465M Ozone Analyzer
Contents
1. Decimal Start Address Description Register Type Bit Bits 1 Stream Concentration g Nm Float Inverse 0 32 3 Hi Alarm Status Byte 0 8 3 Hi Hi Alarm Status Byte 8 8 19 Sensor Reference Value Float Inverse 0 32 21 Sensor Measure Value mV Float Inverse 0 32 23 Sensor Pressure Value mV Float Inverse 0 32 25 Sensor Gas Temperature K Float Inverse 0 32 27 Sensor UV Lamp Temperature Float Inverse 0 32 8 6 3 Instrument Setup and Configuration Registers Read Write Decimal Register Start Address Description Type Bit Bits 1030 Hi Alarm Value PPM Float Inverse 0 32 1032 Hi Hi Alarm Value PPM Float Inverse 0 32 1034 Hi Alarm Enable PPM Byte 0 8 1034 Hi Hi Alarm Enable PPM Byte 8 8 1035 Alarm Latch Mode Byte 0 8 1038 Analog Range PPM Float Inverse 0 32 P N 06160F DCN6854 API Model 465M Monitor User Manual Page 50 9 MAINTENANCE A WARNING Electrical Shock Hazard THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE A PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLYI 9 1 Maintenance Schedule Table 9 1 below outlines the suggested maintenance procedures and intervals for ensuring the 465M continues to operate accurately and reliably Table 9 1 Maintenance Schedule Maintenance Item Recommended Interval Section Replace particulate filter 6 months 92. 51 Table 10 1 Status LED Output Definitions ss 65 P N 06160F DCN6854 Teledyne Model 465M Monitor User Manual Page viii 1 INTRODUCTION Teledyne API s Model 465M Ozone Monitor is a medium range ozone monitor that measures process ozone concentrations this microprocessor controlled instrument provides fast response times with minimal zero drift and has built in tests and diagnostics to allow maximum uptime We at Teledyne API will be pleased to provide you with any support required so that you may utilize our equipment to the fullest extent Our full time technical support department is always available to answer your questions Teledyne API Technical Support 9480 Carroll Park Drive San Diego California 92121 5201 USA Toll free Phone 800 324 5190 Phone 858 657 9800 Fax 858 657 9816 Email sda_techsupport teledyne com Website http www Teledyne API com P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 9 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 10 2 SPECIFICATIONS AND AGENCY APPROVALS 2 1 Model 465M Specifications Measuring principle UV absorption Beer Lambert Law Ranges User selectable to any full scale range from 0 1000 PPM to 0 10 000 PPM 0 5 g Nm to 0 50 g Nm 0 1 wt to 0 3 wt Measurement Units PPM wt g Nm
3. 21 2 0002 000000 27 6 OPTIONAL HARDWARE AND SOFTWARE eese 2020220 29 6 TRACK MOUNT SLEIDES smart mes dames mts REPE ERU RD TREES 29 6 2 LOW FLOW ALARM ois sieves tema te ta itin 29 FRONT PANEL OVERVIEW ste eis cie a 31 7 1 1 Ozone Concentration Display ss 31 7 2 Menu Navigation Keypad ie reri eir ree e pe er oe teles 31 7 1 3 Concentration Alarm 5 32 sinis e REDE RENI UIN HII PI 32 7 2 FRONT PANEL MENU Sirena a e 33 7 2 1 Men Navigation BASICS eere e RP Pe 33 722 Values eR oU Ua 33 PRI DIAM MUA me tee a edat rte ey 36 72 4 Ment nu ER 39 72 3 SETUP VARS Men iii EE EE EE 40 SETUP ALARM Men ee rr eter as ie 41 CONFIG siii RB IBID I ERR 41 P N 06160F DCN6854 Model 465M Monitor User Manual Page v 8 DIGITAL nia 3 8 1 DIGITAL COMMUNICATIONS OVERVIEW ccsessssecececeesessscececccsceeuecececececsesssaececececseseaaeeeeececseseaaeeeeess 43 8 2 CHANGING COM PORT HARDWARE CONFIGURATION 43 8 3 RS 232 CONFIGURATION noi 45 8 4 RS 485 CONFIGURATION cccccccccccssssssecec
4. Accuracy 1 of Full Scale Precision Repeatability 0 5 of Full Scale Display Resolution 1 PPM 0 001 wt 0 01 g Nm Response Time 95 lt 45 seconds to 95 Pressure Temperature NTP 273 15 760 Compensation mmHg Gas Inlet Pressure Range 11 0 16 0 psia Sample Flow Rate 0 8 LPM Humidity Range 10 9096 RH non condensing Temperature Range 5 450 C Dimensions H x W x D Rack Mount 3U Panel 5 22 133 mm x 19 0 483 mm x 15 3 388 mm With NEMA 4X enclosure 16 01 407 mm x 15 77 401 mm x 8 02 204 mm Weight Rack Mount 13 6 Ibs 6 17 kg With NEMA 4X enclosure 16 5 Ibs 7 5 kg Power 100 240 V 47 63 Hz 74 W Installation Category II Pollution Degree 2 For Indoor Use Only Maximum Operating Altitude 2000 meters Analog Output 0 5 V or 4 20 mA isolated output Status Outputs System OK Invalid Reading UV Lamp Fault Pneumatic Error RS 232 optional RS 485 57 6 Kbaud DB 9 connector P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 11 2 2 5 This section presents Safety and Electromagnetic Compatibility EMC compliance approvals for the Model 465M monitor 2 2 1 Safety IEC 61010 1 2001 Safety requirements for electrical equipment for measurement control and laboratory use CE 2006 95 EC Low Voltage Directive 2 2 2 EMC EN 61326 1
5. 61326 1 Class A Emissions Industrial Immunity EN 55011 CISPR 11 Group 1 Class A Emissions FCC 47 CFR Part 15B Class A Emissions CE 2004 108 EC Electromagnetic Compatibility Directive 2 2 3 Other Type Certifications For additional certifications please contact Technical Support Toll free 800 324 5190 Phone Phone 858 657 9800 Fax 858 657 9816 Email sda_techsupport teledyne com P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 12 3 PRINCIPLE OF OPERATION The detection of ozone molecules is based on absorption of 254 nm UV light due to an internal electronic resonance of the O3 molecule The 465M uses a mercury lamp constructed so that a large majority of the light emitted 1s at the 254nm wavelength Light from the lamp shines through an absorption cell through which the sample gas is passed The ratio of the intensity of light passing through the absorption cell and the intensity of light measured by a reference detector forms a ratio This ratio forms the basis for the calculation of the ozone concentration The Beer Lambert equation shown below calculates the concentration of ozone from the ratio of light intensities 6 a 10 2 T 14695psi I 2 axL 273K 1 o Where I Intensity of light passed through the sample lo Intensity of light through sample free of ozone absorption coefficient L path length concentration of ozone in parts per million
6. 7 2 3 5 Span Calibration The Span Calibration also allows the instrument to calibrate its internal ozone offset factor The Span Calibration however is done with some controlled concentration gas connected to the Sample In port of the 465M It is recommended that a span gas is concentrated to around 8046 of the operating range Set the SPAN VALUE to the measured concentration of your calibration gas This normally takes 10 15 minutes NOTE A Span Calibration should only be performed with a stable source of Ozone and a reference monitor measuring the same gas supply If you are unsure regarding the suitability of a particular source of calibration gas contact Technical Support at Teledyne API for assistance see Section 12 See Figure 7 4 shows the Span Cal menu After the instrument has stabilized on the source of span gas navigate to the Span Cal menu See Figure 7 4 and Press ENT Next enter the Span Target concentration the actual concentration of ozone being supplied to the monitor and press ENT The display will next show a confirmation menu ENT TO SPAN Press ENT to perform the Span Calibration or CFG to abort back to the start If the calibration is successful the display will return to the concentration menu and the monitor reading should change adjust to read very close to the target value If the calibration cannot be performed an OUT OF RANGE error will be displayed Press ENT to confirm and the display wil
7. sample temperature in Kelvin P pressure in pounds per square inch absolute As can be seen the concentration of ozone depends on more than the intensity ratio Temperature and pressure influence the density of the sample The density changes the number of ozone molecules in the absorption path which impacts the amount of light removed from the light beam These effects are addressed by directly measuring temperature and pressure and including their actual values in the calculation The absorption coefficient is a number that reflects the inherent ability of ozone to absorb 254 nm light Most current measurements place this value at 308 cm atm l at STP The value of this number reflects the fact that ozone 15 a very efficient absorber of UV radiation which is why stratospheric ozone protects the life forms lower in the atmosphere from the harmful effects from solar UV radiation Lastly the absorption path length determines how many molecules are present in the column of gas in the absorption tube P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 13 The intensity of light is converted into a voltage by detector preamp module The voltage is converted into a number by a high resolution A D analog to digital converter The digitized signal along with the other variables is used by the CPU to compute the concentration using the above formula P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual
