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Teledyne O3 User's Manual

1. aaa as 1 7 1 INSFALEATIONANDOSERVIEW 255 bi halo aa iaa 1 7 1 6 ELECTRICAL AND PNEUMATIC CONNECTIONS 2 2 1 14 CONN ECHONS dala 1 14 A leale dae 1 14 6 3 P neumatie System on 1 16 1 6 4 Exhaust Connections See Figure Liu iia 1 16 1 6 5 Output Flow Adjustment ilari 1 16 1 20 1 7 1 Final Test And Calibration Values iii 1 21 9 1 22 LOA Rack yusa sta uwa n 1 22 1 6 255101 5 OWIDSIS 1 22 2 ATION iran 2 1 Dil KEY FEATURES sobria 2 1 RECIO UL 2 1 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Dl OG as asa ep khana as re 2 1 2 1 3 ROM Backup Of Software Configuration 2 1 DL A Ri RAR RR RI 2 1 21 3 Data nt 2 2 2 K0ORS 292 ME also 2 2 ZAS Password Protecti n AA AA i 2 2 2 ZERONT PANE Edad alar re 2 4 2 2 I Eronti Panel A a deba 2 4 2 2 2 Pushbuttons an 2 7 DD 3SIUUS LEDS sr ir asti di IA a e EE E T A 2 9 GALIBRATION see 3 1 3 ZERO AIR SUPPE Y atus h aun aa Qawa
2. is 9 16 9 7 WARRANTY REPAIR QUESTIONNAIRE iii 9 18 10 ROUTINE MAINTENANGCGE Q 10 1 IO TOAMATNTENANCESCHEDUDB ii dali 10 1 A 10 2 OF SAMPLE rallenta 10 2 0 2 CHANGINGITHEPROMz2 ans apa an aan su is aa u awia 10 3 11 MODEL 401 SPARE PARTS AND EXPENDABLES KITS 11 1 11 1 SPARE PARTS FOR CE MARK u ansa net au QS eee 11 1 11 2 SPARE PARTS FOR NON CE MARK UNITS 11 3 Appendix A LIST OF AVAILABLE MODEL 401 OPTIONS 1 Appendix B RECOMMENDED ZERO AIR SYSTEM 1 Appendix REFERENCES ale 1 Appendix D SOFTWARE MENU TREES iii cene conc conos D 1 Appendix E ELECTRICAL SCHEMATIC INDEX 1 vi Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 LIST OF FIGURES FIGURE 1 1 FIGURE 1 2 FIGURE 1 3 FIGURE 1 4 FIGURE 1 5 MODEL 401 OZONE CALIBRATOR BLOCK DIAGRAM ii 1 11 M401 REAR PANEL ELECTRICAL CONNECTIONS cc
3. Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 TABLE OF CONTENTS SAFETY MESSA GEG Il TABLE OF CONTENTS u Q 11 LIST OF FIGURES Q VII OF TABEES osa u VIII 1 INTRODUCTION coincida 1 1 L PPREEBAGE apa a a Sed bath ua 1 1 EZWARRANTY s fani alana ui 1 1 L 3 PRINGIPLE OEFOPERATION a rh 1 2 MEROS ETE OE Q 1 4 FA SPECIFICATIONS A 1 5 PPB ARMS talloni ihihih 1 6 1 4 2 Lower Detectable Limit LDL PPB iii 1 6 PEDIA E AE 1 6 144 Span DOVE A A A A 1 6 II AA 1 6 o hay 1 6 TAT Rise And u Ai ana Lila ni se oi 1 6 T148 Temperature Rang n int au AS 1 6 1 4 9 H midit IRON OS SAA ZAS Beh nqa a 1 6 EEA Rates AA 1 7 LAST EP QW a la 1 7 LAI Werehi
4. For example the format of the PMT output in millivolts would be 194 11 29 0000 PMT 254 MV lt CRLF gt To request a test measurement the host must issue a command of the form T MEASUREMENT lt CRLF gt For a summary of all test functions issue the command T LIST Table 7 8 lists the commands and the corresponding test measurements which will be returned 7 7 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 7 8 Test Measurement Request Commands 7 6 Viewing And Modifying Variables The most powerful feature of the RS 232 interface is the ability of a host computer to view and modify the calibrator s internal variables Just as the operator modifies the variables by means of the setup mode the host computer modifies them by means of the RS 232 interface To view a variable s value the host computer issues a command of the following format V VARIABLE lt CRLF gt The CPU will respond by sending a message of the following format to the RS 232 output VARIABLE VALUE WARNLO WARNHI lt DATALO DATAHI gt lt CRLF gt In both cases VARIABLE is the name of the variable that is being viewed VALUE is the current value of the variable WARNLO and WARNHI are the low and high warning limits respectively but may not appear for all variables since some variables do not have warning limits DATALO and DATAHI are the low and
5. GEN Lamp Check GEN lamp heater and SHUTDOWN cannot be maintained at its 48 C thermistor as described in set point Section 8 10 SAMPLE The Sample Pressure is less than 15 Hg or Check for pressure transducer PRESSURE is greater than 35 Hg problems as described in Sections 9 6 1 and 9 6 5 SAMPLE FLOW The sample flow is less than 500 cc min or Check for flow transducer WARNING greater than 1000 cc min Check for problems as described in pneumatic system problems as described Section 9 6 5 in Section 9 6 1 BOX TEMP The inside chassis temp is less than 5 C See Section 9 6 2 WARNING is greater than 50 C SAMPLE TEMP The Sample Temperature is less than 10 C See Section 9 6 2 WARNING or is greater than 50 C V F NOT The CPU is unable to communicate with Check and re seat CPU and V F INSTALLED the V F Board board See Section 9 6 3 SYSTEM RESET A power Off On cycle has occurred Dynamic memory has been re initialized None required ei in response to the installation of a new PROM or memory chip 03 FLOW IZS flow rate is less than 1 8 L M or gt 5 5 Adjust pressure regulator to set WARNING proper flow rate 9 4 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 4 Troubleshooting Using Test Function Values The Model 401 Photometric Calibrator provides the capability to display on operator demand the values of Test Functions which allow the observ
6. 2 The warranties set forth in this section shall be of no force or effect with respect to any Product 1 that has been altered or subJected to misuse negligence or accident 1 that has been used in any manner other than in accordance with the instruction provided by Teledyne API iii not properly maintained THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY WHETHER EXPRESSED OR IMPLIED THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN TELEDYNE APISHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API S PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE TERMS AND CONDITIONS All 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 1 3 Principle Of Operation M401 Ozone calibrator consist of two major parts the ozone generating device and the photometer Ozone generating device itself also consist of a pump an air scrubber to self generate zero air a pressure regulator to control flow rate an ozone generator using UV lamp and a manifold The pressure regulat
7. 273 L Where I Intensity of light passed through the sample 1 Intensity of light through sample free of ozone a absorption coefficient path length C concentration of ozone in ppm T sample temperature in Kelvin P pressure in inches of mercury n natural logarithm As you can see 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 tube 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 15 a number that reflects the inherent ability of ozone to absorb 254 nm light Most current measurements place this value at 308 atm at STP The value of this number reflects the fact that ozone is 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 pathlength determines how many molecules are present in the column of gas in the absorption tube Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 3 1 The intensity of light is converted into a voltage by the detector preamp module The voltage is converted into a number
8. 2 2 3 Status LEDs The three status LEDs to the right of the display indicate the general status of the Model 401 Photometric Calibrator The green SAMPLE LED indicates the sampling status The yellow CAL LED indicates the calibration status The red FAULT LED indicates the fault status Table 2 5 summarizes the meanings of the status LEDs Table 2 5 Status LEDs LED Green Yellow State Meaning Off Not monitoring should never be off On Monitoring normally STBY ZERO 0 GN ASEQ MODE Off Auto cal disabled On Auto cal enabled Blinking Calibrating Off No warnings exist Blinking Warnings exist Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 INTENTIONALLY BLANK 2 10 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 3 CALIBRATION The 401 is designed to be used as a dedicated ozone calibrator with built in photometer Zero Span gas generation and calibration of Model 401 are discussed in Section 3 The emphasis in Section 3 is on the operation of the buttons and the Internal adjustments they make in the instrument 3 1 Manual Zero Air Supply The Model 401 calibrator can generate zero air using the internal scrubbing module Press zero and enter password 512 to generate zero air The IZS pump will start to run and flow control system will maintain stable flowrate of zero air to both the photometer and the analyzer being calibrate
9. 4 11 SETTING THE RS 232 BAUD RATE liceale 4 4 4 12 SETTING THE ANALYZER ED u anu le teense boats 4 5 4 13 DISABLING THE CALIBRATION PASSWORD 0202 0 00 0 100000000000000000000 4 5 4 14 SETTING THE FAULT LED TIMEOUT 4 5 AS SOFTWARE CONFIGURATION u qa aa 4 6 4 16 SUMMARY OF SETUP VARIABLES r hua aus 4 6 DIAGNOSTICS E iii 5 1 5 1 PEST MEASUREMENTS adi 5 1 52 DIAGNOSTIC TESTS 5 1 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 I2 LDA 5 2 6 HANDLING WARNINGS 6 1 7 RS 232 CONMUNICATIONS 7 1 TLADASREPORTINC ai 7 2 T 2 WARNINGS A 7 3 STATUS CONTROLS 7 4 DIAGNOSTIGS uu l 7 6 PO LEST ASA AS LZ nun ani payta ats d 7 1 7 6 VIEWING AND MODIFYING VARIABLES ere 7 8 S AD
10. Photometric Calibrator Instruction Manual 01124 Rev 2 6 HANDLING WARNINGS When a system warning occurs a warning message 15 displayed and the FAULT LED blinks warning indicates that something in the system needs to be checked or adjusted Failure by the operator to respond to a warning may result in poor system performance and or less accurate data acquisition Warnings should be taken seriously When a warning is displayed the MSG and CLR buttons will appear on the menu line when not in setup mode Pressing MSG will scroll through the warning messages if there is more than one CLR will clear the currently displayed warning message and if there are no more warning messages remaining the MSG and CLR buttons will disappear and the FAULT LED will be turned OFF If after pressing CLR warning messages still exist the FAULT LED will continue to blink and the MSG and CLR buttons will remain on the menu line If after clearing a message the warning condition for that message still exists the message will reappear after a period of time which depends on how frequently the condition is checked by the CPU usually every few seconds If a warning message reappears every time after CLR is pressed the problem should be solved and the Analyzer restarted Some problems may be temporary and may not reappear after CLR is pressed e g temperature too high too low etc To ignore the warning messages and display the test measurement again
11. simply press TEST The warning messages will remain active and may be viewed again by pressing MSG Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 INTENTIONALLY BLANK 6 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 7 RS 232 COMMUNICATIONS The Model 401 Photometric Calibrator features a powerful RS 232 interface which is used both for reporting test results and for controlling the Photometer from a host computer Because of the dual nature of the RS 232 interface the message format has been carefully designed to accommodate both printers and host computers All message outputs from the Model 401 Photometric Calibrator have the following format X DDD HH MM lt gt The X is character indicating the message type see Table 7 1 Table 7 1 RS 232 Message Types 7 7 The DDD HH MM is a time stamp indicating the day of year DDD as a number from 1 to 366 the hour of the day as a number from 00 to 23 and the minute as a number from 00 to 59 The is a 4 digit Analyzer I D number The MESSAGE field contains variable information such as warning messages test measurements DAS reports etc The lt CRLF gt is a carriage return line feed combination which terminates the message and also makes the messages appear neatly on
12. 000 ppb Whatever range 15 selected the value chosen will correspond to 5 00 volts on the analog outputs For other analog voltage ranges check the jumper table for the V F board schematic drawing 00515 in the Appendix The front panel display does not have a range setting due to the fact that it can display any concentration value up to 20 000 ppb 4 10 Setting The Analog Output Offset In order to permit the Analyzer to connect to a wider variety of strip chart recorders and other instruments the analog output of the ozone readings can be adjusted by up to 500 mV for 0 5 V range or 10 of current analog output range in software The default output offset is 0 mV To change it press SETUP MISC D A OFFS and enter a value of from 500 mV to 500 mV other ranges will ratio accordingly followed by ENTR to accept the change or EXIT to leave it unchanged The offset will be reflected immediately on the strip chart recorder or other instrument 4 11 Setting The RS 232 Baud Rate To set the baud rate for the RS 232 channel press SETUP COMM BAUD Press 300 1200 or 2400 followed by ENTR to accept the new baud rate or EXIT to leave the baud rate unchanged Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 4 12 Setting The Analyzer I D Each Analyzer may be programmed with a unique I D number which appears on all RS 232 messages set the Analyzer I D press SETUP COMM ID Enter 4 digi
13. 01124 Rev J2 Figure 1 3 Rear Panel Electrical and Pneumatic Connections CE Version Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 6 Electrical And Pneumatic Connections 1 6 1 Electrical Connections Output 1 Ozone concentration chart recorder Output 2 Ozone concentration DAS Output 3 Test function analog output Input 4 Zero valve request Input 5 Span valve request Input 6 N C There are 2 six pin connector strips on the rear panel shown in Figure 1 2 The pins are divided into 3 plus minus pairs and have the functions shown above Outputs 1 and 2 have identical signals and electrical characteristics Output 3 is the same as 1 and 2 electrically but has analog TEST function signals routed to it See Diagnostics in Section 5 for details 1 6 2 RS 232 See Figure 1 4 The RS 232 connection 15 a male 9 pin D sub connector Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 lt 4 4 6 i Figure 1 4 5 232 Pin Assignments Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 6 3 Pneumatic System The Model 401 Photometric Calibrator is equipped with a compression pump to deliver up to 5 L MIN for ozone generator system It is also equipped with a second pump capable of pulling 800 cc min across a critical flow orifice This allows a smooth
14. 6 Table 2 2 lists all the possible modes in the Analyzer and their meanings Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 Table 2 2 System Modes SPAN Bench span calibration SETUP xxx 4 Configuring analyzer operation continues 1 xxxx AZS Auto Zero amp Span programmed AZ2S Auto Zero amp 2 span points 25 amp 100 of set concentration AZ5S Zero amp 5 span points 20 40 60 80 amp 100 of Os set concentration programmed 2 x M manual A auto R remote 3 diagnostic test modes 4 xxx software revision 5 0 20 25 40 60 80 100 The message field shows test measurements or warning messages Table 2 3 and Table 2 4 summarize the test measurements and warning messages and their meanings Refer to Sections 4 and 5 for detailed information on viewing test measurements and warning messages and clearing warnings 2 5 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 2 3 Test Measurements 2 6 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 2 4 Warning Messages 03 FLOW WARNING SAMPLE FLOW WARNING SAMPLE PRESSURE WARN 03 GEN LAMP TEMP WARN The menu field changes depending mode of Analyzer and buttons that been pressed It indicates the current function of e
