Teledyne 460H Computer Monitor User Manual
Contents
1. filt Digital Concentration 0 05 1 0 filter 1 0 No Filtering lower values increases filtering 6 conc units O3 Concentration 0 wt measurement units 1 g Nm3 Response lt address gt lt var_value gt lt checksum gt lt CR gt Example Command 1VGET 0 lt CR gt Response 1 15 0 303 Request analog range value analog range returned as 15 0 wt P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 30 5 4 9 VLIST Syntax address VLIST CR Description Returns a verbose list of an internal configuration variables Data Parameters Sent None Response Var List See Below Example Command 1VLIST lt CR gt Response 0 analog_range azero_enable azero_period carrier_weight 32 0 comm_mode 0 0 iir filt 0 conc_units How dl C DOP PO ES O A Notes Note that no checksum is sent in the response to the VLIST command P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 31 5 4 10 VSET Syntax address VSET var index new value CR Description Sets value of an internal configuration variable VAR Data Parameters Sent var index is index number for internal VAR See VGET for index list new value new value for VAR Response lt address gt lt var_value gt lt checksum gt lt CR gt Example Command 1VSET 0 15 0 lt CR gt Set analog range VAR to 15 0 wt Respo2. command is the command string being sent colon is the data separator and is only included if data is being sent as part of the command See Command Details below to see if a command requires data or not datal is the first data parameter if required data2 is the second data parameter if required is the Checksum separator sent only if optional checksum is included checksum is an Ascii checksum of all characters up to the character The checksum is optional commands sent without the checksum and checksum separator are also valid CR is a carriage return Ascii 13 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 21 Examples of valid Commands with no data Checksum Included 103 179 lt gt No Checksum 103 lt CR gt Examples of valid Commands with data Checksum Included 1VSET 1 20 620 lt CR gt No Checksum 1VSET 1 20 lt CR gt 5 3 Command Summary Table 5 2 below lists the commands available and a summary of their function Table 5 2 Serial Port Command Summary computed based on current O3 reading in cell VSET Sets value of internal VAR P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 22 5 4 Command Reference 5 4 1 CAUTO Syntax address CAUTO CR Description Perform an Auto Zero Calibration Valid only if Auto Zero option is installed in monitor Data Parameters Sent None Response lt address gt lt success_flag gt lt checksum gt
3. 16 2 4 4 RS232 RS485 Serial Communications Port A bi directional RS232 485 Serial Port Interface is provided that can be used for data acquisition and instrument control All that is required to use this interface is a computer with a serial communications port COM port and terminal software Three pins are provided on the I O connector for serial communications as shown in Table 2 3 Table 2 3 Serial Port Pins Label Description SERIAL TX Serial Transmit RS485 A SERIAL RX Serial Receive 5485 SERIAL GND Serial Ground RS232 Only The Serial Port can be configured for either RS232 or RS485 The standard factory configuration is RS232 For direct connection to a PC or Laptop RS232 should be used For a permanent connection into a data acquisition system RS485 is recommended because it has better noise immunity and is more reliable when communicating over longer distances See Appendix A for details on changing the Serial Port configuration Figure 2 5 below shows typical connections using RS232 and RS485 Note that the RS485 connection does not use the SERIAL GND pin DB9 FEMALE SERIAL GND SERIAL RX SERIAL TX SERIAL TX SERIAL RX Figure 2 5 Typical RS232 and RS485 Connections See Chapter 5 for information on the Serial Communications protocol used by the 460 P N 03662D Teledyne Model 460H Monitor Operator Manual 17 3 0 Startup Perform the follo
4. NT MR 24 SAS DA CST EP RE 25 En EOE RU EUR 26 Oe ONY H VAND D RR 27 5 L6 IDUMP usse tit Ng AG sass eire te ce rci ee ees 26 SUL BG attestation RR teo AU UE A tr e no 29 SANGET eese eec dae stie quede e ag ag D I a 30 Debs OVAS T it att sete Sos Np LEN C EE ME P ILE Rd 3l 5210 VSET dea a aan Bee Re des 32 6 0 DEC EE 33 6 1 REPLACING THE GAS FILTER ELEMENT OPTIONAL 400000000000 aana 33 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page iii 6 2 CLEANING EXTERIOR SURFACES OF THE M460H eese e ener nnn nennen 33 6 3 DEGREE OF PROTECTIONG rae eise SANE TE tepore ree Sie e dee ee eee e eres 33 7 0 SENSOR AND SYSTEM TROUBLESHOOTING 4 ee ee 000000 000000000000 0000000000000009 0000000000 34 7 1 STATUS QUTPUT SUMMARY sere eei eee decade ee eine ue uin d 34 TO SENSOR i eene NERVIS 34 ES INVALID READING a E GA aaa a Ba Got a a haa a cci ni Soest 35 AIG AMPS OW MP CELER 35 Jed DIRTY iu Aa ab Na aaa Ga eat nie gah EE 35 T GSSTATUS OUTPUT SUMMARY TAB E rna iei re ere tt teet da du Soe Goat vous eo eie te BEN sag de gga GAK 36 APPENDIX A SERIAL PORT CONFIGURATION 0000000000000000 000000000000 0000000000000000 0000000000000000 00000000