8. Ground 5 G NOTE For RS 485 configuration the DTE DCE switch should always be set to DCE See Section 8 2 for details on changing this configuration The serial port setup for RS 485 configuration is shown in Table 8 4 below Table 8 4 RS 485 Port Setup Property Value Baud Rate 57600 Data Bits 8 Parity None Stop Bits 1 Flow Control None P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 46 8 5 Ethernet Configuration Ethernet is commonly used for factory automation busses with a computer or PLC acting as a master The communications protocol used for the Ethernet configuration is MODBUS TCP IP For details on the MODBUS TCP IP specification please see http www modbus org A Windows software application Devicelnstaller is available for configuring the Ethernet module used in the 465M This application is available for download here http www lantronix com device networking utilities tools device installer html 8 5 1 Hardware Setup for Configuring the Ethernet Module To make the first time configuration of the Ethernet module as easy as possible the module comes from the factory with DHCP enabled The 465M can simply be plugged into a network with a DHCP server and an IP Address should be automatically assigned to and stored in the device A simple network can easily be constructed for this purpose by using a small broadband r
9. Page 14 4 GETTING STARTED The 465M is shipped with the following standard equipment 1 Power cord Rack mount version only 2 Instruction manual Upon receiving the 465M please do the following 1 Verify that there is no apparent shipping damage If damage has occurred please advise shipper first then Teledyne 4 1 Mechanical Installation for NEMA 4X Enclosure Mount the enclosure securely to a vertical surface e Figure 4 1 shows the locations of the four mounting holes All four mounting holes should be used to secure the monitor e Use stainless steel 5 16 diameter bolts 4 1 1 Ventilation Clearance When installing the 465M be sure to leave sufficient ventilation clearance Table 4 1 465M Ventilation Clearances NEMA Version Area Minimum required clearance Back of the monitor None Sides of the monitor inch Above and below the monitor inch P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 15 10 24 1260 41 15 06 382 5 Figure 4 1 465M Mounting Hole Locations and Dimensions 4 2 Mechanical Installation 19 Rack Version The Rack Mount version of the 465M was designed to be operated as a bench top monitor or to be mounted in a standard 19 RETMA instrumentation rack For rack installations the four mounting feet should be removed from the bottom of the monitor 4 2 1 Ventilation Clearance When installing th
10. port that can be connected to a computer or digital data acquisition system This COM port uses the standardized MODBUS 9 protocol and can be configured for RS232 RS485 or Ethernet 10 Mbit allowing for connections to a wide variety of devices and networks See Section 8 2 for more information on configuring the COM port The COM port can be used for data acquisition alarm triggering and instrument configuration the functions that are available at the front panel of the instrument can also be performed over the COM port NOTE The APICOM software provided by Teledyne API does not currently support communications with the 465M Contact Technical Support for more information on compatible MODBUS software that can be used with the 465M 8 2 Changing COM port Hardware Configuration WARNING Electrical Shock Hazard THE OPERATIONS OUTLINED IN THIS SECTION ARE TO BE A PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY The COM port can be configured for RS232 RS485 or Ethernet To change the COM port hardware configuration perform the following steps Disconnect power from the 465M Remove the six screws and the top cover Locate the DIP switches labeled SW3 on the rear portion of the mainboard JI qe Turn ON the switches specified for the desired COM configuration See Figure 8 1 other switches on SW3 should be OFF 5 Locate SW2 DTE DCE switch on mainboard P N 06160F DCN685
11. units or components returned to Teledyne API should be properly packed for handling and returned freight prepaid to the nearest designated Service Center After the repair the equipment will be returned freight prepaid The complete Terms and Conditions of Sale can be reviewed at http www teledyne api com terms and conditions asp CAUTION Avoid Warranty Invalidation Failure to comply with proper anti Electro Static Discharge ESD handling and packing instructions and Return Merchandise Authorization RMA procedures when returning parts for repair or calibration may void your warranty For anti ESD handling and packing instructions please refer to the manual Fundamentals of ESD PN 04786 in its Packing Components for Return to Teledyne API s Customer Service section The manual can be downloaded from our website at http www teledyne api com under Help Center Product Manuals in the Special Manuals section RMA procedures are under Help Center gt Return Authorization P N 06160F DCN6854 Teledyne Model 465M Monitor User Manual Page iii THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page iv TABLE OF CONTENTS 2 SPECIFICATIONS AND AGENCY 2 1 MODEL 465 M SPECIFICATIONS Eres tesa tr Pe AUS 11 2 22 APPROVALS eee tt reme aeree etel tana
12. DEA nt D 12 LLANOS auti e iie e Ue te Rete uts A petendo 12 202 EM Cs a n gestes eave EG er P e ED e er DU ERE E URP 12 22 3 Other Type Certifications Lee nee RI fr eee 12 2520 eco cisco bi ones eerie es ooi ae 4 1 MECHANICAL INSTALLATION FOR NEMA 4X ENCLOSURE esse 15 ALA Ventilation Cledr nc s o e ward Er SERRE ee CU ERE RI Pn iria 15 4 2 MECHANICAL INSTALLATION 197 RACK VERSION 4 2 4242 0000 000000000000000000000000000000004 16 4 21 Ven latiori Clearance sd e teo d Re ER ese as 16 4 3 AC POWER CONNECTION FOR MONITORS IN NEMA 4X ENCLOSURES see 17 4 3 1 Wiring Requirements for NEMA Enclosures ss 17 4 32 Wirinp InStFACIORS s ien aee pde eh e rece eet pete 17 4 4 PNEUMATIC CONNECTIONS 19 4 4 1 Ozone Inlet Connection eii teet tenent entes entente nennen nne 20 44 2 Exhaust CONNECHOM EE 21 4 5 ELECTRICAL I O CONNECTIONS biet tet e t Rp ort eee eerte ie e Quee ee Pe RARUS 23 4 5 1 Location of I O Connectors in the NEMA Configuration ses 23 4 5 2 Analog Outp t 25 5 dtt aUe e cei e eee dee dde ES 24 4 53 Status Outp ls eite aep pene e eerta ee eer Rd re 24 45 14 Hi Current Relay OUtp uls inue e nee ente RE et fr Rp p ee 23 2 5 5 Digital Serial Interfaces sense nee t qe Int e te iR ele 25 5 FREQUENTLY ASKED
13. Ne ANALOG RANGE 5000 1000 9999 Used to scale analog output 05 50 wt T J P N 06160F DCN6854 API Model 465 Monitor User Manual Page 40 7 2 6 SETUP ALARM Menu The ALARM menu allows the operator to view and edit properties of the concentration alarms The table below summarizes the alarm configuration settings Table 7 7 Alarm Configuration Settings Property Meaning Default Range Value HI ALARM HI alarm trigger value 10 PPM 10 9999 PPM HIHI ALARM HI HI alarm trigger value 20 PPM 10 9999 PPM ON OFF HI HI alarm enable enables HI alarm ON ON OFF ALARM operation ON OFF HI HI HI HI alarm enable enables HI HI ON ON OFF ALARM alarm operation 7 2 7 CONFIG Menu The CONFIG menu displays important information about the instrument The Serial Number COMM address settings and the latest revision of software installed are information available in the CONFIG menu Settings can be changed under other menus see Sections 7 2 3 7 2 5 and 7 2 6 however the CONFIG menu just contains instrument specific information P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 41 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 42 8 DIGITAL COMMUNICATIONS 8 1 Digital Communications Overview The 465M comes equipped with a digital communications Com
14. STAT AUX 2 AUX OUT 2 UNDEFINED 7 2 3 3 Memory Reset This function is currently disabled 7 2 3 4 Zero Calibration The zero calibration allows the instrument to calibrate it s internal ozone offset factor This should only be done with a source of zero air connected to the Sample In port of the 465M Allow the instrument to stabilize on the zero air source before attempting to zero This normally takes 10 15 minutes If the zero calibration is enabled the internal ozone offset factor will automatically be reported as zero every 6 minutes If the zero calibration is disabled then manual calibration is necessary based on the customer s applications For normal applications the zero calibration is not necessary When entering the Zero Calibration menu the prompt ENT TO CAL appears on the display Simply confirm the calibration by pressing the ENT button to perform the calibration to abort the calibration press and hold the CFG button to return to the previous menu level After pressing ENT the instrument will automatically exit the menu mode and return to Concentration mode The concentration reading should quickly go to Zero P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 37 While measuring zero air a certain amount of noise or dithering of the concentration about the zero point will occur and is normal This noise is typically 1 3 PPM in magnitude