15. AND DETECTOR DIAGNOSTICS 9 15 TABLE 10 1 MAINTENANCE SCHEDULE n 10 1 TABLE 11 1 SPARE PARTS FOR MARK 11 1 TABLE 11 1 SPARE PARTS FOR CE MARK UNITS CONTINUED ii 11 2 TABLE 11 2 SPARE PARTS FOR NON CE MARK 11 3 TABLE 11 2 SPARE PARTS FOR NON CE MARK UNITS CONTINUED 11 4 TABLE 1 AVAILABLE MODEL 401 OPTIONS iii A 1 TABLE F 1 ELECTRICAL SCHEMATIC INDEX 2 12 1211 1240242240000000000000000000000000000000 E 1 viii Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 INTRODUCTION 1 1 Preface Teledyne API is pleased that you have purchased the Model 401 We offer a full one year warranty see Section 1 2 and 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 The Teledyne API Model 401 keyboard operator interface with its talking keys makes the Teledyne API a very user friendly system We hope you will not experience any problems with the Teledyne API Model 401 but if you do the built in tests and diagnostics should allow you to quickly and easily find the problem In addition our full time customer service departmen
16. API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 2 Confirm that all Jumpers on the V F board are set properly as follows Table 9 3 V F Board Jumpers Factory Settings Factory Set Jumpers 1 1 2 Table 9 4 V F Board Dip Switches Ranges For Analog Output User Set DIP Switches Switch 100 mV 5 10 Full Scale Full Scale Full Scale Full Scale SI DAC 0 1 6 ON 1 5 ON 1 4 ON 1 3 ON S2 DAC 1 DAS 1 6 ON 1 5 ON 1 4 ON 1 3 S3 DAC 2 1 6 7 1 5 7 1 4 7 1 3 7 3 If Voltages and Jumper settings are correct the V F card is faulty and should be replaced 9 12 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 9 6 4 Checking The DC Power Supply Board A schematic and physical diagram of the DC Power Supply Board are shown on Drawings 00015 and 00016 in Appendix D The overall performance of the DC Power Supply Board can be checked by observing the value of the DCPS test functions If this value a composite of five regulator outputs deviates by more than 10 from the value recorded in Table 1 1 of this manual under Test Values the outputs of the individual regulators should be checked by measuring for the following voltages 1 Remove Plugs J8 J6 and J13 from the front of the Power Supply Module Verify that the following voltages are present 24 VDC between J
17. API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 To do a remote adjustment via the RS 232 interface the host computer should issue a message with the following format C COMMAND lt CRLF gt The commands are summarized in Table 7 4 Table 7 4 Control Commands Command Message Meaning O GEN lt CRLF gt Do a span check ASEQ lt CRLF gt Do a multi point check C STBY lt CRLF gt Exit zero span or ASEQ NOTE The commands in Table 7 4 can only be entered via the RS 232 port when the calibrator is in the stand by mode ASEQ is enabled only if ASEQ is pre selected When a control command is issued the CPU will respond issuing a status report For example if the host computer issues the command C ZERO lt CRLF gt to do a zero check the CPU will send the report DDD HH MM GENERATE ZERO to the RS 232 output Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 7 4 Diagnostics The diagnostics mode can be entered from the RS 232 port as well as from the front panel The diagnostics commands available are listed below NOTE The diagnostics mode may only be entered via the RS 232 port when the calibrator is in stand by mode Table 7 5 Diagnostic Commands D PAUSE lt CRLF gt These commands may be used whether the diagnostics have been entered from the keyboard SETUP DIA
18. FLOW WARN message the host computer can issue the command W WSMPFLOW lt CRLF gt To clear all warning messages W CLEAR ALL lt CRLF gt Attempting to clear a warning which is not active has no effect Table 7 2 lists the command to use to clear each possible warning message Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 7 2 Warning Message Clear Commands W WSYSRES lt CRLF gt W WRAMINIT lt CRLF gt W WALMPINT lt CRLF gt W WO3LMPHLT lt CRLF gt W WO3REFDET lt CRLF gt W WO3FLOW lt CRLF gt W WSMPFLOW lt CRLF gt W WSMPPRES lt CRLF gt W WSMPTEMP lt CRLF gt W WBOXTEMP lt CRLF gt W WO3LMPTMP lt CRLF gt W WALMPTMP lt CRLF gt W WVFINS lt CRLF gt 7 3 Status Control This subset of messages is concerned with reporting the status of the calibrator and controlling the calibrator remotely Whenever the calibrator does a calibration it issues a report to the RS 232 output The table on the following page summarizes the status reports Table 7 3 Status Reports Report C DDD HH MM START ZERO CALIBRATION C DDD HH MM FINISH ZERO CALIBRATION C DDD HH MM START SPAN CALIBRATION DDD HH MM FINISH SPAN CALIBRATION C DDD HH MM START MULTI POINT CALIBRATION DDD HH MM III FINISH MULTI POINT CALIBRATION DDD HH MM START CALIBRATION HOLD C DDD HH MM III FINISH CALIBRATION HOLD 7 4 Teledyne
19. FOLLOWING TABLE NOTE DEPENDING ON OPTIONS INSTALLED NOT ALL TEST PARAMETERS SHOWN BELOW WILL BE AVAILABEL IN YOUR INSTRUMENT Parameter Observed Value Units Normal Range DCPS MV 2300 2700mV BOX TEMP DEG C Ambient 3 5 C OFFSET PPB 10 20PPB Os SLOPE 1 0 15 REG PRESSURE IN HG A 10 21 Hg A GEN TMP DEG 48 19 C GEN FLOW L MIN 2 5 LPM ANA LAMP TMP DEG C 52 1 SAMPLE DEG 10 50 SAMPLE FLOW SCC MIN 700 900 cc min SAMPLE PRESS IN HG A Ambient 0 2 Hg A O DRIVE MV 0 5000m V GEN REF MV 120 5000m V REF MV 2500 4700mV MEAS MV 2500 4700 mV O SET PPB PPM 05 PPM 1 PPM 2 HAS THE UNIT BEEN LEAK CHECKED YES NOL 3 WHAT ARE THE FAILURE SYMPTOMS IF POSSIBLE PLEASE INCLUDE A PORTION OF A STRIP CHART PERTAINING TO THE PROBLEM CIRCLE PERTINENT DATA 4 THANK YOU FOR PROVIDING THIS INFORMATION YOUR ASSISTANCE ENABLES TELEDYNE API TO RESPOND FASTER TO THE PROBLEM THAT YOU ARE ENCOUNTERING TELEDYNE API CUSTOMER SERVICE EMAIL api customerserviceO teledyne com PHONE 858 657 9800 TOLL FREE 800 324 5190 FAX 858 657 9816 9 18 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 10 ROUTINE MAINTENANCE NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only 10 1 Mainten
20. Procedure Due to the stability of modern electronics this procedure should not have to be performed more than once a year or whenever a major sub assembly is exchanged or whenever analog output voltage range 15 changed To calibrate the ADC do the following 1 2 Press SETUP MISC D A CAL The M401 display will read DAC 0 60 mV where 60 mV is the target voltage which should be coming out the DAC it should be 60 mV Put the probe of a voltmeter between TP3 AGND and TP9 DAC 0 on the top of the V F card See Drawing 00514 Appendix E then press the up down buttons on the M400 front panel until the voltmeter displays the target voltage 60 mV on the 5 V range Note that the value on the M401 display will not change When the voltmeter shows the same value 3 mV as the M401 display press ENTR The reading will be close to 60 mV if the analyzer is setup for the 5 V range 120 mV for the 10 V range etc DAC 0 is the recorder output DAC 1 is the DAS output and DAC 3 is the test output The M401 display will now show a new voltage in the same format as above This voltage will be 90 of the full scale DAC output range 4500 mV on the 5 V range As before press the up down buttons on the M401 front panel until the voltmeter displays the same 3 mV reading as the M400 display then press ENTR The first DAC is now calibrated and will be used as a voltage reference for calibrating the ADC The M401 display will
21. Very dirty air may require a pre cleaning process to remove large particles oil mist liquid water etc The primary purification process is based on mechanical and chemical filtering While various schemes may be acceptable systems similar to the following have been used successfully The air is first dried with a Perma Pure type dryer followed by a column of indicating silica gel The air is then irradiated with a UV lamp to generate ozone that converts existing NO to NO2 and a large column of activated charcoal removes NO2 hydrocarbons and various other substances If desired molecular sieve can be included for good measure A final particulate filter removes particulates which can originate in the scrubber columns The removal of moisture may not be necessary but fewer problems seem to be encountered when dry air is used The particulars of air purification are not well known so some experimentation may be necessary to determine the appropriate size of volume for scrubber columns Also the capacity of the scrubber materials may not be accurately known so frequent replacement of renewal of these materials is advisable Additional information on air purification is available APHA Intersociety Committee 1977 Section 20 Part I A very important requirement in photometer operation is the need for the zero air supplied to the photometer during the I measurement to be obtained from the same source as that used for generation of ozo
22. a standard 19 wide x 30 deep RETMA rack 1 8 2 Status Outputs The status output is an option that reports Analyzer conditions to a 50 pin connector from the mother board The contacts are NPN transistors which can pass 50 ma of direct current See Section 8 6 for status output pin assignments 1 22 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 2 OPERATION 2 1 Key Features The important features of the Teledyne API Model 401 Photometric Calibrator are listed below 2 1 1 03 Readout The Teledyne API Model 401 Photometric Calibrator constantly displays the current ozone reading in PPB in the upper right hand corner of the alphanumeric display 2 1 2 03 Analog Output The Teledyne API Photometric Calibrator provides a buffered analog output of the current Os readings on each of two pairs of outputs on the rear panel see Figure 1 2 for DAS and recorder reporting The analog outputs provide for 20 overrange For example on the 500ppb range the M401 will correctly report concentrations up to 600 ppb and output up to 6 00 volts to the DAS and recorder outputs See Table 9 4 for setting proper analog output voltage jumpers In addition TEST function values can be routed to a third analog output 2 1 3 ROM Backup Of Software Configuration The Teledyne API Photometric Calibrator has few DIP switches or jumpers that need to be set by the operator Configuration of the calibrator is
23. a printer The uniform nature of the output messages makes it easy for a host computer to parse them Input messages to the Model 401 have a format which is similar to that for output messages X COMMAND lt CRLF gt Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 The X indicates the message type as shown above in Table 7 1 and COMMAND is the command type each of which is described individually below The lt CRLF gt is used to terminate the command Typing lt CRLF gt a few times by itself is good way to clear the input buffer of any extraneous characters 7 1 DAS Reporting Every N minutes N is software selectable the data acquisition system issues a report to the RS 232 interface This report shows the average reading during the last N minutes the range and the number of 1 minute samples taken during that interval The message format 15 DDD HH MM RANGE xxxx PPB SAMPLES xx lt CRLF gt Whenever the Model 401 15 in calibration or diagnostics mode no readings are included in the average Thus it is possible for an average to contain 0 samples If the number of samples in an average is 0 then XXXX is shown as the O readings The host computer can request the DAS reports stored in the battery backed RAM by means of the command R NNN lt CRLF gt where is the number of reports requested starting fro
24. a problem is the result of the UV Lamp or the Lamp Power Supply However the following steps will provide a reasonable confidence test of the Lamp Power Supply 9 16 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 WARNING Hazardous voltage present use caution 1 Unplug the cable connector at J1 on the Lamp Power Supply and confirm that 24VDC is present between Pins 1 and 2 on the cable connector If this voltage is incorrect check the Power Supply Module as described in Section 9 6 4 2 Remove the cover of the Lamp Power Supply and check for the presence of the following voltages 15VDC between 14 and 2 20VDC 2VDC between TP14 and TP7 If these voltages are incorrect the Lamp Power Supply is faulty and should be replaced If the above checks are successful it is more likely that a problem is due to the UV Lamp than due to the Lamp Power Supply Replace the Lamp and if the problem persists replace the Lamp Power Supply 9 17 Teledyne API Model 401 Os Warranty Repair ak ae Calibrator Instruction Qu estionnaire fa INSTRUMENTS anual 01124 Rev 2 Advanced Pollution Instrumentation Model 401 A Teledyne Technologies Company 9 7 Warranty Repair Questionnaire CUSTOMER PHONE CONTACT NAME FAX NO SITE ADDRESS MODEL 401 SERIAL NO FIRMWARE REVISION 1 ARE THERE ANY FAILURE MESSAGES PLEASE COMPLETE THE
25. case of using external dry zero air verify proper pressure of external air source 3 Allow to sample span gas for approximately 10 minutes 4 Follow the sequence of SETUP BCAL and enter correct span concentration related to the Model M400 master standard Then select yes to set span 3 7 Remote Zero Span Check Contact Closure In addition to calibration check via the front panel buttons the calibrator can be activated by means of two contact closures called EXT ZERO CAL and EXT SPAN CAL See Figure 1 2 for the location of the terminals for connection of the contacts on the rear panel The CPU monitors these two contact closures every 1 second and looks for positive transition 1 0 gt 1 on either signal If a positive transition occurs on EXT ZERO CAL the M401 will perform a zero check If a positive transition occurs on EXT SPAN CAL the M401 will perform a span check If a positive transition occurs on both EXT ZERO CAL and EXT SPAN CAL simultaneously and ASEQ 15 preset then the M401 will perform a multi point sequence as selected in SETUP EVNT ASEQ menu see Section 4 2 When a negative transition i e 1 gt 0 is detected the CPU will go into standby mode Also if a positive transition occurs on either signal while the M401 is in zero span check ASEQ mode it will immediately switch to the specified mode For example if the analyzer is in zero check and a positive transition is detected on EXT_SPAN_CAL