5. above 0 5wt 6 or 5 0 g Nm3 the monitor will not perform the calibration and will display a ZERO ERR message on the display The monitor will also turn on the Auto Zero Error status signal See Section 2 4 2 Digital Status Outputs This Status Signal will remain on until another Auto Zero Calibration is successfully performed or a Manual Zero Calibration is performed If an Auto Zero error is detected a manual Zero Calibration should be performed See Section 4 1 3 Zero Calibration P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 20 5 0 Serial Communications The M460H comes equipped with a powerful digital Serial Communications Port that can be used for Data Acquisition and for changing instrument configuration This port can be configured for either RS232 or RS485 half duplex operation See Section 2 4 4 for details on connecting the port to a computer or Data Acquisition system 5 1 Serial Port Configuration The Serial Port of the device being used to communicate with the M460H should be configured as follows Table 5 1 Serial Port Configuration 9600 bps 5 2 Command Syntax characters sent and received are standard Ascii characters and all numbers are decimal numbers converted to Ascii text All commands are sent using the following syntax lt address gt lt command gt lt datal gt lt data2 gt lt checksum gt lt CR gt Where address 15 the instrument address default 1
6. displayed in the 4 digit readout in the center of the display The concentration is displayed in the currently selected units either wt or g Nm3 4 1 2 Pressure Display The pressure inside the measurement cell can be displayed on the readout by pressing and holding the Pressure key on the front panel The pressure is displayed in units of psia pounds per square inch absolute The normal ambient pressure at sea level is about 14 7psia Ambient pressure at higher elevations will be somewhat less The M460H can accurately measure ozone at cell pressures of 12 20psia Care should be taken in setting up the monitor to avoid over pressurizing the cell as this will result in erroneous readings 4 1 3 Zero Calibration A Zero Calibration can be performed on the monitor at any time by simultaneously pressing the two Zero buttons on the front panel The monitor will briefly display dashes after which the concentration should quickly go to zero The Zero Calibration is calculated based on the current measurement in the cell so care must be taken to ensure that all ozone is purged from the cell before pressing the Zero buttons If the Auto Zero option is not used API recommends performing a manual Zero Calibration on the monitor once a week 4 1 4 Status LED s The four status LED s to the right of the display indicate the general status of the Model 460H Monitor During normal operation after the monitor has wa
7. lt CR gt Example Command 1CAUTO lt CR gt Response 1 OK 261 lt CR gt Calibration Successful 1 FAIL 391 CR Calibration Failed P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 23 5 4 2 CZERO Syntax address CZERO CR Description Perform a Zero Calibration Note that calibration is performed based on concentration currently in measurement cell Instrument should be sufficiently purged with zero gas before issuing this command Data Parameters Sent None Response address success flag tt checksum CR Example Command 1CZERO lt CR gt Response 1 0K4261 CR Calibration Successful 1 FAIL 391 lt CR gt Calibration Failed P N 03662D Teledyne API Model 460H Os Monitor Operator Manual Page 24 5 4 3 DACSTEP Syntax address DACSTEP CR Description Puts instrument in the Analog Output setup mode The Analog Output steps from zero to full scale in 2096 increments pausing for 4 seconds at each level This repeats 5 times after which the instrument returns to normal operation This mode is useful for testing the Analog Output and the operation of any equipment measuring the Analog Output Data Parameters Sent None Response lt address gt lt success_flag gt lt checksum gt lt CR gt Example Command 1DACSTEP lt CR gt Response 1 0K4261 CR Calibration Successful 1 FAIL 391 CR Calibration Failed Notes Note that th