15. Section 7 2 6 to configure the concentration for the alarm trigger Table 4 4 Relay Functions Relay Function Normal Operating State 1 System OK Diagnostic On Identical to Sensor OK status output as described in Table 4 3 2 Hi Alarm Off 3 Hi Hi Alarm Off 4 5 5 Digital Serial Interfaces There is one external communications port available on the 465M that can be configured as RS232 RS485 Half Duplex or Ethernet 10Mbit This section provides only a brief overview of the digital serial connections for more detailed information on configuring and using the digital serial interfaces see Section 8 4 5 5 1 RS232 Connection With the instrument configured for RS232 connection can be made to the DB 9 connector labeled RS232 485 or to the three COM pins on the General I O connector See Section 8 2 for additional details When using RS232 a 9 pin serial cable TAPI P N WR77 can be used to connect the instrument to a standard PC personal computer serial port P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 25 4 5 5 2 5485 Connection With the instrument configured for RS485 connection can be made to the DB 9 connector labeled RS232 485 or to the three pins on the General I O connector See Section 8 2 for additional details 4 5 5 3 Ethernet Connection With the instrument configured for Ethernet connection should be made to th
16. by pressing ENT The 5 points will correspond to the following analog output values depending on whether the output is configured for 0 5V or 4 20mA Table 7 3 Analog Step Test Values Point 0 5V Output 4 20 mA Output 096 0 00 V 0 02 4 mA 0 02 25 1 25 V 0 02 0 02 50 2 50V 0 02 12 mA 0 02 75 3 75 V 0 02 16 0 02 100 5 00 V 0 02 20 0 02 Press to exit from Analog Step Test function 7 2 3 2 Signal I O The Signal I O menu allows the operator to manually control the various relay outputs and control inputs available on the rear panel of the 465M This function is useful for testing or debugging external control systems i e dataloggers or PLC s to which the instrument may be connected See Section 4 5 for additional details on making connections to these I O signals on the rear panel See Table 7 4 for additional details on entering the Signal I O menu P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 36 Table 7 4 Signal I O List Signal Name Rear Panel Label Function AUX 1 IN CTRL IN 1 UNDEFINED AUX 2 IN CTRL IN 1 UNDEFINED RELAY 1 RELAY 1 SENSOR OK RELAY 2 RELAY 2 HI ALARM RELAY 3 RELAY 3 HI HI ALARM STAT OUT I STATUS OUT 1 SENSOR OK STAT OUT 2 STATUS OUT 2 INVALID READING STAT OUT 3 STATUS OUT 3 CHECK LAMP STAT OUT 4 STATUS OUT 4 PNEUMATIC ERROR STAT AUX I AUX OUT 1 UNDEFINED
17. confirms whether or not the files are a match 1 Press Verify The screen will display Wait for boot loader 2 When the screen displays Power cycle instrument now power up the instrument NOTE Search for boot loader will time out in 20 seconds If the instrument is not powered up in 20 seconds the screen will display No boot loader detected Go back to step 1 to verify the firmware P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 61 The firmware loader software should display a message Boot loader found verifying If this message is not displayed power down the instrument and receck the COM port configuration and cable see Section 9 10 1 and retry When the upload is complete a message Verify flash completed successfully should be displayed If it is an unsuccessful upload a message Verify flash error 1s displayed If a Verify flash error occurs ensure that the correct PC COM port is selected for the instrument see Section 9 10 2 step 4 NOTE A verification process can be stopped at any point in time This will not affect the firmware that is already uploaded on the instrument The instrument will automatically go to the firmware in 10 seconds P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 62 10 TROUBLESHOOTING A WARNING Electrical Shock Hazard 2 THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED
18. the instrument See Figure 4 6 for their location Connection to these terminals is usually made via a conduit connection to the NEMA enclosure A standard conduit penetration may be added to one of the walls of the enclosure for this purpose or the existing penetration may be used The I O label inside the NEMA cover provides information on the functions of the connectors See Figure 4 7 below for the location of I O Label NEMA COVER LABEL Figure 4 7 NEMA I O Label P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 23 4 5 2 Analog Output The analog output is located at the General I O connector See Figure 4 5 and is labeled ANA The analog output can be configured for 0 5V voltage or 4 20 mA current output See Section 7 2 3 1 to automatically step test the analog output The analog output is automatically scaled to the range of the instrument i e if the monitor range is 1000 PPB then 5V would correspond to 1000 PPB and 0V would correspond to 0 PPB See Section 7 2 5 for information on changing the range of the monitor 4 5 3 Status Outputs There are four instrument status outputs located at the General I O connector These status outputs mirror the state of the four diagnostic LED s on the front panel If any of these status outputs are in a different state than shown in Table 4 3 then some adjustment or troubleshooting should be performed See Section 10 2 f
19. the Menu mode and return the display to Concentration mode 7 2 2 Editing Numeric Values At certain places in the menu structure the operator can edit numeric values The menu buttons behave somewhat differently when in this mode Press CFG to select a digit to edit The selected digit will blink Next press the UP DOWN arrows to increment decrement the selected digit Press CFG again to select another digit Pressing CFG at the last digit will wrap back to the first digit Once all the digits have been edited press ENT to accept the new value To abort the editing process without changing the original value press and hold the CFG button until the display returns to the previous menu level NOTE Limit checking is enforced while editing values The display will flash to indicate the user has selected an invalid or out of range value The ENT button will not operate until a valid value 15 entered P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 33 Concentration Display SETUP ALARM en 9 VARS EXIT SEE DIAG DETAIL NEXT PAGE SEE VIEW DETAIL NEXT PAGE SEE CFG DETAIL NEXT PAGE EXIT 465M Front Panel Menu Diagram Mount Figure 7 2 Front Panel Menu Diagram See Section 6 2 5 WEIGHT 3209 ANALOG 5000 EXIT gt QA y ALARM ON OFF HI See Sectio
20. 0 PCS 037420000 ASSY UV LAMP BIR 06182E 465M SPL NEMA DCN5191 11 26 08 P N 06160F DCN6854 Teledyne Model 465M Monitor User Manual 73 13 2 Spare Parts List for NEMA Version Part Number Description Les 0 037420000 ASSY UV LAMP BIR 061600000 MANUAL OPERATORS 465M 06183E 465M SPL Rack DCN5191 11 26 08 P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 74
21. 3 element Adjust UV lamp As Indicated by Check Lamp 9 4 LED or status output Replace lamp As required when adjustment can 9 5 no longer be performed Replace sample pump 2 years 9 6 Replace Auto Zero Valve annually 9 7 Rebuild cells replace o 3 years Return rings to factory P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 51 9 2 Instrument Layout Figure 9 1 and Figure 9 2 show the internal layout of the 465M rack mount and NEMA respectively These figures will be referenced in the procedures that follow Note the caution areas where high voltage line voltage may be present when power is connected to the instrument UV DETECTOR UV DETECTOR AUTO ZERO PARTICULATE ADJUSTMENT ADJUSTMENT VALVE MANIFQLD FILTER HOUSING POT PR3 POT PR4 MAINBOARD PCA UV LAMP UV LAMP SETSCREWS SENSOR ASSEMBLY DRYER SAMPLE PUMP ASSEMBLY OZONE DESTRUCT Figure 9 1 Instrument Layout Rack Mount Configuration P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 52 AC POWER AC DC SENSOR UV DETECTOR UV DETECTOR CONNECTOR POWER MODULE ADJUSTMENT ADJUSTMENT CAUTION HIGH SUPPLY POT PR4 POT PR3 VOLTAGE AREA MAINBOARD PCA OZONE 2 DESTRUCT 2 00 0 DRYER SAMPLE AUTO ZERO COALESCING PUMP VALVE PARTICULATE FILTER ASSEMBLY MANIFOLD FILTER HOUSING ASSEMBLY Figure 9 2
22. 4 Teledyne API Model 465M O Monitor User Manual Page 43 For RS 232 operation set SW2 to either DTE or DCE See Section 8 3 For RS 485 operation set SW2 to DCE Re install the instrument cover Re connect power to the instrument The software portion of the COM port configuration will now automatically be completed after the next instrument boot up 5 3 in 7 8 9 RS232 Configuration Sees ETHERNET RS485 RS232 Close Indicated Positions Only RS485 Configuration ETHERNET RS485 RS232 Close Indicated Positions Only Ethernet Configuration SS ee ETHERNET RS485 RS232 Close Indicated Positions Only Figure 8 1 Com Configuration Jumper Settings SW2 P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 44 8 3 RS 232 Configuration The RS 232 configuration is usually used when making a one to one connection between the instrument and a single computer or PLC The communications protocol used for the RS 232 configuration is MODBUS RTU For details on the MODBUS RTU specification please see http www modbus org With the instrument configured for RS 232 connection can be made to the DB 9 connector labeled RS232 485 or to the three pins on the General I O connector Only one of these connections should be used the other must be left un connected Table 8 1 below details the pinouts of th
