AC Power switch. Release the Pump
switch, and the unit will go into Override Mode. In this mode, the heater is off, all
alarms are disabled, and the CC detector is latched on. The Zero valve is also latched
in the On position. This precludes the possibility of applying high gas concentration
to the inlet and destroying the CC detector.
7. Connect a terminal to the Console port of the instrument, with the communication
settings at 19200,N,8,1 with hardware handshaking disabled. A laptop or desktop
computer running TeraTerm Pro, Hyperterminal, or other terminal software can be
used. A null modem cable is required to connect two computers together.
8. Upon startup, “System Started” will be sent out the port.

27
Note: All commands sent to the TGD via serial port must be Upper Case (Capital)
characters. The system will not recognize lower case characters.

9. Once communications have been established, and the system is in Override Mode,
type the command “CCC” in the terminal window. This should cause the TGD to go
into CC Sensor Initialization mode. There will be a numerical display at the bottom
of the terminal screen similar to: (note that the actual numbers and status on the
bottom line may vary)

Pwr| Cnts |CC Gas|Cal Gas|Span Cnts|Set Cnts|DPOT|Zero

Valve|Entry
On| 02240| 0.58| 2.50| 8000| 8368| 128| On|_

The Pwr indicator shows whether sensor power is on or off. Cnts shows the current sensor voltage
in A/D counts. CC Gas shows the current calculated gas value in %. Cal Gas is the entered gas
concentration for the calibration gas. Span Cnts is the target number of counts for full scale with
gas applied, and is adjusted using the CC Span pot. Offset Cnts is an additional zero offset value
adjusted after the Span Cnts, and is set using the CC Bridge Zero pot. The DPOT value is the
current setting of the electronic Zero pot, Zero Valve shows the valve status, and Entry is used to
enter the cal gas value if different than 2.5%.

10. Also on the screen, immediately above the numerical display, will be a set of
instructions. Follow these instructions in the order listed to do the initial setup of the
amplifier board pots and control settings related to the CC detector. This
initialization procedure sets the values of the Bridge Zero Pot, the CC Span Pot, and
the electronic Zero Pot for the CC detector channel to known starting values. This
step eliminates the possibility of the CC channel values being out of range when
calibration is first attempted, and will substantially lessen the frustration of setting up
a new system.
11. Once the steps have been completed, press “D” to return to the main display screen.
There will be a numerical display at the bottom of the terminal screen similar to that
shown below. This is the main display screen and the default display mode, and
entering the “D” mode is also used to exit any other setup mode. (note that the actual
numbers and status on the bottom line may vary)

Time sec|Press PSI|Temp C|CC %|TC %|Flags

|Alarms
187|06710 2.99|13099 40.01|02223 0.57|00683
1.26|PHC____|

The Time sec value is the number of seconds of system uptime, Press PSI shows the counts and
calculated PSI at the pump. Temp C shows the temperature sensor counts and calculated values.
CC % and TC % show the raw A/D counts and calculated gas percentage for the CC and TC
detectors, respectively. Flags show system status flags, and Alarms show active alarm flags.

12. Now the TC channel can be initialized. Once again, ensure that the system is still in
Override Mode, and type the command “CTC” in the terminal window. This should
cause the TGD to go into TC Sensor Initialization mode. There will be a numerical

28
 display at the bottom of the terminal screen similar to: (note that the actual numbers
and status on the bottom line may vary)

Pwr| Cnts |TC Gas|Cal Gas|Span Cnts|Offset Cnts|DPOT|Zero

Valve|Entry
On| 00687| 1.28| 100.00| 15633| 16001| 128|
On|_

The Pwr indicator shows whether sensor power is on or off. Cnts shows the current sensor voltage
in A/D counts. TC Gas shows the current calculated gas value in %. Cal Gas is the entered gas
concentration for the calibration gas. Span Cnts is the target number of counts for full scale with
gas applied, and is adjusted using the TC Span pot. Offset Cnts is an additional zero offset value
adjusted after the Span Cnts, and is set using the TC Bridge Zero pot. The DPOT value is the
current setting of the electronic Zero pot, Zero Valve shows the valve status, and Entry is used to
enter the cal gas value if different than 100%.