26. diagnostic test mode press SETUP DIAG When the diagnostic mode 15 entered a message 15 sent to the RS 232 channel indicating entry into the diagnostic mode The TEST button is used to scroll through the test measurements until the one of interest is displayed The EXIT button exits the diagnostic mode and turns all the diagnostic tests OFF This ensures that a diagnostic test is not accidentally left ON A message is also sent to the RS 232 channel to indicate that the diagnostic mode has been exited Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 5 1 Test Channel Output 1 NONE No output O3 DETECT Outputs Os detector REF DETECT Outputs IZS ref det SAMP PRESS Outputs sample press SAMP FLOW Outputs sample flow O3 LAMP TEMP Outputs lamp temp Table 5 2 Diagnostic Tests D A OUTPUT Tests analog outputs 5 2 1 D A Output This test cycles 3 of the analog output channels from 0 to 100 of Full Scale in 20 FS steps It starts by outputting 0 volts to all four channels and displaying a 0 button Then every five seconds the output is increased 20 FS and the button is changed accordingly Thus the button and the analog outputs will cycle through the following values 0 20 40 60 80 100 0 To pause the output at current voltage press n button resume automatic cycling press the n button again 5 2 Teledyne API Model 401
27. done under software control and the configuration options are stored in electrically erasable E ROM Thus configuration options are saved even when the Analyzer is powered off There is one exception to this The analog output voltage ranges are set by DIP switches on the A D I O board as shown in Section 9 6 3 2 1 4 Adaptive Filter The Teledyne API Photometric Calibrator is able to provide a smooth stable output by means of an adaptive filter During conditions of constant or nearly constant concentration the filter is allowed to grow to 32 samples 2 minutes in length providing a smooth stable reading If a rapid change in concentration is detected the filter is cut to 6 samples to allow the Analyzer to quickly respond to rapidly varying signals Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 2 1 5 Data Acquisition The Teledyne API Photometric Calibrator contains a built in data acquisition system which keeps track of the average Os readings and the last 100 averages This data is made available to other systems via the RS 232 interface The Photometric Calibrator can be programmed to automatically output a 1 minute to 60 minute average The last 100 averages can be called up through the remote RS 232 or viewed on the display through keyboard call up 2 1 6 RS 232 Interface The Teledyne API Photometric Calibrator features an optional RS 232 interface which can output the instant
28. high data entry limits respectively and are given for all variables The CPU will not set a variable s value or warning limits to values which are outside of the data entry limits 7 8 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 For example to see the analyzer lamp temperature set point the host computer would issue the command V ALAMP_SET lt CRLF gt and the CPU would respond with something like V DDD HH MM ALAMP_SET 25 20 30 lt 0 100 gt lt CRLF gt indicating that the current set point is 25 degrees the warning limits are 20 to 30 degrees and the data entry limits are 0 to 100 degrees To modify a variable s value almost the same format of command is used VARIABLE VALUE WARNLO WARNHI lt CRLF gt The VARIABLE field is the name of the variable being modified and the VALUE field is the new value WARNLO and WARNHI are the low and high warning limits respectively and may only be given if the variable uses warning limits They are optional for variables which use warning limits and if not given the warning limits are not changed After changing the variable s value the CPU will respond with VARIABLE VALUE WARNLO WARNHI DATALO DATAHI lt CRLF gt which should reflect the new value The values in square brackets are not required for all variables If needed the values are included on the co
29. now read ZR 60 60 3 mV where 60 mV is the voltage being output from the DAC as input to the ADC and 60 3 mV is the voltage as read from the ADC The two values should be the same 60 60 If they are not adjust the zero pot R27 on the V F card as indicated by ZR on the display until the two values are the same then press ENTR The M401 display will now read GN 4500 4500 where 4500 is the voltage being output from the DAC as input to the ADC and 4500 3 15 the voltage as read from the ADC The two values should be the same If they are not adjust the gain pot R31 on the V F card as indicated by GN on the display until the two values are the same 4500 4500 3 mV then press ENTR The ADC is now calibrated and M401 will automatically calibrate all the DAC s The display will show the percent completion as the analyzer goes through the procedure Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Next to automatically calibrate all the DACs press SETUP MISC D A CAL DAC The display will show the percent completion as the analyzer goes through the procedure You must calibrate the ADC before calibrating the DACs because the ADC is used during the DAC calibration procedure Once the ADC 15 calibrated you may recalibrate the DACs anytime simply by pressing SETUP MISC D A CAL ENTR ENTR ENTR ENTR 8 3 Output Voltage Range Changes Output voltage ranges are set by jumper placement
30. password is entered the analyzer will beep when enter is pressed 2 3 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 2 2 Front Panel This section describes the operator interface from the point of view of the front panel The front panel consists of a 2 line by 40 character alphanumeric display 8 pushbuttons and 3 status LEDs Each of these features are described in Section 2 2 1 2 2 1 Front Panel Display The display is divided into 4 main fields the mode field in the upper left the message field in the top center the sample concentration field consisting of the most recent instantaneous ozone value field in the upper right and the MENU field which occupies the entire bottom line of the display A typical display is shown in Figure 2 1 Figure 2 1 Model 401 Front Panel The mode field indicates the current mode of the Analyzer Usually it shows STBY ZS indicating that the instrument is in the standby mode and that automatic zero span checking is enabled Manual span checking or calibration can only be performed by pressing the buttons on the front panel labeled ZERO O3GN or ASEQ is a sequence of multipoint calibration which is displayed only if automatic multipoint sequence is selected see Section 3 3 for detailed information Automatic span check only occurs at the preset time Calibration and span adjustments are discussed in greater detail in Section 3
31. the DAS average Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 INTENTIONALLY BLANK 3 6 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 4 SETUP MODE This section describes the setup variables which are used to configure the analyzer 4 1 Setup Mode Operation the setup variables are stored in the analyzer s EEPROM and are retained during power off and even when new software revisions are installed NOTE If a variable is modified but ENTR is not pressed the variable will not be changed and the analyzer will beep when EXIT is pressed 4 2 Setting Automatic Multipoint ASEQ Check Automatic sequence of multipoint calibration can be programmed to select one zero and five span points 20 40 60 80 and 100 of selected see Section 3 4 How to set concentration Os concentration by pressing sequence of SETUP EVNT ASEQ AZ5S Likewise select AZS for zero and one span point selected Os concentration select AS2S for zero and two span points 25 and 100 of selected Os concentration or press OFF to disable pre programmed automatic sequence If ASEQ is selected then front panel s yellow status LED will be turned on 4 3 Setting Automatic Zero Span Duration Duration of each zero span calibration step can be programmed by selecting SETUP EVNT WAIT Enter the duration between 1 20 minutes for the zero check and then press ENTR simil
32. the temperatures to come up to their respective setpoints then press the leftmost button on the front keyboard to scroll through the TEST values Compare these values to those noted during the final factory checkout listed in Table 1 1 The values observed should closely match the Table 1 1 values NOTE Words in all caps are messages on the analyzer front panel 12 Select the range the analyzer will be calibrated on a From the MAIN menu press SETUP to enter the SETUP menu See Figure 2 2 for appearance of front panel b Press MISC c Press D A d Enterthe PASSWORD 818 e Press RNGE RANGE f Enter the derived full scale range for analog outputs and press ENTR Example if full scale range is 500 ppb then press corresponding 41215 button until desired range is selected and press ENTR g Press EXIT 3 times to return to the MAIN menu 13 Os generator flow adjustment The Os generator flow is controlled by a precision pressure regulator and flow restrictor Increasing upstream pressure of flow restrictor will increase flowrate and vice versa In order to increase pressure adjust knob clockwise as needed while monitoring the O3 flow test measurement display In general the O3 generator flow should be at least 1 L MIN in addition of total flow demands for the Model 401 800 cc min and remote analyzers NOTE Adjustment of the Os generator flow is to be performed by qualified maintenance personnel only T
33. warning message or messages being displayed on the front panel Table 9 1 lists the warning messages which the Calibrator may display along with their meaning and the recommended corrective action It should be noted that if multiple more than 2 or 3 warning messages occur at the same time it is often an indication that some fundamental analyzer sub system power supply V F board CPU has failed rather than an indication of the multiple failures referenced by the warnings In this situation it is recommended that proper operation of power supplies see Section 9 6 4 and the V F Board see Section 9 6 3 be confirmed before addressing the specific warning messages Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 9 1 Warning Messages ANA LAMP The Os REF value is greater than 5000 mV Check and adjust Source Lamp WARNING or less than 2500 mV and UV detector as described in Section 9 6 6 ANA LAMP Temperature control of the Source Lamp Check source lamp heater and SHUTDOWN cannot be maintained at its 52 C set point thermistor as described in Section 8 10 O3 GEN LAMP The Ozone Generator is unable to produce Check and adjust the O GEN WARNING at least 1000 ppb at its maximum output or lamp and reference det as the GEN feedback control is adjusting described in Section 9 6 8 the Ozone generator drive signal by more than a factor of two O3 GEN LAMP Temperature control of the
34. zero and multipoint calibration switch and the feedback mode These are described individually below To set the duration of the zero span check press the following sequence of buttons from the STBY mode SETUP EVNT WAIT Enter the duration for the zero check and then press ENTR Similarly enter the duration for the span check and then press enter To shift the Z S check time backwards each day select and enter a number from 1 to 60 To disable shifting of the check time i e to 7 5 check at the same time each day enter a time shift of 0 To enable automatic zero span checking press following sequence of SETUP EVNT ASEQ The CPU will display the current setting in the menu field above the first button Press OFF in order to disable automatic sequence then press ENTR Likewise select AZS for zero and span See Section 3 2 or 3 4 How To preset Os concentration which is specified in Os GN or ASEQ of main menu AZ2S for zero and two span points 25 AND 100 of preset Os concentration and AZSS for zero and five span multipoint 20 40 60 80 and 100 of preset concentration sequence O generator has three different modes of lamp feedback control Press sequence of SETUP MISC 03 GEN MODE to select constant CNST lamp current control reference REF detector feedback control or bench BNCH feedback lamp control Bench feedback is recommended to generate fast response stable and accurate Os concentration in which the
35. 0 mV CAUTION UV light present Do not pull the lamp from the IZS assembly Re tighten the hold down screws securing the ozone lamp to the O generator assembly 3 Remove access cap from the generator preamp cover and adjust the pot to refine the front panel reading to 2500 mv 25 4 The O generator lamp and feedback circuit are now set up Proceed to Section 8 11 to finish calibration of the O3 generator Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 8 10 Ozone Generator Calibration The ozone generator can be calibrated against the analyzer calibration by using the analytical section of the M401 to determine the ozone generator s output Calibration of the generator allows the operator to enter the desired calibration concentration directly in PPB s The 401 should be calibrated by relating to the master standard using the method described in Section 3 before doing this procedure Press SETUP MISC O3 GEN CAL to start the calibration process which works as follows 1 The M401 will measure the Os generator reference signal and the Os concentration at 5 different Os concentrations 2 For each test point the machine outputs the drive setting and waits 10 minutes for the M401 to stabilize Then it takes two readings and stores them in a table for future use 3 During calibration the analyzer displays completion so that you monitor the progress of the calibration Full c
36. 2 1 4 1 Noise PPB RMS The standard deviation of reported concentration calculated over 25 samples times 7 runs minimum N 1 weighted 1 4 2 Lower Detectable Limit LDL PPB LDL is defined as twice the RMS noise at the lower end of the most sensitive operating range 1 4 3 Zero Drift PPB Zero drift is defined as unadjusted automatic operation maximum shift over the given period at constant temperature and pressure 1 4 4 Span Drift Span drift is defined similarly to zero drift requiring unadjusted operation at constant temperature and pressure 1 4 5 Linearity lt 1 0 of URL best straight line deviation over range of LDL to URL 1 4 6 Lag Time Lag time is defined as the time interval between a step change at the sample inlet port of input concentration and the first observable corresponding change in analyzer output 1 4 7 Rise And Fall Times Rise fall times are defined as the time interval between a step change in input concentration and 95 of final response unless otherwise noted 1 4 8 Temperature Range 5 40 C 1 4 9 Humidity Range 0 to 95 relative humidity non condensing Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 1 4 10 Flow Rates 800 scc min 10 standard cubic centimeters minute sample flow rate 2 5 l min 10 standard cubic liter minute Os generator flow rate 1 4 11 Power Standard input power 120VAC rms 60 Hz 250 watts m
37. 8 pins 2 and 4 24 VDC between J6 pins 12 and 13 25 VAC between J13 pins 4 and 5 15 VAC between J13 pins 3 and 2 8 between J13 pins 6 and 7 WARNING Hazardous voltage present on the power supply module If any of these voltages is not present the Power Supply Module is defective and should be replaced 2 Confirm that the following voltages are present on the V F Board 5V between V F TP 4 and V F TP 5 15V between V F TP 1 and V F TP 3 15V between V F TP 2 and V F TP 3 12V between Mother Board Pad J13 6 and J13 7 If any of these voltages is incorrect it is probable that the DC Power Supply Board is faulty and should be replaced 9 13 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Four Temperature linearization circuits are contained on the DC Power Supply board The outputs of these circuits can be checked by measuring the voltages at test points on the board as follows 1 Sample Temp 30 C 2 5V 0 125V C TP2 Source Lamp Temp 50 C 2 5V 0 125V C TP3 IZS Lamp Temp 50 C 2 5V 0 125V C TP4 Chassis Temp 20 C 2 5V 0 125V C If any of these voltages 15 Incorrect check thermistor operation as described in Section 9 6 2 If thermistors are operating correctly it is probable the DC Power Supply Board is defective and should be replaced 9 6 5 Checking The Pneumatic Sensor Board A schematic and physical diagram of the Pneumatic S