23. 54 Teledyne API Model 465M O Monitor User Manual Page 39 7 2 5 SETUP VARS Menu The VARS menu allows viewing and editing of various global setup variables that effect how the 465M operates These variables are stored in the instrument s non volatile memory Table 7 6 lists these variables and their function Table 7 6 VARS List Default VAR Meaning Range UR us 2 bg of LATCHING ALARM MODE Re np E QATOBNG NON ection 7 1 3 for additiona LATCHING details ALARM DELAY Number of readings above alarm 5 1 20 limit required to trigger alarms Boxcar filter length for concentration filter Higher BC FILT SIZE values will smooth out the 30 1 30 concentration readings but will also increase the response time FLOW SWITCH Enables disables operation of ENABLE optional flow switch QU CL COMM ADDRESS DUUM 1 1 247 UNIT Concentration unit of measure PPM PPM NI setting g Nm Adjustment for display scroll SCROLL DELAY delay Higher values result in 20 6 100 slower scrolling speed AZERO ENABLE Enables Disables auto zero ON ON OFF calibration AZERO INTERVAL Time interval for performing the 6 3 1440 auto zero calibration minutes Molecular weight of carrier gas ie feed gas for ozone generator GAS CARRIER This value is only used for the WEIGHT calculation of wt concentration in units It is not used for PPM g Nm3 calculations Full scale concentration range ee
24. ADVANCED POLLUTION INSTRUMENTATION A Teledyne Technologies Company TELEDYNE USER MANUAL MODEL 465M OZONE MONITOR TELEDYNE ADVANCED POLLUTION INSTRUMENTATION TELEDYNE 9480 Carroll Park Drive San Diego CA 92121 5201 TOLL FREE 800 324 5190 TEL 858 657 9800 FAX 858 657 9816 EMAIL api sales teledyne com WEB SITE http www teledyne api com Copyright 2007 2014 06160F DCN6854 Teledyne Advanced Pollution Instrumentation 26 February 2014 SAFETY MESSAGES Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage Please read these messages carefully Each safety message is associated with a safety alert symbol and placed throughout this manual and inside the instrument The symbols with messages are defined as follows WARNING Electrical Shock Hazard HAZARD Strong oxidizer GENERAL WARNING CAUTION Read the accompanying message for specific information CAUTION Hot Surface Warning Do Not Touch Touching some parts of the instrument without protection or proper tools could result in damage to the part s and or the instrument Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only Electrical Ground This symbol inside the instrument marks the central safety grounding point for the instrument gt gt gt CAUTION GENERAL SAFETY HAZARD This ins
25. BY QUALIFIED MAINTENANCE PERSONNEL ONLY The drawings contained in this section are for general reference and may be useful when performing certain troubleshooting activities 10 1 1 Pneumatic Diagram Figure 10 1 and Error Reference source not found below is a pneumatic diagram that can be referenced when performing troubleshooting on the monitor O Gas In gt Y Dryer Flow Meter AutoZero Valve O Measurement Cell Destruct Flow Switch Optional Exhaust Out 7 Flow Control Pump Orifice Figure 10 1 Pneumatic Diagram Rack Mount and NEMA P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 63 10 1 2 Interconnect Diagram Figure 10 2 provides details on the electrical connections between the various electronic modules in the 465M RACK MOUNT CN0000073 TYPE VERSION ONLY POWER ENTRY MODULE Y SVV0000051 POWER SWITCH CIRCUIT BREAKER 05072 0100 MAINBOARD PCA TUN AC DC Power 219 a 521 Supply PANEL J15 FLOW SWITCH OPTIONAL J24 ANALOG IN EXPANSION d 9 M a tf nl S 03484 XXXX SENSOR ASSY SVV0000062 PRESSURE SENSOR Rd 04511 0100 HEATER dy TEMP SENSOR PCA J20 02571 0100 MEAS DE
26. D s Status LED Normal State Sensor OK ON Invalid Reading OFF Check Lamp OFF Pneumatic Error OFF If any of these LED s are in a different state than shown above then some adjustment or troubleshooting should be performed See Section 10 2 for more detailed information P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 32 7 2 Front Panel Menus The 465M has an interactive menu structure that can be operated from the front panel From within this menu structure the operator can view real time parameters such as temperature and pressure view configuration information and edit setup parameters such as alarm limits See Figure 7 2 and Figure 7 3 shows the menu structure as well as the buttons that are used to navigate it Starting with the display in Concentration mode press CFG to enter Menu mode At this point the unit of measure LED should turn off and the first level of the Menu tree will be active Pressing the UP DOWN arrows will now select from the items available at this menu level Press ENT to enter one of these sub menus or press CFG to back out of this menu level back to Concentration mode 7 2 1 Menu Navigation Basics Press CFG from Concentration mode to enter Menu mode 2 Oncein Menu mode CFG will move backwards one level in the menu structure and ENT will move forward 3 Each menu level contains an EXIT selection Selecting EXIT and pressing ENT will exit
27. Devicelnstaller gt Devicelnstaller If your PC has more than one network adapter a message displays Select an adapter and click OK 2 Click on the Search icon After a moment a list of instruments on the network will be displayed The 465M should be listed as an XPORT IAP type device 3 Double click on the device in the right hand section of the Devicelnstaller window a list of configuration parameters will be shown including the IP Address If multiple devices are shown the correct one can be determined by matching the Hardware Address shown with the address printed on the label of the Ethernet module in the 465M NOTE The instrument cover must be removed to inspect this address in the instrument 8 5 4 Manually Assigning a Static IP Address For applications where the IP Address must remain constant a static IP Address can be manually assigned to the instrument and the DHCP function must be disabled 1 Click Start gt Programs gt Lantronix Devicelnstaller gt Devicelnstaller If your PC has more than one network adapter a message displays Select an adapter and click OK NOTE If the unit already has an IP address e g DHCP has assigned an IP address click the Search icon and select the unit from the list of Lantronix device servers on the local network 2 Click the Assign IP icon 3 If prompted enter the hardware address on the product label and click Next 4 Select Assign a specific IP address and c
28. ED MAINTENANCE PERSONNEL ONLY 11 1 Factory Calibration The 465 is calibrated to internal TAPI calibration standards prior to shipment calibration certificate for your instrument can be purchased from Teledyne API if required Teledyne API also recommends that the 465M be re calibrated once a year Teledyne API can provide NIST traceable calibration services at our factory or on site Please contact Technical Support for details on these services see Section 12 P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 69 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 70 12 TECHNICAL ASSISTANCE If this manual does not solve your problems technical assistance may be obtained from Teledyne API Technical Support 9480 Carroll Park Drive San Diego California 92121 5201USA Toll free Phone Phone Fax Email Website 800 324 5190 858 657 9800 858 657 9816 sda_techsupport teledyne com http www Teledyne API com P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 71 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 72 13 465M SPARE PARTS 13 1 Spare Parts List for Rack Mount Version 025710100 PCA UV DETECTOR PREAMP 028510000 KIT EXPENDABLES 25MM GLASS FIBER FILTER 036750000 AKIT ELEMENTS 47MM 30 MICRON 1
29. Instrument Layout NEMA Configuration 9 3 Replacing Internal Particulate Filter 1 Disconnect power from the 465M 2 Loosen the six screws from the top cover Rack Mount Configuration see Figure 9 1 or open front panel NEMA Configuration see Figure 9 2 Remove the six screws and top cover from the instrument 4 Locate the particulate housing filter on the rear panel Rack Mount Configuration see Figure 9 1 or the bottom panel NEMA Configuration see Figure 9 2 5 Loosen the four screws on the sample filter body see Figure 9 3 P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 53 Remove fours screws four washers and sample filter body from sample filter base Remove the o ring and inspect for any cracks or deformities If there are no cracks or deformities place the o ring back in the sample filter body NOTE If the o ring is cracked or deformed discard the o ring and replace with a new one Remove the two sample filter retainers and glass fiber filter element from the sample filter body Discard the glass fiber filter element 10 Place a new glass fiber filter element in between the two sample filter retainers 11 and place in the sample filter body Place the sample filter body on the sample body base and secure with the four screws and fours washers 12 Reinstall the top cover on the instrument and secure with the six screws or close the front