8. 1 of Full Scale 0 5 of Full Scale Range 0 1 96 w w or 01 g Nm 5 sec to 9596 Pressure Temperature NTP 273 15K 760mmHg 3 0 30 0 psig 0 2 2 0 LPM 5 459 12 64 x 11 19 x 6 08 321mm x 284mm x 154mm 9 40Ib 4 27kg 110 240 50 60Hz 2 5A Installation Category Overvoltage Category II Pollution Degree 2 2000 meters 0 5V 4 20mA Optional Maximum voltage between outputs and ground 60V peak IPX65 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 10 2 0 Installation Upon receiving the Model 460H please verify that there is no apparent shipping damage If damage has occurred please advise shipper first then Teledyne API 2 1 Mechanical Installation 1 Mount the enclosure securely to a vertical surface Figure 2 1 below shows the locations of the four mounting holes All four mounting holes should be used to secure the monitor 6 050 153 67 10 700 271 78 Figure 2 1 Mounting Hole Locations P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 11 2 2 Pneumatic Connections 1 Connect a 14 exhaust line to the fitting labeled Exhaust This line should be vented to an outside area since the exhaust gas may still contain trace levels of ozone that may not be completely removed by the built in the ozone scrubber CAUTION Exhaust gas from the M460H may contain dangerous levels of ozone 2 Connect the ozone delivery line
9. 37 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page iv FIGURES Figure 2 1 Mounting Hole Locations 00000000000000000000 0000000000000000 ano ne 0e0aeen none neoeenan ene tasas na 11 Figure 2 2 Pneumatic Connections eere eese seen eese en ense end sesenta sense tasa ena 12 Figure 2 3 Electrical Connections 606000000000000000000 0000000000000000 ente sene tasas enses en nenen ta statu sesso seta sone 14 Figure 2 4 Digital Output Connections eere eee 000000000000 anane nins tn sts tn sten tuse tasa suse tasse ta ses esso 15 Figure 2 5 Typical RS232 and RS485 Connections eere e eee snae ta sone ta an 17 Figure 1 RS232 RS485 Jumpers Controller PCA 03492 eee eee eee esee seen ense tn ense tn tune tan 37 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page v TABLES Table 2 1 Digital Status Output Pins 0e00000000000000000000000e0 000 etes eene ano ne0e0ee anna nenen stesso seta sene neneeeenanen 15 Table 2 2 Control Inputs s scccescasccsecccisteaseasacesacsesacdsacseienssencosdsesestcesdeseacascevanessesvessasesncncssvesesesscdssesencssuavesseae 16 Table 2 3 Serial Port Pins ssssssssssssessssessessssessersesessessssessessssessessesessesessessesessessesessessesessesessesessessesess 17 Ta
10. Cleaning Exterior Surfaces of the M460H If necessary the exterior surfaces of M454H can be cleaned with damp cloth Do not attempt to clean any of the other surfaces of the instrument Do not submerge any part of the instrument in water or cleaning solution 6 3 Degree of Protection The Model 460NEMA has a water ingress rating of IPX65 which indicates that it can withstand strong jets of water and is totally protected against dust P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 33 7 0 Sensor and System Troubleshooting This chapter gives guidelines for diagnosing system and sensor malfunctions using the five digital Status Outputs provided by the M460H All troubleshooting should be done after the M460H has been turned on and allowed to warm up for at least 15 minutes 7 1 Status Output Summary Table 7 1 below gives a summary of the operation of the five Status Outputs on the M454H See 2 4 2 Digital Status Outputs for information on connecting these outputs Table 7 1 Digital Status Outputs Output Name On State Off state 1 Sensor O K Normal State Reference or Measure gt 4995mV Reference 1000mV 2 Invalid Reading Pressure gt 45 psia Normal State Negative Ozone Concentration Concentration Over Range 3 Lamp Low Reference Normal State Detector lt 2500mV 4 Cell Dirty Measure Reference Normal State ratio lt 0 5 zero gas 5 Auto Zero Error Auto Zero Failed Nor
11. INSTRUCTION MANUAL MODEL 460H NEMA OZONE MONITOR Teledyne Instruments Advanced Pollution Instrumentation Division 6565 Nancy Ridge Drive San Diego CA 92121 2251 TOLL FREE 800 324 5190 TEL 858 657 9800 FAX 858 657 9816 EMAIL api sales teledyne com WEB SITE www teledyne api com 03662 Rev D 1 8 04 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 is 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 9 danger AN 29N Caution Hot Surface Caution Electrical Shock Hazard N Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTION The monitor should only be used for the purpose and in the manner described in this manual If you use the monitor in a manner other than that for which it was intended unpredictable behavior could ensue with possibly hazardous consequences P N 03662D Teledyne API Model 460H Monitor Operator Manual Page ii TABLE OF CONTENTS SAFETY MESSAGES it