38. 930 01934 CB004 FA004 FL003 FM004 FM05 FM06 HW020 HW036 HW037 OP001 OR001 OR012 OR014 OR021 OR026 OR028 OR030 OR048 SW006 SW008 TU001 TU002 TU009 VA003 Fan Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 11 2 Spare Parts For Non CE Mark Units Table 11 2 Spare Parts For Non CE Mark Units FA004 Fan FL003 Filter DFU 036 040180 table continued Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 11 2 Spare Parts For Non CE Mark Units Continued ono won Sw Swan Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Appendix LIST OF AVAILABLE MODEL 401 OPTIONS Table A 1 Available Model 401 Options om _ Rack Mount and Slides Rack Mount Only A 1 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 INTENTIONALLY BLANK A 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Appendix B RECOMMENDED ZERO AIR SYSTEM The following is from the TECHNICAL ASSISTANCE DOCUMENT FOR THE CALIBRATION OF AMBIENT OZONE MONITORS Richard J Paur and Frank F McElroy 1979 Zero air must be free of ozone and any other substance that might react with ozone e g NO2 various hydrocarbons and particulates Air from any source must be purified to remove such substances
39. Air Monitoring Stations SLAMS Code of Federal Regulations Title 40 Part 58 Appendix B Quality Assurance Requirements for Prevention of Significant Deterioration PSD Air Monitoring Code of Federal Regulations Title 40 Part 50 Appendix D Aeros Manual Series Volume II Aeros User s Manual EPA 450 2 76 029 OAQPS No 1 2 039 December 1976 Quality Assurance Handbook for Air Pollution Measurement Systems Volume II abbreviated Handbook Volume ID National Technical Information Service NTIS Phone 703 487 4650 part number PB 273 518 uality Assurance Handbook for Air Pollution Measurement Systems Volume II abbreviated Q A Handbook Volume II Available through USEPA Center for Environmental Research Information Phone 513 569 7562 EPA 600 4 77 027A Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 INTENTIONALLY BLANK C 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Appendix D SOFTWARE MENU TREES Figure A 1 Model 401 Sample Software Menu Tree Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Figure A 2 Model 401 Setup Software Menu Tree D 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Appendix E ELECTRICAL SCHEMATIC INDEX Table E 1 Electrical Schematic Index 00015 Power Supply Board Assembly 00016 Supply
40. Board Diagram E 1 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 INTENTIONALLY BLANK E 2
41. D 8 6 CPU If the display 15 operating and the green sample light is on the CPU should be operating If not check the red LED the CPU board itself it should be blinking If the RED led on the CPU board is not blinking make the following checks 1 Verify 5 Volt supply on the power connector to the CPU Backplane 2 Check for any loose memory chips on the CPU board 3 Tryremoving and reseating the CPU V F Card assembly in the motherboard Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 8 7 Status Lines Table 8 1 The Calibrator Has The Following Status Conditions 19 20 LAMP WARNING Alarms If The Calibrator Lamp Intensity Is Out Of Limits 8 8 UV Lamp Power Supply Adjustment Adjust the drive power of the lamp power supply as follows 1 Remove the cover of the lamp power supply Attach DVM across TP7 and TP10 and adjust the pot VR1 until the DVM reads 20 volts 1 volt 2 Adjust the positioning of the source lamp as follows a At the front panel of the instrument Press the TEST key until Os REF XXXXX is displayed b Loosen the lamp retaining thumb screw and rotate the lamp until the Os REF reading on display is 4500 mV 320 mV Re tighten the thumb screw Note that the full range of lamp adjustment can be achieved within revolution of the lamp Note also that the O3 REF display is updated approximately once every six seconds and slow rotation of the l
42. G or the RS 232 D ENTER lt CRLF gt However when the diagnostics are entered via the keyboard no feedback is sent to the RS 232 channel This prevents the RS 232 output from getting unnecessarily cluttered with diagnostic data In addition to the above commands three special diagnostics commands have been added to provide complete control over a remote Analyzer These commands may be executed no matter what mode the instrument is in Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 7 6 Special Diagnostic Commands D SYS RESET lt CRLF gt Reset Calibrator same as power off on D RAM RESET lt CRLF gt Reset Calibrator and erase RAM D EE RESET lt CRLF gt Reset Calibrator and erase RAM amp EEPROM Whenever the diagnostic mode is entered or exited a report is issued to the RS 232 output Table 7 7 summarizes the diagnostic reports Table 7 7 Diagnostic Reports C DDD HH MM ENTER DIAGNOSTIC MODE C DDD HH MM EXIT DIAGNOSTIC MODE 7 5 Test Measurements the test measurements which can be displayed by pressing the TEST button are also available to the host computer via the RS 232 interface The host computer should issue a request for a test measurement and then the CPU will send the current value of the test measurement to the RS 232 output The format of the test measurement message 15 DDD HH MM TEST MEASUREMENT lt CRLF gt
43. INSTRUCTION MANUAL MODEL 401 CALIBRATOR TELEDYNE INSTRUMENTS ADVANCED POLLUTION INSTRUMENTATION DIVISION T API 9480 CARROLL PARK DRIVE SAN DIEGO CA 92121 5201 TOLL FREE 800 324 5190 FAX 858 657 9816 TEL 858 657 9800 E MAIL api sales teledyne com WEB SITE www teledyne api com 01124 REV 42 Copyright 2005 Teledyne Advanced Pollution 11 July 2005 Instrumentation Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 SAFETY MESSAGES Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message 15 associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger CAUTION Hot Surface Warning CAUTION Electrical Shock Hazard Technician Symbol operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTION The analyzer should only be used for the purpose and in the manner described in this manual If you use the analyzer in a manner other than that for which it was intended unpredictable behavior could ensue with possible hazardous consequences
44. JUSTMENT O SU UU ai 8 1 8 1 POWER SUPPLY BOARD ADJUSTMENT ieri 8 1 Oh Box Temperature Limits or 8 1 8 2 A D D A CALIBRATION PROCEDURE 8 3 8 3 OUTPUT VOLTAGE RANGE CHANGES 8 4 8 4 FLOW READOUT ADJUSTMENT ccccccssssssecececececeesessesecececeeeesensnseceeeeceeesesessaeceseeceseeensseseeeseceeeenes 8 4 8 5 IDG POWER SUPPLY at saat BOOS a Ded BAS CL N aM Ss 8 6 sO PU SY mna aaa eee tad Sev 8 6 SI STATUS LINES Maar 8 7 8 8 UV LAMP POWER SUPPLY ADJUSTMENT 8 7 8 9 OZONE GENERATOR LAMP SETUP n 8 8 8 10 OZONE GENERATOR CALIBRATION ii 8 9 8 11 DARK CURRENT SIGNAL ADJUST PROCEDURE iii 8 9 8 12 BENCH FEEDBACK OPTION cirie 8 10 9 TROUBLESHOOTING 9 1 O L OVERVIEW 5 A E VOR 9 1 9 2 TROUBLESHOOTING FUNDAMENTAL CALIBRATOR OPERATION 000000000000 9 1 9 2 1 Checking The Power Sub Systems iaa 9 2 9 2 2 Checking The CPU And 9 3 9 2 3 Che
45. US LEDS maa umasa 2 9 TABLE 3212 CALIBRATION CONTROLS 3 3 TABLE 4 1 SETUP VARIABLES han h 4 7 TABLES 1 TEST CHANNEL picnic la IL 5 2 5 2 DDTAGNOSTIC TESTS ii a sa ini iena 5 2 TABLE 7 51 RS 232 MESSAGE FY PES WS au A usa aa S 7 1 TABLE 7 2 WARNING MESSAGE CLEAR COMMANDS 7 4 TABLE SS STATUS REPORTS isti lasa A a tna sa Gs 7 4 TABLE 7 4 CONTROL COMMANDS a ug u ul E a u l a w 7 5 TABLE 7 5 DIAGNOSTIC COMMANDS ie 7 6 TABLE 7 6 SPECIAL DIAGNOSTIC COMMANDS 1 220220220000000000000000000000000000000000 7 1 TABLE 5 DIAGNOSTIC REPORTS S San techs shoes Seda 7 1 TABLE 7 8 TEST MEASUREMENT REQUEST COMMANDS ieri 7 8 TABLE 7 9 RS 232 VARIABLE 5 7 10 TABLE 8 1 THE CALIBRATOR HAS THE FOLLOWING STATUS CONDITIONS 8 7 TABLE9 1 WARNING MESSAGES mua qa lie la lalla isla laine ata 9 4 9 2 TEST FUNCION VALUES A A AN 9 5 TABLE 9 2 TEST FUNCTION VALUES CONTINUED 9 6 TABLE 9 3 V F BOARD JUMPERS FACTORY SETTINGS a 9 12 TABLE 9 4 V F BOARD DIP SWITCHES RANGES FOR ANALOG OUTPUT 9 12 TABLE 9 5 UV SOURCE LAMP
46. a master standard such as certified Model 400 Os photometric analyzer The calibration of Model 401 photometer can be verified by periodic recommended every 3 months intercomparison between Model 401 photometer and a master standard Photometer Zero Calibration 1 Turn the power on for both Model 401 and Model 400 as master standard and allow them to stabilize for minimum of one hour 2 Start to generate the zero gas by pressing zero button from the main menu and enter the password 512 In case of using external dry zero air verify proper IZS flow and pressure of external air source See Figure 1 5 for pneumatic connections 3 3 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 3 Allow to sample zero gas for approximately 10 minutes 4 Follow sequence of SETUP BCAL and ZERO Then select yes to adjust zero NOTE in case of using external dry zero air check if dry zero air is supplied into the rear panel port see Figure 1 5 for pneumatic connections at about 30 40 PSI pressure Os generator flow should be exceeding at least 1 l min in addition of total flow demands See Section 1 6 5 for 03 generator flow adjustment Photometer Span Calibration 1 Turn the power on for both Model M401 and Model M400 master standard Let them stabilize for minimum of one hour 2 Start to generate the span Os gas by pressing OsGN from the main menu and enter the password 512 In
47. ach of the 8 pushbuttons below the display See Section 2 2 2 for information on using the pushbuttons 2 2 2 Programmable Pushbuttons The 8 pushbuttons below the display are programmable by the CPU in that their functions change depending on the mode of the Analyzer or the operations being performed The legend above a button identifies its current function If there is no legend above a button it has no function and will be ignored if pressed 2 7 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Figure 2 2 Illustration Of Normal Display If TEST is pushed the upper center display cycles through the menu of test parameters e g Sample flow see Table 2 3 If STBY is pushed the calibrator is in stand by mode If ZERO is pushed the sequence of operations for generating ZERO gas is initiated O3GN is used to initiate span setting using sample gas such as during a formal calibration Pushing ASEQ will initiate multi point calibration if it is preset see Section 3 4 Pushing MSG will cause a message to appear on the upper center display if warning exits also red status led will be blinking Pushing CLR will erase a message provided the condition causing the message has ceased Pushing SETUP changes the function of the pushbuttons and is used for setting basic parameters as described in Section 4 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2
48. alibrated plus 1 LPM for the internal photometer in the M401 For example when calibrating one analyzer the O flow rate should be set to at least 2 LPM Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Figure 1 5 M401 Calibrator Pneumatic Connections Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 VENT _ SAI PLUG N y S x TN A Ne NY N Joooeoo 00000 2 lt ANALOC ITA O O UTPUTS NPUTS ZERO AIR SCRUBBER RS 232 STATUS CONNECTOR 2 R N 2 RC 2 PAN GAS VEN JU XTERNAL DRY SAMPLE EXHAUS CAP PLUG ZERO AIR INI N 2 N N NS NZ 1555556 _ Z ANALOG GITA O UTPUTS NPUTS ZERO AIR SCRUBBER A RS 232 24 5 05 2 REAR PANEL EXTERNAL DRY ZERO AIR Figure 1 6 M401 Rear Panel External Dry Zero Air 1 18 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 POWER SWITCH FRONT MOTHER BOARD V CENTRAL PROCESSING UNI DETECTOR BACKPLANE POWER SUPPLY CARD PUMP PHOTOMETER ZERO AIR TRAY PUMP PUMP OPTICA gt I BENCH SAMPLE REF SW VALVE PRESSURE REGULATOR 75 SUPPLY POWER SUPPLY MODULE LAMP OUSING 4 lt BYPASS FLOW RESTRICTOR FLOW SENSOR Figure 1 7 M401 Calibrator Chassis Layout 1 19 Teledyne API Model 401 Photometr
49. alibration will take 1 hour 6 points x 10 minutes point 4 You can abort calibration by pressing EXIT This will not restore the table contents already computed however If you EXIT within the first 10 minutes of the calibration the table will not be modified NOTE You can now use the Os generator See Section 3 for details 8 11 Dark Current Signal Adjust Procedure The detector dark current changes little as the detector ages Therefore this procedure should not need to be performed except whenever a major sub assembly is changed such as new UV lamp or UV lamp power supply To calibrate the dark current signal press SETUP MISC DARK CAL and the analyzer will do the following 1 Turn the analyzer lamp off 2 Average 6 successive O detector readings taken 1 second apart 3 Turn the analyzer lamp back on This offset will then be stored and subtracted from all future detector readings Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 To view the current dark offset press SETUP MISC DARK VAL Press EXIT when finished No password 15 required to view the dark offset only to change it 8 12 Bench Feedback Option The Bench Feedback Option uses the Photometer to control the lamp drive current This option assures very stable and repeatable ozone concentrations Press SETUP MISC O3 GEN MODE BNCH to activate this option It is recommended to select the bench feedback mo
50. all of the legs insert into the socket correctly Replace the CPU board and re attach the connectors making sure to observe the polarity Re attach the CPU card to the STD BUS Move the power switch to the ON position and observe the front panel display As the analyzer goes through the setup the version number will be displayed on the front panel It should read the same as the version number that was located on the top right corner of the label on the PROM Re enter any non default settings such as RANGE or AUTOCAL Check all settings to make sure that expected setup parameters are present Re calibrate the analyzer so that the default slope and intercept are overwritten with the correct values Perform Dark Calibration see Section 8 11 10 3 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 INTENTIONALLY BLANK 10 4 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 11 MODEL 401 SPARE PARTS AND EXPENDABLES KITS 11 1 Spare Parts For CE Mark Units NOTE Use of replacement parts other than those supplied by Teledyne API may result in non compliance with European Standard EN 61010 1 Table 11 1 Spare Parts For CE Mark Units table continued Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 Table 11 1 Spare Parts For CE Mark Units Continued Part No 01112 01509 01916 01 01