30. S PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 30 7 7 1 Front Panel Overview The 465M front panel provides a number of functions in addition to displaying the current ozone concentration being measured Figure 7 1 below shows the display and keypad portion of the front panel U Oman dene 8 Figure 7 1 Front Panel Display 7 1 1 Ozone Concentration Display The 4 character LED display in the center of the front panel normally shows the current ozone concentration being measured by the 465M While displaying concentration one of the unit of measure indicators i e WT PPM should be backlit indicating the current measurement units If none of these indicators are backlit then the display is in Menu mode or Startup mode and is not displaying the concentration If the display is in Menu mode the display can be returned to Concentration mode by repeatedly pressing the CFG button until one of the unit of measure indicators is lit Note that even when the display is in Menu mode normal measurement operation will continue in the background NOTE Even when the display is in Menu mode normal measurement and stream selector operation will continue in the background 7 1 2 Menu Navigation Keypad The menu navigation keypad CFG ENT and UP DOWN buttons is used to navigate the various menu items available on the 465M The menus al
31. TECTOR PCA J16 02571 0100 REF DETECTOR PCA 03742 UV LAMP ASSY J18 05313 0100 DISPLAY PCA J14 MODULE 15 J4 Lp 15V J2 0 22 04702 PUMP ASSY M465M ONLY i 12v J12 PUMP 12 05125 AUTO ZERO VALVE ASSY ai 15V J13 VALVE Figure 10 2 Interconnect Diagram P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 64 10 2 Troubleshooting Using Front Panel Status LED s or Status Outputs The 465M has 4 front panel status LED s that reflect the current operating status of the monitor and indicate fault conditions There are also four relay Status Outputs on the rear panel or internally in the NEMA configuration that also reflect the state of these status LED s See Section 4 5 3 for more information on the Status Outputs Table 10 1 Status LED Output Definitions Status Status LED Normal Triggers Critical Output Label Operating Warning State 1 Sensor OK On e Reference 125 0 mV Yes e Reference gt 1230 0 mV 0 5 Wt 2 Invalid Reading Off Concentration F S Range No O3 Concentration gt F S Range 3 Check Lamp Off e Reference 250 0 mV No 4 Pneumatic Off e Pressure 9 0 psia No Error e Pressure gt 18 0 psia e Flow 500 cc min If Flow Switch install
32. TERIOR SURFACES OF THE 465 0 59 9 10 BOOT LOADER OPERATION ccccceceessssscecececseseuececececeeseseaesecececseeaaececececsesauececececeesesasseeececeeneaees 59 9 10 1 Boot Loader Hardware Setup eese nene enne tenete trennen eene nne 60 9 10 2 Boot Loader Software Setup cito deute a ee A ive iere b ve 60 10 TROUBLESHOOTING eis orion donam et iae x anu s vu caa rS ene tena iioii voor 10 1 1 Pneumatic Diagram iiie eene 63 10 1 2 Interconnect Diaeramu conte et ge ter Oe iia 64 10 2 TROUBLESHOOTING USING FRONT PANEL STATUS LED S OR STATUS 65 TODA Sensor OK esten es etus b bte In PR RII lee ERE dl 66 102 2 Invalid Reading ie Eat da 66 10 2 3 Check Lamp trintina m n e PEN P ca PH RR SOR NR GR rr IR E RR ET p 66 102 Prima ro a EE 66 11 1 FACTORY CAFIBRATION ee treo eite essen reete ner dore 69 12 TECHNICAL ASSISTANCE oscar isis 13 465M SPARE PARTS aida 13 1 SPARE PARTS LIST FOR RACK MOUNT 73 13 2 SPARE PARTS LIST FOR NEMA 74 P N 06160F DCN6854 Teledyne Model 465M Monitor User Manual Page vi FIGURES Figure 4 1 465M Mounting Hole Locations and Dimensions 0000 0 esses 16 Figure 4 2 NEMA AC Power Connection to Mo
33. de la mise la terre s curitaire de l instrument gt OpD PPPP MISE EN GARDE Cet instrument doit tre utilis aux fins d crites et de la mani re d crite dans ce manuel Si vous utilisez cet instrument d une autre mani re que celle pour laquelle il a t pr vu l instrument pourrait se comporter de facon impr visible et entrainer des cons quences dangereuses NE JAMAIS utiliser un analyseur de gaz pour chantillonner des gaz combustibles P N 06160F DCN6854 API Model 465M Monitor User Manual Page ii WARRANTY POLICY 020246 COVERAGE Teledyne Advanced Pollution Instrumentation TAPD a business unit of Teledyne Instruments Inc provides that Prior to shipment TAPI equipment is thoroughly inspected and tested Should equipment failure occur TAPI assures its customers that prompt service and support will be available After the warranty period and throughout the equipment lifetime TAPI stands ready to provide on site or in plant service at reasonable rates similar to those of other manufacturers in the industry All maintenance and the first level of field troubleshooting are to be performed by the customer NON TAPI MANUFACTURED EQUIPMENT Product Return Equipment provided but not manufactured by TAPI is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturer s warranty
34. e 465M be sure to leave sufficient ventilation clearance Table 4 2 465M Ventilation Clearances Rack Mount Version Area Minimum required clearance Back of the monitor 3 inches Sides of the monitor inch Above and below the monitor 1 2 inch P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 16 4 3 AC Power Connection for Monitors NEMA 4X Enclosures WARNING Electrical Shock Hazard Disconnect power to the AC mains before making or removing any electrical connections to the 465M WARNING Electrical Shock Hazard A proper earth ground connection must be made to the receptacle labeled Earth Ground on the 3 pin AC connector Failure to do so may result in a shock hazard and malfunction of the monitor 4 3 1 Wiring Requirements for NEMA Enclosures Use appropriate wiring rated for this type of equipment ensuring that it meets local and national safety and building requirements Ensure that overcurrent protection is used a 5 A circuit breaker is recommended and that it fulfills the following requirements e be located as near to the instrument as possible e quickly and easily accessible e clearly labeled as the disconnecting device for this instrument 4 3 2 Wiring Instructions 1 Install a conduit fitting for routing the electrical wiring into the monitor through the hole provided in the bottom face of the NEMA enclosure an appro
35. e RJ 45 port labeled Ethernet Connection can be made using a standard Category 5 or better network patch cable TAPI can provide an appropriate cable please see the spare parts list in Appendix A See Section 8 2 for additional details P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 26 5 FREQUENTLY ASKED QUESTIONS 1 Q How long does the UV Lamp last A The typical lifetime is about 2 3 years The lamp output will steadily decrease until lamp adjustment can no longer be performed The Check Lamp warning LED will tell the operator when this adjustment should be attempted When this adjustment can no longer be performed the lamp should be replaced See Chapter 9 for more information P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 27 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 28 6 OPTIONAL HARDWARE AND SOFTWARE 6 1 Rack Mount Slides Rack mount slides can be attached to the sides of the Rack Mount version of the 465M allowing it to slide completely out of a RETMA rack facilitating maintenance activities 6 2 Low Flow Alarm The 465M can be fitted with an internal electronic flow switch that enables the instrument to detect gas flow and provide a Pneumatic Error if the flow is outside it s normal limits P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual 29 THI
36. ececsesssaececcceceesssaececececsesssaececeeseseneaesecececeesessaaeceeeceeseneaeeeeecs 46 8 5 ETHERNET CONFIGURATION cessessccssccecesssnsccuccsscesesnseeuecsececeenseaueesecsceensnsueesecsceeseennesscesseessnncenecesce 47 6 5 1 Hardware Setup for Configuring the Ethernet Module 47 6 5 2 Verifying Network Hardware Connection ss 47 6 5 3 Determining a Dynamically Assigned IP Address DHCP Mode 48 6 5 4 Manually Assigning a Static IP Address 48 8 6 MODBUS REGISTER MAPS a terne Tee Pepe E e ea eee ERE n de 50 6 6 1 Notes on MODBUS registers ie 50 6 6 2 Real Time Concentration and Status Registers Read Only ss 50 6 6 3 Instrument Setup and Configuration Registers Read Write ss 50 9 1 MAINTENANCE SCHEDULE i aci mecanisme PETER e P EXE ERO ERE 51 O2 INSTRUMENT IZAYOUT ment saga Same tentent naro 52 9 3 REPLACING INTERNAL PARTICULATE FILTER sise 53 O 4 UV EAMPEADJUSTMENT s iere ore irc E RE ERO EET 56 9 5 UV LAMP REPLACEMENT siemens nine 56 9 6 SAMPLE PUMP REPLACEMENT 2 0 0200 0000000 001010000000000000000000 000 57 9 7 AUTO ZERO VALVE REPLACEMENT ccssssssccecsesessscecececeesenssaeseccceesesauececececeessaueceeececeesesaseeeeeseseneaaees 57 9 8 CONFIGURING THE ANALOG 1 7 2 2 0000000000000000000002020000 58 9 9 CLEANING EX
37. ed P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual 65 10 2 1 Sensor The Sensor OK LED indicates the status of the sensor module in the monitor The normal state of this LED or Status Output is On If this LED remains off after the normal warm up period then a failure has occurred and the monitor should be removed from service and repaired The most common cause of this warning is a failure of the UV Lamp A UV Lamp Adjustment See Section 9 4 should be attempted If the UV Lamp cannot be adjusted to meet the specified values then a UV Lamp Replacement should be performed See Section 9 5 10 2 2 Invalid Reading The Invalid Reading LED indicates that the instrument is reading a value that cannot be represented properly on the analog output Since the analog output is limited to O SV or 4 20mA it cannot properly represent negative values or values in excess of the full scale range If the monitor is consistently reading negative values then a zero calibration should be performed see Section 7 2 3 4 If the monitor is consistently reading values in excess of the full scale range then the range value should be adjusted higher See Section 7 2 5 for details on setting the range value 10 2 3 Check Lamp The Check Lamp LED indicates that the UV Lamp intensity has dropped below 250mV a level where UV Lamp Adjustment See Section 9 4 should be made at the next convenient oppor