13. Also on the screen, immediately above the numerical display, will be a set of
instructions. Follow these instructions in the order listed to do the initial setup of the
amplifier board pots and control settings related to the TC detector. This initialization
procedure sets the values of the Bridge Zero Pot, the TC Span Pot, and the electronic
Zero Pot for the TC detector channel to known starting values. This step eliminates
the possibility of the TC channel values being out of range when calibration is first
attempted, and will substantially lessen the frustration of setting up a new system.
14. Once the steps have been completed, press “D” to return to the main display screen.

C. Temperature and Pump Calibration

1. Assuming communications have been established, and the system is in Override

Mode, type the command “CTE” in the terminal window. This should cause the TGD
to go into Block Temperature Sensor Calibration mode. There will be a numerical
display at the bottom of the terminal screen similar to: (note that the actual numbers
and status on the bottom line may vary)

Cnts |Curr Temp|MTemp |MVolts|Set Volts|Set Cnts|Zero

Valve|Entry Mode|Entry
12989| 39.67| 30.00| 2.501| 0.124| 9820| On|
Temp|_

The Cnts and Curr Temp values show the current A/D reading and computed equivalent
temperature of the block, respectively. The M Temp and M Volts are the measured block
temperature and the measured voltage on R37 as entered by the user. Set Volts is the calculated
voltage to be set at R37 using the Zero Pot, and Set Cnts is the number of counts that Cnts is to be
set to using the Span pot. Zero Valve shows the valve status, and Entry Mode shows the current
entry mode for user entered data. It will read either Temp or Volts. Entry is where the data is
actually entered, cleared when the Enter key is pressed.

2. Also on the screen, immediately above the numerical display, will be a set of
instructions. Follow these instructions in the order listed to do the initial calibration
of the amplifier board pots and control settings related to the temperature sensor.

29
 This initialization procedure sets the values of the Zero Pot and the Span Pot to
calibrate the temperature sensor output to a known value. An accurate temperature
measurement device will be required to calibrate the block temperature sensor
against, as well as an accurate multimeter to measure voltages. The software in the
unit requires only the measurement of the voltage on two of the board components,
(shown in Photo 4 as R37 and U4 Pin 8), and the actual block temperature as

Ground
(Black TP)
U4 Pin 8

RH end
Of R37
Measure
Output here

measured by the

Photo 4 – Voltage on R37

thermometer. It then uses these entered values to calculate the settings of the Zero
and Span pots to make the internal temperature sensor read correctly.
3. Once the steps have been completed, press “D” to return to the main display screen.
4. Now the Pump calibration can be performed. Again, assuming communications have
been established, and the system is in Override Mode, type the command “CPU” in
the terminal window. This should cause the TGD to go into Pump Calibration mode.
There will be a numerical display at the bottom of the terminal screen similar to:
(note that the actual numbers and status on the bottom line may vary)

PWM %|PWM Cnts|Target PSI|Press PSI|Pump RPM|Zero Valve

23.3| 10427| 3.00|06774 3.02| 2529| On

The PWM % and PWM Cnts values indicate the current PWM values applied to the pump motor.
Target PSI and Press PSI indicate the setpoint and actual pressure at the pump output,
respectively. The Pump RPM is derived from the pulsations caused by the pump on the pressure
sensor. The Zero Valve status indicator shows the current state of the zero valve.

5. Also on the screen, immediately above the numerical display, will be a set of
instructions. Follow these instructions in the order listed to do the initial calibration
of the pneumatic system needle valves and control settings related to the Pump and
Pressure sensor. This initialization procedure sets the pump PWM value and the

30
 flows through the sensor block and to the Gas Chromatograph. The System pressure
will be pre-adjusted to some value, using the Bypass Control. (The control locations
are shown in Photo 2) Then the flows to the chromat and detector cell are adjusted,
and finally the system is compensated for the length of sample line attached.
6. Once the steps have been completed, press “D” to return to the main display screen.

31