51. amp is needed for proper adjustment Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 CAUTION UV light present Do not pull the lamp from the optical bench assembly 3 Adjust the UV Detector Pre Amp gain as follows a Remove the access cap on the Detector cover at the front end of the optical bench and adjust the pot R7 until the REF reading on the display is 4500 mV 50 mV b Ifitisstill not possible to achieve a 4500 mV O REF reading increase the UV lamp drive power by adjusting the lamp power supply as described in Step 1 DO NOT however allow the voltage measured across the TP7 and 10 to exceed 21 volts 4 Re calibrate the automatic Detector Dark Current compensation by pressing SETUP MISC DARK CAL at the front panel See Section 9 3 for dark current adjustment procedure 8 9 Ozone Generator Lamp Setup This procedure only needs to be done if the lamp is replaced or if the lamp is accidentally moved The procedure adjusts the lamp for optimum operation of the generator and its feedback circuit 1 Enter the SETUP menu by pressing SETUP MISC 03 GEN ADJ This causes the lamp drive circuit to output a constant 2 5 V If you are installing a new lamp allow approximately 30 min for lamp output to stabilize 2 Select the GEN TEST function on the front panel display Loosen the Os generating lamp and rotate until the reading on the display is 2500 mv 50
52. ance Schedule Table 10 1 shows a typical maintenance schedule for the Model 401 Please note that in certain environments 1 dusty very high ambient pollutant levels some maintenance procedures may need to be performed more often than shown Table 10 1 Maintenance Schedule Date Instrument Was Recieved Zero Air Replace charcoal Scrubber quarterly Pump every 6 Diaphragms DFU particulate Replace filter for annually zero air Inspect quarterly Sample Cell Clean as necessary Section 10 3 277 annually 277 80 Check annually Section 10 2 Leak Check leak check after any maintenance 10 1 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 10 2 Leak Checking There are two methods of leak checking 1 2 By vacuum This is simplest method but it does not show location of leak By pressure By using bubble solution this method shows a leak location NOTE Be careful using the bubble solution There is no internal pressure the solution may enter and contaminate the cell Use only bubbles not liquid If you know you have a leak use pressure If you want to confirm that you do not have a leak use vacuum 10 3 Cleaning Of Sample Cell 1 2 Remove center cover from the optical bench Loosen the screws that hold the retaining rings at each end of the glass tube Usi
53. aneous and or average O data to another computer It can also be used as a command and status channel to allow another computer to control the Analyzer Refer to Figure 1 4 for details on using the RS 232 interface 2 1 7 Password Protection The Teledyne API Photometric Calibrator provides password protection of the calibration and setup functions to prevent incorrect adjustments to the Calibrator There are three levels of passwords which correspond to operator supervisor maintenance and dynamic span level functions When prompted for a password any of the valid passwords can be entered but the CPU will limit access to the functions allowed for that password level Each level allows access to the functions of all the levels below plus some additional functions The table on the following page lists the password levels and the functions allowed for each level Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 2 1 Password Levels Password Functions Allowed No password required TEST MSG CLR SETUP DAS VIEW ZERO 03GN ASEQ Operator 512 Setup 717 SETUP MISC O3 SLPE SETUP MISC 03 OFFS Setup 818 2 SETUP EVNT SETUP BCAL SETUP COMM SETUP MISC O3 GEN SETUP MISC DARK SETUP MISC CLK SETUP MISC D A SETUP MISC MORE SETUP PASS SETUP DIAG 3 NOTE All passwords can be disabled To do this enter setup password enter 818 turn enable off If the wrong
54. arly enter the duration for span check and press ENTR NOTE Teledyne API recommends that the durations are set at least 10 minutes to allow for an accurate and reliable ZERO or SPAN value to be established Automatic zero span calibration will be initiated once per day on a timed basis Set starting time of the automatic calibration by selecting SETUP EVNT TIME Time should be between 00 00 23 59 Starting time of the automatic cal can be shifted 60 min to avoid missing data of remote analyzer during same time of the day Set desired shift time by selecting SETUP ENVT SHFT Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 4 4 Examining The Ozone Formula Slope And Offset The slope and offset parameters can be examined or changed by SETUP MISC O3 SLPE or SETUP MISC O3 OFFS The slope and offset parameters are set only during zero and span calibration routines These parameters are used to adjust the span and zero values to their exact values NOTE Do not change slope or offset value unless it is absolutely necessary to restore the known original values Take a note of new slope and offset values after each bench calibration for reference The current value of the ozone reading that 15 displayed on the front panel and output on the D A terminals on the back panel is computed as follows 1 The Model 401 Analyzer switches into reference mode 2 The Analyzer waits 2 seconds to pu
55. ation of key analyzer operating parameters These Test Functions can be accessed by depressing the TEST Button on the instrument s front panel with each depression of the button causing the next test function to be displayed By comparing the values of Test Functions to acceptable operating limits it is possible to quickly isolate and correct most problems Table 9 2 provides a list of available Test Functions along with their meaning their range of acceptable values and the recommended corrective actions if the value is not in the acceptable range Additionally Table 1 1 in this manual provides a list of the values of all Test Functions at the time the analyzer left the factory Table 9 2 Test Function Values Test Corrective Action for RANGE The Full Scale Range ofthe Any between 100 None required analyzer s analog outputs in 10000 PPB PPB O MEAS The most recent detector 2500 4700 mV Check and adj source lamp reading taken in Measure and UV det as described in mode i e with sample gas Section 9 6 6 bypassing the Ozone Scrubber O REF The most recent detector 2500 4700 mV Check and adj source lamp reading taken in Reference and UV det as described in mode i e with sample gas Section 9 6 6 passing through the Ozone Scrubber O GEN The reading from the O 75 175 mV with Os Check and adjust the IZS lamp GEN lamp reference gen off gt 75 mV with and reference detector as detector O gen on described in Sectio
56. aximum and 220 240 V 50 Hz 5 resettable circuit breaker 1 4 12 Weight 27 Kg 60 lb maximum 1 5 Installation And Overview The Model 401 is shipped with the following standard equipment 1 Power cord 2 Instruction manual CAUTION To avoid personal injury always use two persons to lift and carry the Model 401 Upon receiving the Model 401 please do the following 1 Verify no apparent shipping damage If damage has occurred please advise shipper first then Teledyne 2 Remove all red colored shipping screws from the underside of the Instrument Note Save these shipping screws and re install them whenever the unit is shipped to another location 3 When installing the Model 401 allow a minimum of 4 inches 100mm of clearance at the back of the instrument and 1 inch 25mm of clearance on each side for proper ventilation 4 Check that all options ordered are enclosed 5 Connect analyzer sample inlet line to the M401 sample port of manifold on rear panel Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 NOTE See Figure 1 4 for rear panel pneumatic connections Span gas should only come into contact with PTFE or glass Leak check all fittings with soap solution Maximum pressure for leak check is 15 PSIG 6 Connect the pump exhaust to a suitable vent outside the analyzer area CAUTION Connect the exhaust fitting on the rear panel see F
57. by a voltage to frequency V F converter capable of 80 000 count resolution The digitized intensities along with the other variables are used by the CPU to compute the concentration using the above formula Every 8 seconds the M401 Photometer completes a measurement cycle consisting of a 2 second wait period for the sample tube to flush followed by 2 seconds of measuring the average light intensity to determine I The sample valve is switched to admit scrubbed sample gas for 2 seconds followed by 2 seconds measuring the average light intensity to obtain Io Measurement of the I every 8 seconds minimizes instrument drift due to changing intensity of the lamp due to aging and dirt The 120 sec filter provides 32 averages Interferent Rejection It should be noted that the UV absorption method for detecting ozone is subject to interference from a number of sources The Model 401 has been successfully tested for its ability to reject interference from sulfur dioxide nitrogen dioxide nitric oxide water and meta xylene While the instrument rejected interference from the aromatic hydrocarbon meta xylene it should be noted that there are a very large number of volatile aromatic hydrocarbons that could potentially interfere with ozone detection If the Model 401 is installed in an environment where high aromatic hydrocarbon concentrations are suspected specific tests should be conducted to reveal the amount of interference these compounds may be ca
58. by measuring for the following voltages on the V F Board 5V between TP4 and TP5 15V between 15V between TP2 and TP3 If any of these voltages are incorrect check the DC Power Supply as described in Section 9 6 4 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 2 2 Checking The CPU And Display When the analyzer 15 turned on the front panel display should energize and the green Sample LED should light If proper DC power is present see Section 9 2 1 the absence of these actions will usually indicate either a CPU or Display failure To determine which module is defective perform the following procedure 1 Turn off power 2 Remove the ribbon cable from the CPU board to the Display 3 Turn Power on 4 A cursor character should appear in the upper left corner of the display If it does not the display is defective and should be replaced If the cursor does appear it is probable that the CPU is faulty 9 2 3 Checking The Keyboard During normal Calibrator operation depressing the right most key of the keyboard should cause a change of display modes If it does not check 1 Cable connections 2 CPU and Display operation see Section 9 2 2 If these checks are satisfactory it is probable that the keyboard is defective and should be replaced 9 3 Troubleshooting Using Warning Messages The most common and or serious instrument failures will result in a
59. cceceessssscececececsesessaeceeeeeesenesesseaeeesees 1 12 REAR PANEL ELECTRICAL AND PNEUMATIC CONNECTIONS VERSION 1 13 RS 232 PIN ASSIGNMENTS 1 15 M401 CALIBRATOR PNEUMATIC 1 17 FIGURE 1 6 M401 REAR PANEL EXTERNAL DRY ZERO AIR i 1 18 FIGURE 1 7 M401 CALIBRATOR CHASSIS LAYOUT i 1 19 FIGURE 2 1 MODEL 401 FRONT PANEL eee 2 4 FIGURE 2 2 ILLUSTRATION OF NORMAL DISPLAY ii 2 8 FIGURE 8 1 ELECTRICAL BLOCK DIAGRAM 24024240000000000000000000000000000000000 0 8 2 FIGURE 8 2 FLOW AND PRESSURE READOUT ADJUSTMENT naa 8 5 FIGURE 1 MODEL 401 SAMPLE SOFTWARE MENU TREE D 1 FIGURE 2 MODEL 401 SETUP SOFTWARE MENU D 2 vii Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 LIST OF TABLES TABLE 1 155 9 VAGUESQ da Qaqa ts is 1 21 TABLE 2 4 PASSWORD LEVEL barrio i aa db 2 3 TABLE 2 23 SYSTEM MODES 2 5 TABLE 2 3 TEST MEASUREMENTS iii 2 6 TABLE 2 4 WARNING 55 8 1 2 2 21 2 00660 00 0000000000000000000000000000 i 2 7 TABLE 2 3 STAT
60. cking Th KeyDoagrd 9 3 9 3 TROUBLESHOOTING USING WARNING MESSAGES iii 9 3 9 4 TROUBLESHOOTING USING TEST FUNCTION VALUES 9 5 9 5 TROUBLESHOOTING DYNAMIC PROBLEMS cccccccccccsesessssecececeeeceesenseaeeeseceesenesasececeeecsesensasaeeesees 9 6 9 5 1 Noisy Or Unstable Readings At Zero ia 9 7 9 5 2 Noisy Unstable Or Non Linear Span Readings 9 7 9 5 3 Slow Response To Changes In Concentration 9 7 9 5 4 Analog Outputs Do Not Agree With Front Panel Readinsgs 9 8 DIED CANNOT 9 8 9 35 60 Cannot Span a caves ah ie a A eo sna a 9 8 9 6 TROUBLESHOOTING INDIVIDUAL SUB ASSEMBLIES AND COMPONENTS ee 9 9 9 6 1 Troubleshooting Flow Problems nei 9 9 9 6 2 Troubleshooting Temperature Problems 9 10 06 3 Checking The VIF 9 11 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 6 4 Checking The DC Power Supply Dodd ui aida 9 13 9 6 5 Checking The Pneumatic Sensor Board nta 9 14 9 6 6 Checking The Source Lamp And Detector iii 9 14 9 6 7 Checking Main Switching Valve cuac did 9 16 9 6 8 Checking The Lamp Power Supply
61. d Supply flowrate should exceed demand flowrate to ensure good zero measurement Dry air should be provided into the inlet of rear panel for internal zero air supply 3 2 Manual O Generation Press O3GN then enter the password 512 to generate the Os span gas Specify O gas concentration up to 1000 ppb and minimum of 50 ppb and press enter to select Again the generator pump will start to run and the flow control system will maintain stable flowrate through the Os generator Supply flowrate should exceed demand flowrate to ensure good span measurement Pressing CONC allows a change of gas concentration during specified gas generation NOTE The M401 software has a Learning feature that will remember the parameters from the last several concentrations that were generated by the instrument The first time a specific concentration is requested the response time may be somewhat slow Any subsequent requests for that same concentration will be much faster since the instrument will remember the previous settings This information remains in memory even when the instrument is turned off Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 3 3 Automatic Zero Span or Multipoint Check Automatic zero span gas supply must be enabled in the setup mode There are five parameters that affect zero span checking the zero and span duration the time of day for calibration the time shift the
62. d in the following sections 9 2 Troubleshooting Fundamental Calibrator Operation When the Calibrator is turned on several actions will normally occur which indicate the proper functioning of basic instrument sub systems These actions are 1 The green sample light on the front panel should turn on 2 The Display should energize and display a log on message followed by a standard STBY display See Figure 2 2 for illustration of a normal display 3 The pumps should start momentarily Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 If these actions all occur it is probable that the Calibrator s Power Supplies CPU and Display are working properly If any of these actions fail to occur power and or CPU operation should be checked as follows 9 2 1 Checking The Power Sub Systems 1 Check incoming line power for proper Voltage and Frequency 2 Check the Circuit breaker on the Calibrator s rear panel 3 Check the 3 wire safety power input plug on the Calibrator s rear panel 4 Check for proper internal AC power by confirming that the Red right most LED on the Power Supply Module 15 lit If this LED is not lit replace the fuse at the bottom center of the Power Supply Module CAUTION Hazardous voltages are present on the power supply module Always remove AC power cord from instrument before attempting to remove or replace any parts 5 Check for proper DC Voltages