38. elect the HEX file for the appropriate firmware 19 49 Refer to Section 9 10 2 1 to upload firmware to Section 9 10 2 2 to verify the firmware P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 60 9 10 2 1 Upload Firmware 1 Press Write The screen will display Wait for boot loader 2 When the screen displays Power cycle instrument now power up the instrument NOTE Search for boot loader will time out in 20 seconds If the instrument is not powered up in 20 seconds the screen will display boot loader detected Go back to step 1 to rewrite the firmware The firmware loader software should display a message Boot loader found uploading If this message is not displayed power down the instrument and receck the COM port configuration and cable see Section 9 10 1 and retry 3 When the upload is complete a message Write flash completed successfully should be displayed If it is an unsuccessful upload a message Write flash error 1s displayed If a Write flash error occurs ensure that the correct PC COM port is selected for the instrument see Section 9 10 2 step 4 NOTE It is not recommended to stop the writing process half way through This will cause the firmware to not be fully uploaded 9 10 2 2 Verify Firmware The verify function compares the instrument s current firmware to the selected HEX file see Section 9 10 2 step 5 and
39. er 0 5V DC or 4 20mA operation To change or verify the configuration of the analog output 1 Disconnect power from the 465M 2 Remove the six screws and the top cover Rack Mount Configuration or open front panel NEMA Configuration 3 Locate the Mainboard see Figure 9 1 or Figure 9 2 4 Setthe desired operation as shown in Figure 9 4 5 Re Install the top cover or re secure the front panel NEMA Configuration P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 58 Su I m E 1 aper A ei Me cud 0 5 OUTPUT PM 12V 15 15V ps1 LAMPQNVERTER Figure 9 4 Mainboard Analog Output Configuration 9 9 Cleaning Exterior Surfaces of the 465M If necessary the front panel mask and keyboard of the 465M can be cleaned with a damp cloth Do not attempt to clean any of the other surfaces of the instrument Do not submerge any part of the instrument in water or cleaning solution 9 10 Boot Loader Operation The main function of a boot loader is to load or update the firmware to the microcontroller on the Printed Circuit Board PCB of an instrument There are two types of boot loader setup hardware and software descr
40. ese two connectors Table 8 1 RS 232 Connector Details Function DB 9 DB 9 General I O Connector Pin Connector Pin Connector SW2 DTE SW2 DCE Transmit Tx 3 2 2 3 R Ground 5 5 G NOTE A DTE DCE switch is provided so that the instrument can be connected to another device using either a straight through or crossover Null Modem cable See Section 8 2 for details on changing this configuration The serial port setup for RS 232 configuration is shown in Table 8 2 below Table 8 2 RS 232 Port Setup P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 45 Property Value Baud Rate 57600 Data Bits 8 Parity None Stop Bits 1 Flow Control None 8 4 RS 485 Configuration RS 485 is commonly used for factory automation busses with a computer or PLC acting as a master The communications protocol used for the RS 485 configuration is MODBUS RTU For details on the MODBUS RTU specification please see http www modbus org With the instrument configured for RS 485 connection can be made to the DB 9 connector labeled RS232 485 or to the three pins on the General I O connector Table 8 3 below details the pinouts of these two connectors Table 8 3 RS 485 Connector Details Function DB 9 General I O Connector Pin Connector SW2 DCE RS485 A 2 T RS485 3 R
41. ibed in the following sections P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 59 When an external MODBUS host device is attempting to communicate with the instrument over the serial or Ethernet port while the instrument is starting up the instrument may halt In order to prevent the problem from occurring ensure that there are no devices attempting communication with the instrument during start up Once the sign on message is displayed on the front panel it is safe to begin communications 9 10 1 Boot Loader Hardware Setup Verify that the instrument is configured for an RS 232 connection See Section 8 2 for details on changing the COM port configuration The instrument can be connected to the PC COM port using a 9 pin serial cable TAPI P N VVR77 9 10 2 Boot Loader Software Setup Table 9 2 lists the required firmware loader software and firmware options Table 9 2 Required Software SOFTWARE TYPE FILE TYPE VERSION PC Software FirmwareLoader EXE 05498 00 XX HEX for ppb ppm ugm 05498 01 XX HEX for ppb ppm pphm Instrument Firmware The firmware loader is available on Teledyne API s website at http www teledyne api com software 1 Install the firmware loader software onto a PC Verify the cable connections Do not power up the instrument Run the firmware loader application on the PC Select the COM port that the instrument is connected to S
42. ion or open e front panel NEMA Configuration Loosen the two UV lamp setscrews on the UV lamp housing see Figure 9 1 or Figure 9 2 Unplug the lamp power cord from the connector labeled J18 on the mainboard PCA Carefully slide the lamp out of housing Install the new lamp seating it in the lamp housing until it stops Re tighten the two UV lamp setscrews P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 56 8 Plug lamp power cord into 118 mainboard 9 Reconnect power to the instrument and turn on power switch Let instrument warm up for at least 20 minutes 10 Perform UV lamp adjustment procedure per Section 9 4 9 6 Sample Pump Replacement 1 Disconnect power from the 465M 2 Remove the six screws and the top cover Rack Mount Configuration or open front panel NEMA Configuration 3 Locate sample pump assembly See Figure 9 1 or Figure 9 2 4 Cutoff the clamps holding the Tygon tubing to the pump nipples and remove tubing Note which tubing is connected to inlet and outlet 5 Unplug the pump power connector from mainboard PCA at connector J12 6 Remove the four screws attaching the sample pump assembly to the chassis 7 Turn over pump assembly and remove the two screws holding the sheet metal base to the pump 8 Install the base on the new pump 9 Install new pump assembly in chassis 10 Cut off the ends of the used Tygon tubing and reconnect
43. l return to the start of the Span Cal menu If the OUT OF RANGE error occurs it means the Span Cal cannot be performed because it would result in an out of range slope value for the monitor This means that either the sensor in the monitor is malfunctioning causing improper readings or the actual ozone concentration being supplied to the monitor is different than the target value being entered P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 38 Enter Span target concentration actual ozone concentration being supplied to monitor ENTTO RETURN TO SPAN CAL 900 SPAN Yes CONC MODE Figure 7 4 Span Cal Menu 7 2 4 VIEW Menu The VIEW menu allows the operator to view various measurement parameters in real time This can be useful for diagnosing various instrument or system problems NOTE These values are updated in real time as they are repeatedly scrolled on the display Table 7 5 VIEW Menu Parameters Parameter Meaning Units Normal Range MEAS UV detector reading measure cycle mV 250 1230 REF UV detector reading reference cycle mV 250 1230 PRESSURE Sample pressure psia 9 0 18 0 LAMP TEMP UV lamp temperature C 50 0 52 0 SAMPLE 3 TEMP Sample temperature C 5 0 50 0 FLOW Sample Gas Flow Rate ON OFF ON After initial 20 minute warm up period Optional Hardware P N 06160F DCN68
44. lick Next P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 48 5 Enter IP address The Subnet mask displays automatically based on IP address if desired you may change it On a local network you can leave the Default gateway blank all zeros Click Next 6 Click the Assign button and wait several seconds until a confirmation message displays Click Finish 7 Select the device from the main window list and select Ping from the Tools menu The Ping Device dialog box shows the IP address of the selected unit 8 From the Tools menu click the Ping button The results display in the Status window Click the Clear Status button to clear the window so you can ping the device again NOTE If you do not receive Reply messages make sure the unit 15 properly attached to the network and that the IP address assigned is valid for the particular network segment you are working with If you are not sure check with your systems administrator 9 Click the Close button to close the dialog box and return to the main window P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual 49 8 6 MODBUS Register Maps 8 6 1 Notes on MODBUS registers Concentration values in the MODBUS registers are always expressed in units of PPB parts per billion regardless of the concentration units setting of the monitor 8 6 2 Real Time Concentration and Status Registers Read Only