63. de for stable and precise calibration gas 8 10 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 9 IROUBLESHOOTING NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only 9 1 Overview The Model 401 Photometric Calibrator has been designed to rapidly detect possible problems and allow their quick evaluation and repair During operation the calibrator continuously performs self check diagnostics and provides the ability to monitor the key operating parameters of the instrument without disturbing monitoring operations These capabilities will usually allow the quick isolation and resolution of a problem A systematic approach to troubleshooting will generally consist of the following four steps performed in order 1 Confirm the proper operation of fundamental instrument sub systems Power Supplies CPU Display 2 Note any warning messages and take corrective action as required 3 Examine the values of all TEST functions and compare to factory values Note any major deviations from the factory values and take corrective action as required 4 Address any dynamic Sample related problems The following sections provide a guide for performing each of these steps Figure 1 7 in this manual shows the general layout of components and sub assemblies in the analyzer and can be referenced in performing the checks describe
64. ditions it may require 5 to 15 minutes of warm up before the source lamp initially fires Be sure to wait for this period before troubleshooting the lamp detector Detector Pre Amp or Failure The Os REF test value of less than 75 MV usually indicates a failure of the Detector Pre Amp Confirm that the V F 15 operating properly as described in Section 9 6 3 If the V F check 15 successful the Detector pre amp has failed and should be replaced 9 6 7 Checking Main Switching Valve Proper operation of the main Switching Valve can be determined by performing the following procedure 1 Press Zero to generate the Zero gas and allow the analyzer to stabilize 2 Observe the Os REF Test Function and make a note of its value 3 Press span to generate approximately 400 ppb concentration and allow the analyzer to stabilize 4 Observe the REF Test Function and note its value If the Os REF value has decreased by more than 5 from its value with Zero gas then there 15 cross port leak in the main switching valve NOTE If desired this check can be performed using Ozone concentrations higher than 400 ppb In this case the drop in REF should be no greater than 5 x Actual Concentration 400 9 6 8 Checking The Lamp Power Supply A schematic and physical diagram of the Lamp Power Supply are shown on drawings 01217 and 01218 in Appendix D It is not always possible to determine with certainty whether
65. e default mode In Bench Feedback mode the ozone output is actively controlled by adjusting the UV lamp intensity in the ozone generator The gas being produced is continuously sampled by the internal photometer and adjustments are continuously made to maintain the desired ozone concentration The Bench Feedback mode produces the most accurate ozone concentration 4 5 2 REF Mode In Reference feedback mode the ozone generator UV lamp intensity is controlled by using optical feedback from the reference detector mounted on the ozone generator 4 5 3 CNST Mode In Constant mode no feedback is used to control the UV lamp in the ozone generator The lamp is set to an initial drive value from the lamp power supply and is not changed 4 6 Setting The Time Of Day To set the current time of day which is used for determining when to do an automatic calibration and for time stamping the RS 232 reports press SETUP MISC CLK TIME The CPU will display the current time of day as four digits in the format H M where H is the hour in 24 hour format i e hours range from 00 to 23 and M is the minute 00 59 The operator may change the time of day and then press ENTR to accept the new time or press EXIT to leave the time unchanged 4 7 Setting The Date To set the current date which is used for time stamping the RS 232 reports press SETUP MISC CLK DATE The CPU will display the current date as D MMM Y For example April 1 1990 would be d
66. e outlet of the O generator If no independent flow meter is available placing a finger over an inlet port and feeling for a vacuum will at least give an indication whether flow is present If the independent flowmeter shows the flow to be correct check the Pneumatic Sensor Board as described in Section 9 6 5 In general flow problems can be divided into 3 categories 1 Flow is zero no flow 2 Flow is greater than zero but is too low and or unstable 3 Flow is too high Figure 1 1 in this Manual provides a schematic diagram of the Flow in a Model 401 Flow Is Zero 1 Confirm that the sample pump sample flow and or 03 GEN pump 03 GEN flow are operating turning If not check the 115V power to the pump If the pump does not operate with 115V present at its terminal replace the pump Check for plugged pneumatic lines filters or orifices Low Flow 1 Check for leaks as described in Section 10 3 Repair and re check 2 Check for dirty sample filter or dirty orifice filter s 3 Check for partially plugged pneumatic lines orifices or valves High Flow 1 The most common cause of high flow is a leak around an orifice Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 6 2 Troubleshooting Temperature Problems The Model 401 has been designed to operate at ambient temperatures between 5 C and 40 C As a first step in troubleshooting temperature problems confirm the ambient
67. eledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 14 Generate the Zero Air b Press ZERO from the main menu and enter the password 512 Press STBY to terminate or press OsGN to continue to generate Os span gas 15 Generate the Os Span Gas a b pi Press O3GN from the main menu and enter the password 512 Enter the Os concentration value desired 0 05 1 ppm range Press CONC in order to change Os gas concentration while generating specified Os gas Press STBY to terminate gas generation or press zero to continue to generate zero air Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 DRY ZERO AIR 30 PSI Y 5 ARCOA SCRUBBER D PRESS SENSOR gt RESSUR REGULATOR OZON 0 o Y NERATOR RESTRICTOR EN SPAN GAS SPAN GAS SAM CRITICAI FLOW M XHAUS ORIFICE k R ABSORPTION PRESSURE SENSOR LAMP AMP lt co TEMP HEATER SENSOR Figure 1 1 Model 401 Ozone Calibrator Block Diagram Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 eee 0000 e 00000 0 0 00 8 7 Figure 1 2 M401 Rear Panel Electrical Connections Teledyne API Model 401 Photometric Calibrator Instruction Manual
68. ensor Board are shown on Drawings 00402 and 00403 in Appendix D Proper operation of the pneumatic sensor board can best be determined by comparing the values of Flow and Pressure Test functions to measurements obtained with independent flow and pressure meters Flow and pressure readings can be adjusted as described in Section 8 5 If it is not possible to adjust the pneumatic sensor board to agree with independent flow and pressure measurements confirm the presence of 15 V at connector J1 pin 6 If this voltage is not present check the DC Power Supply Board as described in Section 9 6 4 If 15 V is present it is probable that the Pneumatic Sensor Board is defective and should be replaced 9 6 6 Checking The Source Lamp And Detector Basic operation of the source lamp and detector can be determined by observing the value of the REF test function After the analyzer is warmed up 15 min to 30 min after power on this value will give a good indication of the state of Lamp and Detector operation as follows 9 14 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 Table 9 5 UV Source Lamp And Detector Diagnostics UV Source Lamp and Detector Diagnostics The Source Lamp and Detector are operating but 4700 mV to 5000 mV adjustment is required The Source Lamp and Detector are operating properly adjustment is needed The Source Lamp and Detector are operating ya my Adjust
69. ent 10 C DC Power Supply 2500 mV 100 mv This is a composite of all of the DC voltages in the instrument The value is not important but it should be within the range indicated and should be constant If the TEST functions are within the limits given above the instrument should function correctly If there is a problem please read the manual and check your set up The Model 401 is now ready for calibration see Section 3 1 20 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 7 1 Final Test And Calibration Values Table 1 1 Test Values Test Parameter Displayed Value Units TIME HH MM SS DCPS MV BOX TEMP DEG C O OFFSET PPB O SLOPE REG PRESSURE IN HG A GEN TMP DEG O GEN FLOW L MIN ANA LAMP TMP DEG C SAMPLE TEMP DEG C SAMPLE FLOW SCC MIN RACK MOUNTS SLIDES SAMPLE PRESS IN HG A O DRIVE MV O GEN REF MV O REF MV O MEAS MV O SET PPB PPM POWER VOLTS Hz STATUS OUTPUT RS 232 OUTPUT Calibration Settings SPAN SETTING PPB O ZERO SETTING PPB O SLOPE O OFFSET PROM Date Serial Technician 1 21 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 8 Options 1 8 1 Rack Mount With Slides This option including slides and rack mounting ears permits the Analyzer to be mounted in
70. ic Calibrator Instruction Manual 01124 Rev J2 1 7 Operation Verification The Model 401 Calibrator is now ready for operation 1 2 10 11 12 Read Section 1 3 and all of Section 4 of manual to understand Calibrator operation Turn on the power by pressing the on off switch on the front panel see Figure 2 1 The display should turn on and green sample status LED should be energized The green LED should blink indicating the instrument has entered the HOLD OFF mode The standby mode can be entered immediately by pressing the EXIT button on the front panel The red fault light will also be on until the flows temperatures and voltages are within operating limits Clear the fault messages After a 60 minute warm up review the TEST function values in the front panel display by pushing the leftmost keyboard button labeled TEST Not every TEST function is a diagnostic of correct analyzer operation therefore TEST functions not covered below can be ignored for now 03 REF 03 MEAS TEST function values should be between 4200 mv and 4700 mv Pressure 29 to 30 Inches Mercury Absolute at sea level Other values will be displayed depending on altitude of analyzer Sample Flow 800 cc min 10 Sample Temp Ambient temperature 10 C Analytical Lamp Temp 52 C 0 1 The computer drives the temp to this setpoint it should be this value and not vary GEN Lamp Temp 48 C 1 Box Temp Ambi
71. ich appears to be a dynamic problem 15 often a symptom of a seemingly unrelated static problem For these reasons it is recommended that dynamic problems not be addressed until all static problems and warning conditions as described in the preceding sections have been isolated and resolved If all the checks described in the preceding sections have been successfully performed the following will provide an itemization of the most common dynamic problems with recommended troubleshooting checks and corrective actions 9 6 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 5 1 Noisy Or Unstable Readings At Zero 1 2 Check for leaks in pneumatic system as described in Section 10 3 Confirm that the Zero gas is free of Ozone Confirm that the Source Lamp 15 fully inserted and that the lamp hold down thumb screw 15 tight Check for a dirty Absorption Cell and or pneumatic lines Clean as necessary as described in Section 10 4 Disconnect the exhaust line from the optical bench the pneumatic line at the lamp end of the bench and plug the port in the bench If readings remain noisy the problem is in one of the electronic sections of the instrument If readings become quiet the problem is in the instrument s pneumatics 9 5 2 Noisy Unstable Or Non Linear Span Readings 1 2 Check for leaks in the pneumatic systems as described in Section 10 3 Check for proper operatio
72. igure 1 5 to a suitable vent outside the analyzer area 7 For internal pressurized zero air using an external dry air supply connect AIR IN port to a clean dry air supply see Figure 1 6 NOTE For best O generator stability and to avoid moisture condensation it is recommended that zero air be dried to approximately 20 C dew point For external pressurized dry zero air using an external dry pressurized source see Figure 1 6 proceed as follows a Remove cap plug from the tee of zero air scrubber assembly and connect external dry zero air line instead air pressure should be about 30 40 psi b Install the cap plug to dry air inlet port c Verify the power is off and unplug 03 GENERATOR pump s power cable connector 8 Connecta recording device to the terminal strip connections on the rear panel see Figure 1 2 See Table 9 4 for setting proper analog output voltage jumpers 9 Connect the power cord to an appropriate power outlet see the serial number tag for correct voltage and frequency NOTE Power plug must have ground lug Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 10 Turn on the M401 by switching the switch on the lower right corner of the front panel See Figure 2 1 The front panel display should light with a sequence of messages API M401 software version number then a normal display as shown in Figure 2 2 11 Allow about 60 minutes for
73. isplayed as 0 1 APR 9 0 Change the date by pressing the button under each field until the desired date is shown Then press ENTR to accept the new date or press EXIT to leave the date unchanged Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 4 8 Adjusting The Clock Speed In order to compensate for clocks which run a little bit fast or slow there is a variable called SETUP MISC CLK ADJ This variable is set to the number of seconds per day by which to speed up or slow down the clock It should only need to be set once for each Analyzer For example if the clock is running 10 seconds fast each day set the variable to 10 and press ENTR Note that 10 indicates that we want the clock to run 10 seconds slower each day If the clock is running 10 seconds slow each day set the variable to 10 indicating that we want the clock to run 10 seconds faster each day If the clock speed adjust variable has already been set to a value other than 0 and the speed is still too fast or too slow ADD the required adjustment to the current value of the variable For example if the clock speed adjustment is already set to 10 and the clock is 5 seconds too slow per day add 5 to the current value yielding 15 as the new value 4 9 Setting The O Concentration Range To set the range for the ozone reading to the D A s press SETUP MISC D A RNGE The operator can select any arbitrary full scale range between 100 and 20
74. low needed is the sum of the M401 sample flow and the remote analyzers sample flow 9 5 6 Cannot Span 1 Check for leaks in the pneumatic systems as described in Section 10 3 2 Check for proper operation of the Main Switching Valve and Ozone Scrubber as described in Section 9 6 7 3 Check for dirty pneumatic system components and clean or replace as necessary as described in Section 10 4 4 Check for proper adjustment of DAC and ADC electronics by performing the adjustment procedure in Section 9 2 5 Confirm the Sample Temperature Sample Pressure and Sample Flow readings are correct Check and adjust as required 6 Verify sufficient flow from the Os generator in excess of the total flow needed The total flow needed is the sum of the M401 sample flow and the remote analyzers sample flow Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 6 Troubleshooting Individual Sub Assemblies And Components The following sections provide troubleshooting check out methods for the specific sub assemblies and components of the Calibrator 9 6 1 Troubleshooting Flow Problems When troubleshooting flow problems it is a good idea to first confirm that the actual flow and not the flow meter is in error If available use an independent flow meter rotameter or mass flow meter to measure flow s Sample flow can be measured at the inlet port at the optical bench and O generator flow can be measured at th
75. lt will be an irregular blinking of the fault LED You should set the timeout to a value of at least 15 seconds Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 4 15 Software Configuration The software configuration can be displayed by entering the button sequence SETUP CFG LIST For example the M401 could display O3 CALIBRATOR SBC40 CPU Stating that the instrument was an Ozone Calibrator using the SBC40 computer This feature 15 useful for showing any special features that are present in the currently installed PROM 4 16 Summary Of Setup Variables The setup variables are summarized in Table 4 1 in terms of the button sequences used to access them Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 4 1 Setup Variables Button Sequence Default Limits a Zero cal duration 15 min 1 20 min SELU ENDECA Span cal duration 1 20 min SETUP EVNT TIME Cal time of day 23 30 00 00 23 59 SETUP EVNT ASEQ Auto Multipoint cal enable OFF OFF ZS Z2S Z5S SETUP EVNT SHFT Auto check shift 60 min SETUP COMM BAUD RS 232 baud rate 2400 baud 300 1200 2400 SETUP COMM ID 0000 9999 SETUP MISC 03 SLPE 0 85 1 15 SETUP MISC 03 GEN ADJ OFF ON OFF SETUP MISC 03 GEN MODE Feedback mode selection BNCH SETUP MISC CLK DATE 31 DEC 99 SETUP MISC MORE UNITS O conc units ppb_ ppb ppm ugmg 4 7 Teledyne API Model 401 Pho
76. m the most recent one The CPU will output NNN reports to the RS 232 interface each report having the following format R DDD HH MM 03 PPB SAMPLES xx lt CRLF gt where the fields have the same meaning as described above For example if the last DAS report was at 10 00 a m and the report frequency is 60 minutes and the host computer requests the most recent 3 reports by issuing the command R 3 lt CRLF gt and the CPU will respond by outputting something like the following R 91 08 00 0000 03 0 PPB SAMPLES 60 lt CRLF gt R 91 09 00 0000 03 2 PPB SAMPLES 60 lt CRLF gt R 91 10 00 0000 03 0 PPB SAMPLES 60 lt CRLF gt Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 7 2 Warnings Whenever a warning message is displayed on the display it is also sent to the RS 232 output See Table 2 4 for a list of the warning messages These messages are very helpful when trying to track down a system problem and for determining whether or not DAS average data is actually valid The message format is W DDD HH MM WARNING MESSAGE lt CRLF gt An example of an actual warning message is W 194 11 03 0000 SAMPLE FLOW WARN lt CRLF gt Warnings may be cleared via the RS 232 interface by issuing a command of the form W COMMAND lt CRLF gt where COMMAND indicates which warning message to clear For example to clear the SAMPLE
77. ment 15 useful but not required 175 mV to 2500 mV The Source Lamp and Detector are operating but adjustment is required 75 mV to 175 mV Either the Source Lamp or the UV detector is not functioning The Detector Pre Amp or V F Board has failed or is disconnected Less than 75 mV WARNING UV light present Do not look directly at the UV lamp since UV light could cause eye damage Always use safety glasses or view through glass Adjustment Required or Adjustment Useful Adjust the Lamp and Detector Preamp as described in Section 8 8 If it is not possible to achieve an acceptable O3 REF test value by means of adjustment it is possible that the lamp has deteriorated beyond its useful range and should be replaced Lamp or Detector Failure The O REF value of approximately 125 mV usually indicates a total failure of either the source lamp or the detector To determine which component is at fault remove the top cover of the optical bench and observe the lamp end of the glass absorption tube If a blue white light is visible the lamp is operating and the detector is at fault and should be replaced If no light is visible the lamp power supply should be checked as described in Section 9 6 8 If the Lamp Power Supply check is satisfactory then the lamp has failed and should be replaced 9 15 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 NOTE In cold ambient con
78. mmand line separated by spaces For example to change the instrument ID the host computer would issue a command like this V MACHINE_ID 1234 lt CRLF gt and the CPU should respond with DDD HH MM 1234 0 9999 lt CRLF gt Table 7 9 lists the variable names which are variable through the RS 232 interface and their corresponding button sequences Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 7 9 RS 232 Variable Names O3 SPAN SETUP IZSC SPAN SETUP DAS FREQ MACHINE ID SETUP COMM ID 0000 9999 BAUD RATE SETUP COMM BAUD 300 1200 2400 ILAMP SET not available 20 70 IZSLAMP SET not available LAMP PCT SETUP MISC 03 GEN CURR TIME SETUP MISC CLK TIME 00 00 23 59 CURR DATE SETUP MISC CLK DATE 01 01 00 12 31 99 CLOCK ADJ SETUP MISC CLK ADJ 60 60 TIME SPAN SETUP IZSC WAIT x 0 100 1 500 2 1000 DA RANGE SETUP MISC D A RNGE 3 5000 4 10000 DA OFFSET SETUP MISC D A OFFS 500 500 DARK OFFSET SETUP MISC DARK VIEW 1000 1000 PASS ENABLE SETUP PASS OFF ON FAULT TIME SETUP MISC MORE FLT 0 300 7 10 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 8 ADJUSTMENTS NOTE The operations outlined in this chapter are to be performed by qualified maintenance personnel only All adjustments
79. n 8 10 PRES The absolute pres of the 0 1 0 Hg below Check for pneumatic system sample gas in the absorption ambient pressure problems See Section 9 6 1 cell Check for pressure transducer problems See Section 9 6 5 table continued 9 5 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 Table 9 2 Test Function Values Continued Test E Corrective Action for SAMPLE Sample mass flow rate 700 900 cc min Check for pneumatic system FLOW problems See Section 9 6 1 Check for flowmeter problems See Section 9 6 5 SAMPLE The temperature of the 19 59 See Section 9 6 2 TEMP sample gas in the absorption above ambient cell ANA LAMP The temperature of the 52 See Section 9 6 2 TEMP Source Lamp After warm up IZS LAMP The temperature of the 48 C See Section 9 6 2 GEN Lamp After warm up BOX The temperature inside the 1 5 C above See Section 9 6 2 analyzer chassis ambient DC Power Supply reference 2400 2600 mV See Section 9 6 4 A composite of all voltages provided by the DC Power Supply O FLOW The flow rate of O GEN 2 5 L M Adjust pressure regulator to set proper flow rate 9 5 Troubleshooting Dynamic Problems Dynamic problems i e problems which only manifest themselves when the analyzer 15 monitoring sample gas can be the most difficult and time consuming to isolate and resolve Additionally analyzer behavior wh
80. n of the Main Switching Valve as described in Section 9 6 7 Check for dirty absorption cell and or pneumatic system components and clean or replace necessary as described in Section 10 4 Check for proper adjustment of DAC and ADC electronics by performing the adjustment procedure in Section 8 2 Confirm the Sample Temperature Sample Pressure and Sample Flow readings are correct Check and adjust as required Verify sufficient flow from the Os generator in excess of the total flow needed The total flow needed is the sum of the M401 sample flow and the remote analyzers sample flow 9 5 3 Slow Response To Changes In Concentration 1 Check for dirty pneumatic components and clean replace as necessary as described in Section 10 4 Check for pneumatic leaks as described in Section 10 3 Check for improper materials in the inlet manifold Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 9 5 4 Analog Outputs Do Not Agree With Front Panel Readings 1 2 Confirm that the DAC offset SETUP MISC D A OFFS is set to zero Perform a DAC ADC adjustment and Dark Signal adjustment by following the procedure described in Sections 8 2 and 8 3 9 5 5 Cannot Zero 1 Check for leaks in the pneumatic system as described in Section 10 3 2 Confirm that the Zero gas is free of Ozone 3 Verify sufficient flow from the Os generator in excess of the total flow needed The total f
81. ne The impurities present in zero air from different sources can significantly affect the transmittance of an air sample Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 INTENTIONALLY BLANK B 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 C REFERENCES 10 11 12 Calibration of Ozone Reference Methods Code of Federal Regulations Title 40 Part 50 K D Technical Assistance Document for the Calibration of Ambient Ozone Monitors EPA publication available from EPA Department E MD 77 Research Triangle Park N C 27711 EPA 600 4 79 057 September 1979 Transfer Standards for Calibration of Ambient Air Monitoring Analyzers for Ozone publication available from EPA Department E MD 77 Research Triangle Park N C 27711 EPA 600 4 79 056 September 1979 Ambient Air Quality Surveillance Code of Federal Regulations Title 40 Part 58 U S Environmental Protection Agency Evaluation of Ozone Calibration Procedures EPA 600 S4 80 050 February 1981 Quality Assurance Handbook for Air Pollution Measurement Systems Vol I EPA 600 9 76 005 March 1976 Field Operations Guide for Automatic Air Monitoring Equipment U S Environmental Protection Agency Office of Air Programs October 1972 Publication No APTD 0736 PB 202 249 and PB 204 650 Appendix A Quality Assurance Requirements for State and Local
82. ng both hands rotate the tube to free it then slide the tube towards the back of the instrument towards the lamp housing The front of the tube can now be slid past the detector block and out of the instrument CAUTION Do not cause the tube to bind against the metal housings The glass tube may break and cause serious injury Clean the tube with soapy water by running a swab from end to end Rinse with de ionized water then isopropyl alcohol then air dry Check the cleaning job by looking down the bore of the tube It should be free from dirt and lint Re assemble the tube into the lamp housing and leak check the instrument 10 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 10 4 Changing The Prom 1 2 Locate the CPU by referring to Figure 1 7 Remove the screws that hold the CPU card SBC40 printed on the lever top corner to the V F card then remove the card from the STD BUS backplane Remove the two cables attached to the SBC40 taking note of the polarity Remove the card laying it down on an insulating surface such that the card edge pins on the PCB are on the left The PROM chip should be at the top center The current chip should be labeled with something like M401 411A0 Gently pry the chip from its socket and replace it with the new chip Install the chip in the left end of the socket with the notch facing to the right Make sure that
83. on the V F board To change the range for the analog outputs 1 Turn off instrument power Remove instrument cover Locate the V F board near the top of the drawing using Figure 1 7 2 Locate jumpers B7 B9 along the top edge of the card Select the desired range per the table in drawing 00515 located in Appendix D NOTE To adjust analog recorder offset see Section 4 10 8 4 Flow Readout Adjustment The sensor module in the M401 consists of one flow sensor and two pressure sensors See Figure 8 2 for a diagram of this module From these three sensors three values are computed and displayed on the front panel TEST function area These are 1 Sample flow 2 Sample cell pressure 3 Os GEN flow Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 DARA TA SSC No 2 2 x Figure 8 2 Flow And Pressure Readout Adjustment 8 5 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 8 5 DC Power Supply Overall performance of the DC power supply may be checked by observing the value displayed during test DCPS If this value a composite of the five 5 regulator outputs deviates by more than 10 from the value recorded in Table 1 1 of this manual under Test Values the outputs of the Individual regulators should be measured Test points 1 2 3 and 4 provide connection to the temperature outputs on drawing no 00016 in Appendix
84. optical bench is used as a feedback detector to control O generating lamp 3 4 Manual Zero Span or Multi Point Check Manual zero span or multi point is activated by pressing button from the main menu display Then enter the password specify full scale concentration between 50ppb 1000ppb which would be 100 of span concentration and press ENTER to select This feature is identical to the automatic zero span check sequence except it is activated manually This ASEQ entry is not shown on display unless it is programmed In order to enable this feature automatic zero span check parameters must be preset See Section 3 3 or 4 2 While multipoint calibration is in progress pressing STBY will terminate ASEQ Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 3 5 Summary Of Front Panel Calibration Controls The calibration controls are summarized below in terms of the button sequences used to access them Table 3 1 Calibration Controls sty ssa j Cr PATATA ONE E E SENTE gi miei SETUP EVNT TIME 00 00 23 59 SETUP EVNT ASEQ OFF ZS Z2S Z5S SETUP EVNT SHFT Auto check time shift check time shift min SETUP MISCO Select lamp control mode Bench 60 min GEN MODE CNST REF BNCH 3 6 Photometer Calibration Model 401 is capable of accurately reproducing Os span gas However it should be quantitatively verified by relating to
85. or provides very stable flow of zero air through the generator while the light intensity of the UV lamp is controlled to generate accurate and stable ozone output The photometer is used as part of a feedback lamp control to assure stable Os output even during changing conditions The photometer is compensated for both pressure and temperature variations This true photometer operation along with self generated zero air results in a completely self contained O generating system The detection of ozone molecules of the photometer is based on absorption of 254 nm UV light due to an internal electronic resonance of the molecule The Model 401 Photometer uses a mercury lamp constructed so that a large majority of the light emitted is at the 254nm wavelength Light from the lamp shines down a hollow glass tube that is alternately filled with sample gas then filled with zero air The ratio of the intensity of light passing through the zero air to that of the sample forms a ratio This ratio forms the basis for the calculation of the ozone concentration Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 NOTE Model 401 Photometric Calibrator is designed to be a dedicated calibrator The M401 Photometer should not be used as a monitor The Beer Lambert equation shown below calculates the concentration of ozone from the ratio of light intensities 9 _ 10 T 29 92inHg O