45. low the user to view operational parameters of the instrument as well as view and modify the configuration of the instrument See Section 7 2 for more detailed information P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 31 7 1 3 Concentration Alarm Status Reset The 465M front panel displays the concentration alarm status An LED labeled ALARM STATUS shows the alarm status as follows Table 7 1 Alarm LED s Alarm Status LED Color Alarm State Green No alarm active Amber HP alarm active Red HI HF alarm active If the alarms are configured for latching operation then the RESET button can be used to attempt to reset all alarms NOTE Alarms can only be reset if the concentration measured has subsequently dropped below the alarm limit If the alarms are configured for non latching operation they will be automatically cleared when the concentration falls below the alarm threshold The RESET button has no effect when the alarms are configured for non latching operation See Sections 7 2 6 and 4 5 4 for additional details on concentration alarms 7 1 4 Status LED s There are four Status LED s front panel to the right of the concentration display These LED s provide a quick view of the instrument s Status and provides indication of any problems that may exist The normal state for these LED s after the initial warm up period is as follows Table 7 2 Status LE
46. lue The target adjustment range is as high as possible within the range of 800 1150 mV Locate the Measure UV Detector adjustment pot PRA on the mainboard PCA see Figure 9 1 or Figure 9 2 Navigate the front panel menu to VIEW menu and scroll to MEAS display and press ENT At this point there should be a scrolling display similar to MEAS XXXX See Section 7 2 for details on menu navigation While observing the MEAS value on the display slowly turn the pot to adjust the value The target adjustment range is as high as possible within the range of 800 1150 mV If the required adjustment cannot be achieved by adjusting the UV Detector pot alone then additional adjustment can be made by loosening the two UV lamp setscrews on the UV lamp housing see Figure 9 1 or Figure 9 2 and rotating the lamp Rotate the lamp very slowly while observing the REF or MEAS value on the display Make sure the lamp does not pull out and remains seated in the housing while it is being rotated Re tighten the two setscrews when a desired point has been reached If necessary additional fine tuning can now be done with the UV Detector adjustment pots per steps 4 8 Re Install instrument cover and observe REF and MEAS values on display for a couple minutes to verify it does not drift out of the adjustment range 9 5 UV Lamp Replacement l Disconnect power from the 465M 2 Remove the six screws and the top cover Rack Mount Configurat
47. n ALARM 6 2 6 ONIOFF HIHI ALARM LATCHING gt NON LATCHING P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 34 SEE PREVIOUS See Section PAGE 6 2 3 1 See Section 6 2 3 2 See Section MEMORY 6 2 3 3 E See Section ZERO CAL a SPAN CAL Unavailable Unavailable SEE PREVIOUS N m 2 ES PAGE See Section PRESSURE 624 57 SAMPLE FLOW SEE PREVIOUS PAGE SN COMM ADDRESS 3 See Section 6 2 7 Y BOOT EXIT JJ M465M Front Panel Menu Diagram Rack Mount Figure 7 3 Front Panel Menu Diagram P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 35 7 2 3 DIAG Menu The DIAG menu See Figure 7 2 and Figure 7 3 contains functions that are useful for testing and configuring external equipment that may be connected to the rear panel I O of the instrument 7 2 3 1 Analog Step Test When placed in this mode the instrument will automatically step the analog output through 5 points from 0 to 100 and display the current value on the front panel The operator can suspend the automatic cycling and manually control the stepping by pressing either one of the UP DOWN arrow buttons To resume automatic cycling exit the function by pressing CFG and re enter
48. nch absolute P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 20 4 4 2 Exhaust Connection Connect a OD vent line to the Exhaust fitting on the rear panel This line must be vented outdoors or to an appropriate discharge system capable of handling ozone Local regulations regarding the discharge of ozone to the atmosphere must be observed Note that the monitor may be equipped with an internal ozone scrubber for removal of ozone from the exhaust stream For safety reasons the exhaust port must still be vented appropriately as described above CAUTION Exhaust gas from the 465M may contain dangerous levels of ozone Do not vent this gas into enclosed or occupied areas GENERAL I O CTRL STATUS ha AUX an EA 2C 1234C TRG 1 2X 91909 o E ol o E ol B es AM Figure 4 5 Rear Panel Electrical I O Connections P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 21 POWER CONNECTOR I O CONNECTORS CAUTION HIGH VOLTAGE AREA ETHERNET CONNECTOR RS 232 RS 485 CONNECTOR Figure 4 6 NEMA Electrical I O Connections P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 22 4 5 Electrical I O Connections 4 5 1 Location of I O Connectors in the NEMA Configuration In the NEMA configuration of the 465M the I O connectors are located internally in
49. nitor ss 18 Figure 4 3 Pneumatic Connections Rack Mount Configuration 19 Figure 4 4 Pneumatic Connections NEMA Configuration 20 P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page vii TABLES Table 4 1 465M Ventilation Clearances NEMA Version 15 Table 4 2 465M Ventilation Clearances Rack Mount Version ss 16 Table 4 3 Status Output Definitions 22 rere Per rhe tiene ne edit nent 24 Table 4 4 Relay Functions ein tai a o elc Lied eesti sins 25 Table 7 1 AlarmiEED S isset e he Dando CRDI OR PEG 32 Table 7 27 Status gt 025 32 Table 7 3 Analog Step Test 36 Table 74 Signal VO Last eR EUER iaa 37 T ble 7 5 VIEW Menu Parainetets iit rh e he 39 Table 7 6 VARS ais iere tee Qe utto e dd 40 Table 7 7 Alarm Configuration Settings ss 41 Table 8 1 RSz232 Connector Details e teet ee RS ent a eme dei en mens 45 Table 8 2 RS 232 Port Setup neenon eme PER e D ree ERR 45 Table 8 3 RS 485 Connector Details ses 46 Table 8 4 RS 485 Port Setup iscritti E mn ren ER e Ree EHE ERR Eee esse 46 Table 8 5 Ethernet LED Definitions ei ette ee 47 Table 9 1 Maintenance ite eee nter tre rr e
50. of rear panel or applying power to the monitor NEMA configuration The front panel display should light with a sequence of messages including the instrument serial number and software revision When the instrument first powers up the display will show indicating that the instrument is in start up mode waiting for the UV detector readings to stabilize After the start up period the instrument will begin displaying the ozone concentration and the optional stream selector will begin operating if installed 4 4 Pneumatic Connections OZONE IN NOTE EXHAUSTED GASSES MAY CONTAIN DANGEROUS LEVELS OF OZONE Figure 4 3 Pneumatic Connections Rack Mount Configuration P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 19 OZONE INLET FLOW CONTROL EXHAUST OUTLET Figure 4 4 Pneumatic Connections NEMA Configuration 4 4 1 Ozone Inlet Connection Sample gas connections are made to the 4 stainless steel compression fitting on the rear panel See Figure 4 3 and Figure 4 4 1 4 O D FEP Teflon or Stainless Steel tubing is recommended to connect the sample source to the monitor Any fittings used in the sample lines should be constructed of Stainless Steel or Teflon The 465M has an internal sample pump and is designed to sample gas that is close to ambient pressure Ensure that the sample gas pressure is in the range of 11 16 psia pounds per square i
51. or more detailed information Electrically these outputs are SPST dry contact relay closures with a common contact labeled on the rear panel They are capable of switching up to 50 250mA maximum current There are no polarity requirements so the outputs can be used to sink or source current from pin within the maximum voltage and current specified Schematically the outputs look as shown in Figure 4 8 below STATUS OUT 12 3 4 C Figure 4 8 Status Output Schematic The outputs are defined as follows Table 4 3 Status Output Definitions Status Name Normal Operating Output State 1 Sensor 2 Invalid Reading Off 3 Check Lamp Off 4 Pneumatic Error Off P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 24 4 5 4 Hi Current Relay Outputs Three form C relay outputs are provided on the rear panel on the nine pin connector See Figure 4 5 The relays are labeled Relay 1 Relay 2 and Relay 3 The relays are dry contact type form C SPDT relays with Normally Open N O Normally Closed N C and Common COM contacts The relays are capable of driving loads of up to 250VAC 5A For maximum contact life the relays should only be used to drive resistive loads Contact life may be dramatically shortened if inductive loads are driven without any provision for minimizing high voltage inductive kick that can occur See
52. ould be reviewed and corrected 10 2 4 2 Pressure Too Low Something may be restricting the flow through the monitor causing the sample pump to pull a vacuum on the sensor module First unplug the sample pump power plug on the Mainboard PCA and observe the pressure reading If the pressure reading is still too low then likely there is a problem with the pressure sensor on the Sensor Module and the Sensor Module should be replaced Next reconnect the pump and disconnect all sample lines from the monitor and see if the pressure increases to normal levels If it does then the problem is somewhere in the sampling system external to the monitor If the pressure is still below the limit with the sample lines removed then there is a restriction in the pneumatics of the monitor upstream of the sensor assembly The most likely cause is a plugged particulate filter Disconnect the outlet fitting on the sample filter and observe the pressure If it returns to normal levels then the restriction is in the particulate filter or inlet manifold assembly multi stream configurations only Replace particulate filter per Section 9 3 P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 67 THIS PAGE IS INTENTIONALLY LEFT BLANK P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 68 11 CALIBRATION A WARNING Electrical Shock Hazard THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFI
53. outer commonly used for home networks The 465M and a PC can then be connected to the router and the router s DHCP server will assign IP Addresses to both the PC and the 465M enabling them to communicate 8 5 2 Verifying Network Hardware Connection With the 465M connected to a network and powered up check the status of the two LEDs on the Ethernet connector on the rear panel The left hand LED should be lit either amber or green indicating link status and the right hand led should blink periodically indicating activity on the network See Table 8 5 below for more details on the status LED s If neither of the LED s are lit then the Ethernet module may not be powered up or the instrument may not be connected to a valid network Check the COM port configuration per Section 8 2 and make sure that it is set to Ethernet Table 8 5 Ethernet LED Definitions Link LED Left Side Activity LED Right Side Color Meaning Color Meaning Off No Link Off No Activity Amber 10 Mbps Connection Amber Half Duplex Green 100 Mbps Connection Green Full Duplex P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 47 8 5 3 Determining a Dynamically Assigned IP Address DHCP Mode The Devicelnstaller software application See Section 8 5 can be used to search a network for instruments and determine the IP Address assigned by a DHCP server 1 Click Start gt Programs gt Lantronix
54. panel P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 54 RACK MOUNT CONFIGURATION SHOWN SCREWS NEMA CONFIGURATION SIMILAR 6 PLACES TOP GLASS FIBER COVER SAMPLE FILTER ASSEMBLY P N 02832 x USED ON BOTH Vds uz D CONFIGURATIONS eer lt 7 SAMPLE FILTER xe 222 SCREW BE UM Let P N SN0000210 we 4 PLACES CONNECTOR M 127 WASHER P N FT0000012 E P N SN0000183 2 PLACES 4 PLACES GLASS FIBER FILTER ELEMENT P N FL0000017 SAMPLE FILTER BODY P N 02689 SAMPLE O RING FILTER P N OR0000082 RETAINER P N 02814 2 PLACES Figure 9 3 Internal Particulate Filter Replacement P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 55 A A 9 4 1 UV Lamp Adjustment Instrument should be running and warmed up for at least 20 minutes 2 With instrument running remove the six screws and the top cover Rack Mount 10 11 Configuration or open front panel NEMA Configuration Locate the Reference UV Detector adjustment pot PR3 on the Mainboard PCA see Figure 9 1 or Figure 9 2 Navigate the front panel menu to VIEW menu and scroll to REF display and press ENT At this point there should be a scrolling display similar to XXXX See Section 7 2 for details on menu navigation While observing the REF value on the display slowly turn the pot to adjust the va
55. priate sealed conduit connector should be used 2 Attach the leads of the power line to the AC power connector see Figure 4 6 P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 17 3 For the NEMA configuration electrical connection must hard wired to 3 pin connector on the mainboard labeled J23 AC power connection to the monitor should be made with 12 14 AVVG stranded copper wire connected to the monitor as follows a Earth Ground green Connect the earth ground wire to the screw terminal lug on the chassis as shown in the Figure below Do not connect the earth ground wire directly to the PCB connector on the mainboard PCB b Line Black Connect the Line wire to the connector on the mainboard PCB labeled Line c Neutral VVhite Connect the Neutral wire to the connector on the mainboard PCB labeled Neutral White Neutral Black Line Green Earth Ground Figure 4 2 NEMA AC Power Connection to Monitor 4 Connect the power cord to an appropriate power outlet see the serial number tag for correct voltage and frequency WARNING Electrical Shock Hazard Verify that the instrument is set up for proper line voltage and frequency Observe local electrical codes when connecting power to the monitor P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 18 5 Turn on 465M by switching the switch on the left side
56. trument should only be used for the purpose and in the manner described in this manual If you use it in a manner other than that for which it was intended unpredictable behavior could ensue with possible hazardous consequences NEVER use any gas analyzer to sample combustible gas es P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page i CONSIGNES DE S CURIT Des consignes de s curit importantes sont fournies tout au long du pr sent manuel dans le but d viter des blessures corporelles ou d endommager les instruments Veuillez lire attentivement ces consignes Chaque consigne de s curit est repr sent e par un pictogramme d alerte de s curit ces pictogrammes se retrouvent dans ce manuel et l int rieur des instruments Les symboles correspondent aux consignes suivantes AVERTISSEMENT Risque de choc lectrique DANGER Oxydant puissant AVERTISSEMENT G N RAL MISE EN GARDE Lire la consigne compl mentaire pour des renseignements sp cifiques MISE EN GARDE Surface chaude Ne pas toucher Toucher certaines parties de l instrument sans protection ou sans les outils appropri s pourrait entrainer des dommages aux pi ces ou l instrument Pictogramme technicien Toutes les op rations portant ce symbole doivent tre effectu es uniquement par du personnel de maintenance qualifi Mise la terre Ce symbole l int rieur de l instrument d termine le point central
57. tubing note that outlet fitting of pump should be connected to tubing routed to Exhaust fitting on rear panel 11 Re install new tubing clamps or cable ties to secure tubing connections 9 7 Auto Zero Valve Replacement 1 Disconnect power from the 465M 2 Remove the six screws and the top cover Rack Mount Configuration or open front panel NEMA Configuration 3 Locate the auto zero valve See Figure 9 1 or Figure 9 2 4 Unplug the two pin valve connector from the mainboard PCA 5 Remove the silver retainer clip from the top of the sensor valve A pair of pliers may be used to slide off the retainer clip 6 The valve coil can now be removed by sliding upwards 7 Remove the two 2 mounting screws using a 2 Phillips screwdriver Note that there are four screw heads visible on the top of the valve body only two 2 of P N 06160F DCN6854 Teledyne API Model 465M O Monitor User Manual Page 57 these should be removed Use the new valve as a reference to determine which two screws need to be removed 8 Note the orientation of the valve body on the manifold so that the new valve can be installed in the same orientation 9 Remove valve body from sensor manifold 10 Clean any residue or dirt off the surface of the manifold using a lint free cloth and distilled or DI water 11 Install the new valve by reversing steps 1 7 9 8 Configuring the Analog Output The analog output can be configured for eith
58. tunity Note that this is a non critical warning unless it is also accompanied by Sensor OK LED turning off then the instrument does not need to be removed from service at this time If the UV Lamp intensity drops below 125mV then the Sensor OK LED will also turn off indicating that the monitor must be immediately serviced or taken off line 10 2 4 Pneumatic Error The Pneumatic Error LED indicates that one of the pneumatic parameters flow or pressure has gone outside of normal ranges Note that this is a non critical warning Unless it is also accompanied by Sensor OK LED turning off the instrument does not need to be removed from service at this time The first step in troubleshooting a Pneumatic Error is determining which parameter has caused the warning At the monitor front panel navigate to the VIEW menu See Section 7 2 4 Examine the Flow and Pressure values and compare them to the limits described in Table 10 1 and take appropriate action as described below P N 06160F DCN6854 Teledyne API Model 465M Monitor User Manual Page 66 10 2 4 1 Pressure Too High The monitor inlet is being pressurized The monitor inlet should be allowed to sample gas at ambient pressure Disconnect all sample lines from the monitor and read the pressure again If the value then drops to within the acceptable range then one of the sample lines is at elevated pressure If the inlet is being pressurized then the design of the sample system sh
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