86. rge the sample tube 3 The instrument measures the intensity of light striking the detector during the next 1 067 sec This reading forms the reference intensity I in the ozone concentration equation 4 The photometer now switches to the sample mode and waits 2 seconds as in step 2 above 5 The instrument measures the intensity of light striking the detector during the next 1 067 sec This reading forms the sample concentration intensity I in the ozone concentration equation 6 The concentration of ozone is computed using the Beer Lambert equation corrected for temperature and pressure 7 Slope and offset corrections are made to the ozone concentration according to the equation CorrectedConcentration Slope x MeasuredConcentration Offset 8 An average of the last 32 samples is computed and converted to the number displayed on the front panel This is the ozone concentration The number is also routed to the D A converter and the resulting voltage is output to the back panel Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 4 5 Setting the O Generation Mode 4 5 1 There are three modes of feedback operation that can be selected for the ozone generator The mode can be changed by pressing SETUP MISC 03 GEN MODE The three modes are shown below Please note that changing to any Mode other than BNCH may affect the concentration accuracy of the gas being produced BNCH Mode This is th
87. stable flow of sample through the Photometer Compressed air is delivered through a charcoal scrubber While one path is used as zero air reference the other path of same zero air is used to generate the stable ozone output This will ensure reliable ozone output as well as proper Photometer operation Please see Figure 1 1 for flow diagram and Figure 1 5 for pneumatic connections NOTE The photometer output varies linearly with pressure and temperature Temperature and pressure compensation is done automatically A critical flow orifice is used to control the sample flow The orifice is a precision drilled sapphire jewel protected by a 20 micron sintered filter The critical flow orifice never needs adjustment and maintains precise flow control as long as the ratio of the up stream to down stream pressures is greater than 0 53 sonic flow conditions 1 6 4 Exhaust Connections See Figure 1 5 A single 1 4 O D tube should be connected from the Analyzer sample exhaust to an area outside of the room the analyzer occupies The maximum length of the exhaust line should not exceed 30 feet 1 6 5 Output Flow Adjustment The flow rate of gas supplied to the output manifold can be changed by adjusting the internal pressure regulator located on the top of the optical bench see Figure 1 7 The output flow Os FLOW can be read on the front panel test functions Adjust this flow rate to provide a minimum of 1 LPM for each analyzer being c
88. t is always available to answer your questions 1 2 Warranty WARRANTY POLICY 02024c Prior to shipment Teledyne API equipment is thoroughly inspected and tested Should equipment failure occur Teledyne API assures its customers that prompt service and support will be available COVERAGE After the warranty period and throughout the equipment lifetime Teledyne API stands ready to provide on site or in plant service at reasonable rates similar to those of other manufacturers in the industry maintenance and the first level of field troubleshooting is to be performed by the customer NON TELEDYNE API MANUFACTURED EQUIPMENT Equipment provided but not manufactured by Teledyne API is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty GENERAL Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in material and workmanship under normal use and service for a period of one year from the date of delivery replacement parts and repairs are warranted for 90 days after the purchase If a Product fails to conform to its specifications within the warranty period Teledyne API shall correct such defect by in Teledyne API s discretion repairing or replacing such defective Product or refunding the purchase price of such Product Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev
89. t number from 0000 to 9999 followed by ENTR to accept the new I D or EXIT to leave the I D unchanged If changed the new I D number will appear on all RS 232 reports from this Analyzer 4 13 Disabling The Calibration Password Normally operators are required to enter the calibration password when doing a manual calibration via the ZERO or O3GN buttons To allow calibration without entering the password press SETUP PASS and set it to OFF and then press ENTR to accept the change or EXIT to leave it unchanged To require the calibration password set the variable to ON 4 14 Setting The Fault LED Timeout The Model 401 can be set up so that the red fault LED on the front panel turns off automatically if no warning conditions persist Any warning messages will still be displayed however To set the fault LED timeout press SETUP MISC MORE FILT and enter a value of from 0 to 300 seconds A value of 0 disables the timeout meaning that the fault will continue to blink as long as a warning message is displayed For example to cause the fault LED to turn off if no warning conditions have occurred for at least 5 minutes set the variable to 300 sec NOTE It is not advisable to set the timeout to an extremely short value such as 1 second Doing this may make the fault LED behave strangely This is because if a warning condition persists and the fault LED timeout is very short then the warning condition will be trying to turn it off The resu
90. te but control temperatures are not being maintained at their proper value check the operation of the heaters as follows 1 Observe the indicator LED s on the Power Supply Module and confirm that the red right most LED is lit and that the CEL and LED s are lit or cycling turning off and on If these indicators are not correct it is probably that the Power Supply Module or the V F Board is at fault Check as described in Sections 9 2 and 9 6 3 2 Unplug the heater element from Power Supply Module and confirm that 115VAC is present If 115VAC is present the heater element has failed and should be replaced WARNING Hazardous voltage present use caution 9 6 3 Checking The V F Card A schematic and physical diagram of the V F card are shown on Drawings 00514 and 00515 in Appendix D Proper operation of the V F board can be confirmed by performing an ADC calibration procedure as described in Section 8 2 If this calibration procedure can be performed correctly it is probable that the V F card is functioning properly If the V F does not function properly check the following 1 Confirm the presence of appropriate power by checking for 5V between TP 4 and TP 5 15V at TP 1 and TP 3 15V at TP 2 and TP 3 If any of these voltages are incorrect check the DC Power Supply as described in Section 9 6 4 NOTE Do not disconnect CPU or other digital cards while under power 9 11 Teledyne
91. temperature is within this range and that the air inlets slots on the sides of the cover and the fan exhaust on the rear panel are not obstructed The instrument monitors four temperatures 1 Sample Temperature 2 Inside Chassis Temperature 3 Source Lamp Temperature 4 Os GEN Lamp Temperature The instrument controls the temperatures of two components by heating 1 Source Lamp 2 Os GEN Lamp If any of the temperature readings appear to be incorrect check for proper thermistor operation by measuring the resistance of the thermistor s This resistance should be in the range of 7 6K ohms to 95K ohms If it is not the thermistor is defective and should be replaced Points for measuring thermistor resistance are as follows Sample Temperature Unplug the connector at Motherboard J2 and measure across the leads Source Lamp Temperature Unplug the connector at Motherboard J4 and measure across the leads GEN Lamp Temperature Unplug the connector at Motherboard J6 and measure across the leads 9 10 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 Chassis Temperature Turn the analyzer off and remove the DC Power Supply Board Measure across Motherboard J21 pins A30 and C30 If thermistor resistance s are within the proper range check the temperature linearization circuits on the DC Power Supply Board as described in Section 9 6 4 If temperature sensor readings appear accura
92. then the instrument will immediately go into span check To perform a zero check followed by a span check first generate a positive transition on EXT ZERO CAL and then when you want to do the span check generate a positive transition on EXT SPAN CAL The remote calibration signals may be activated in any sequence providing a virtually unlimited number of calibration types Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 NOTE Teledyne API recommends that contact closures remain closed at least 10 minutes to allow for an accurate average zero or span value to be established 3 8 Remote Zero Span Check Or Adjustment RS 232 Besides Z S checking from the front panel automatic Z S checking and remote Z S checking via the contact closure inputs the Analyzer can also be checked via the RS 232 interface Remote checking via the RS 232 interface supports zero span and zero followed by span check and is identical to remote check via the contact closure inputs This RS 232 control feature is provided mainly so that a host computer at another location can control the Analyzer See Section 7 for detailed information on using the RS 232 interface to do a remote Z S check 3 9 Hold Off Every type or check or adjustment zero span manual remote etc is followed by a hold off period of 30 seconds during which the internal data acquisition system DAS does not accumulate ozone readings into
93. to the Model 401 are easy to make Pots and test points are readily accessible without removing any components Figure 1 7 is a plan view of the Model 401 Photometric Calibrator showing all the major components Figure 8 1 is an electrical diagram of Model 401 Photometric Calibrator 8 1 Power Supply Board Adjustment 8 1 1 The power supply board provides 15 v 12 v and 5 v DC power to the Calibrator Four temperature linearization circuits for the Calibrator main lamp Sample temp Box temp and IZS ozone generator are also located on the power supply board Each circuit is a whetstone bridge with the measuring thermistor being leg A feedback circuit performs the required linearization Zero adjust pots have been factory set and no field adjustment should be required NOTE The power supply board also contains a Brown Out detector Box Temperature Limits The box temperature is measured by a thermistor located on the motherboard The box temperature is not controlled in the Model 401 The temperature is measured and displayed as a TEST function on the front panel see Section 5 1 The alarm limits can be set via an RS 232 port command Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 y a Figure 8 1 Electrical Block Diagram 8 2 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 8 2 A D D A Calibration
94. tometric Calibrator Instruction Manual 01124 Rev 2 INTENTIONALLY BLANK 4 8 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev 2 5 DIAGNOSTICS The Teledyne API ozone analyzer contains two levels of diagnostics test measurements which can be viewed at all times except when in setup by pressing TEST and lower level diagnostic operations which can only be performed by pressing SETUP DIAG 5 1 Test Measurements As stated test measurements can be viewed at any time except when in setup To view a different test measurement simply press the TEST button Table 2 3 lists the test measurements which are available Viewing these test measurements does not interfere with the operation of the Model 401 or the ozone reading of the photometer in any way so they may be viewed freely Additionally the values of most TEST functions can output as an analog voltage at the instrument s rear panel see Figure 1 2 The TEST function to be output is selected by pressing SETUP MISC MORE TCHN Table 5 1 lists the Test functions available for analog output In addition to outputting a value to the analog output channel these tests activate a new test measurement which displays the analog voltage reading on the front panel as TEST XXXXX X MV 5 2 Diagnostic Tests The diagnostic tests are used to help diagnose a problem in the Analyzer and should only be used by skilled maintenance people To get into the
95. using Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J2 1 4 Specifications Photometer Ranges Zero Noise Span Noise Lower Detectable Limit Zero Drift 24 hours Zero Drift 7 days Span Drift 24 hours Span Drift 7 days Linearity Precision Lag Time Rise Fall Time 95 Sample Flow Rate Temperature Range Humidity Range Temp Coefficient Voltage Coefficient Dimensions HxWxD Weight Analyzer Power Analyzer Environmental Conditions Recorder Instantaneous Bi Polar Status User selectable to any full scale range from 100 ppb to 20 000 ppb lt 0 3 ppb rms lt 0 5 of reading rms lt 0 6 ppb rms lt 1 0 ppb lt 1 0 ppb 1 of reading 2 of reading Better than 1 FS 1 0 ppb 10 sec lt 20 sec 800 cc min 10 5 40 C 0 95 RH Non Condensing lt 0 05 per C lt 0 05 per V 7 x 17 x 27 178 mm x 432 mm x 686 mm 60 Ib 27 kg 110v 60Hz 220v 50Hz 250 watts Installation Category Overvoltage Category II Pollution Degree 2 100 1 5 10 12 Status Outputs from Opto Isolators Calibration Ozone Generator Flow rate Maximum concentration Minimum concentration Stability 2 to 5 LPM adjustable 1 0 ppm 5 LPM 0 050 ppm 2 LPM 0 002 ppm bench feedback at constant temperature and voltage 1 5 Teledyne API Model 401 Photometric Calibrator Instruction Manual 01124 Rev J
96. y skay 3 1 32 MANUAL Os GENERATION si nada 3 1 3 3 AUTOMATIC ZERO SPAN OR MULTIPOINT CHECK iii 3 2 3 4 MANUAL ZERO SPAN MULTI POINT CHECK 2 2 1 2 2 22 00000000000000000000000000000 3 2 3 5 SUMMARY OF FRONT PANEL CALIBRATION CONTROLS ceci 3 3 3 6 PHOTOMETER CALIBRATION iii 3 3 REMOTE ZERO SPAN CHECK CONTACT CLOSURE an 3 4 3 8 REMOTE ZERO SPAN CHECK OR ADJUSTMENT 5 232 ii 3 5 SO FIOED OPE 3 5 A SETUP MODE sli I ia 4 1 P SETUP MODE OPERATION ys RR RR Le Ra 4 1 4 2 SETTING AUTOMATIC MULTIPOINT ASEQ CHECK 4 1 4 3 SETTING AUTOMATIC ZERO SPAN DURATION ii 4 1 4 4 EXAMINING THE OZONE FORMULA SLOPE AND 00 000 00 4 2 4 5 SETTING THE GENERATION MODE i 4 3 4 3 AD DRE a ia 4 3 LI SCIMMIE LR 4 3 4 6 SETTING THE TIME OF DAY i iii 4 3 4 7 SETTING THE DATE aa n Qam aa PSR 4 3 4 8 ADJUSTING THE CLOCK SPEED 220000 a uu 4 4 4 9 SETTING THE CONCENTRATION RANGE 20 2 21 202022 0001000000000000000000000000000000 4 4 4 10 SETTING THE ANALOG OUTPUT OFFSET 2 0 22 2 216000000000000000000000000000000000000000 4 4

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