12. Y hr a tee peret reve era feeit TE Pie de e eeu 19 oL ASOD readouts seiten ebrio uin oq de e Oe NR RT TUI DOE EM 19 4 1 2 Pressure Display 5 eee ete ar e ORE SE rea e te PAR pene 19 4 19 Zero GCalibratton s oe e E as a a a rene ve Na aa aa e a e Dita ah aa a aan a ah anah 19 2142 LED Sasa EE aeu ane a a a d eade ha 19 4 2 AUTO ZERO OPERATION OPTIONAL ccesssscecssssececessceceessececsesaececsessecessaeeecsesaeeeceeseesesseeessesaeeeseesaeeess 20 4 2 1 Auto Zero Installation eee Ega eene hene AKASA ga E RE aga a NG TERASE b ON E nenne nnn 20 4 2 2 Auto Zero Function eee eene nnn 20 4235 NYO Zero ETFOT i ee i aa e t E cett e a ote a aa 20 5 0 SERIAL COMMUNICATIONS 660000000000000000000 6000000000000000 00000000000000 00000000000000 000000000000 e bi oa Un anoo oa so 21 AVSER PORT CONFIGURATIONS s ga a eg vr ama eem enam eo 21 3 22COMMAND SYNTAX NG e a EFE RC tui rie E ORE a E esee receive en eee binos eee Ue 21 5 COMMAND SUMMARY diste e tur E EE EI e E D E REN QUIS D Drake te HAS ENSE reete Wane 22 5 4 COMMAND RERERENGE e tee bete aid d ad taie ix e HS I ee cie 23 54 CAUTO gaga A ad a ag ag a oA Gaga A ag RSA a is BR RON Bast a 23 DEAD BIA 2 40 RS a aa AAE RM
13. amp Low output is OFF If this output turns on this indicates that the UV lamp intensity as measured by the reference detector has dropped below 2500mV If the Lamp Low output turns ON and the Sensor O K output is ON this indicates that the lamp intensity is still adequate for measurement but adjustment should be made when possible If the Lamp Low output turns ON and the Sensor O K output is OFF this indicates a failure condition and measurement is no longer possible 7 5 Cell Dirty The normal state for the Cell Dirty output is OFF If this output turns on then the ratio of the measure detector to the reference detector at zero is lt 0 5 This value is calculated when the zero calibration is performed When this output is on it indicates a loss of optical transmission through the windows in the absorption cell or a calibration fault P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 35 7 6 Status Output Summary Table Table 7 2 below is a logic truth table summarizing the recommended actions based on the states of the four status outputs A 1 indicates the output is ON a 0 indicates the output is OFF and X indicates the output is in either state Table 7 2 Status Output Truth Table Sensor Invalid Lamp Cell Actions OK Reading Low Dirty 1 0 0 0 Normal operation no action required 0 X X X Service required 1 1 X X Check Pressure gt 45 psia Ver
14. ble 4 1 Auto Zero Function 0e0000000000000000000000 0000000000000000 0000000000000000 anane 0e ene an sse ta sensns estos essen 20 Table 5 1 Serial Port Configuration eerie eese esee eene nete eene tn sins stes 0ne anane genenan ene senta sense tatnen 21 Table 5 2 Serial Port Command Summnary eerie eee 000000000000 anae een e ss toss toas ease tas sense ease tasto 22 Table 7 1 Digital Status Outputs creer eee enengena ananeng sets sas suse ta sensns estos essen seta suae 34 Table 7 2 Status Output Truth Table 4 eee eerte seen eene entes tn stata atentos status taste tne ta sens tasse tasse 36 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page vi 10 INTRODUCTION 1 1 Preface Teledyne API is pleased that you have purchased the Model 460H NEMA Included is 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 Model 460H is a microprocessor based high concentration ozone monitor for monitoring process streams in water treatment food processing and research applications The Model 460H has been designed to give accurate and stable readings over long time periods with little or no maintenance or calibration The flexibility of the software as well as the analog and digital I O allow the Model 460H to
15. e DACSTEP function takes some time to complete When the command is sent to the monitor it will immediately respond with the address and colon as an acknowledgement that the message was received After the function is complete the rest of the response will be sent No additional commands should be issued to the monitor until the function completes P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 25 5 4 4 03 Syntax lt address gt O3 lt CR gt Description Returns the current ozone concentration measured by the monitor Data Parameters Sent None Response lt address gt lt o3_conc gt lt checksum gt lt CR gt Example Command 103 lt CR gt Response 1 12 018984518 CR Current Concentration reading 12 02 wt Notes Note that the concentration value returned shows more digits after the decimal than the front panel display Concentration values should only be considered valid to 4 significant digits P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 26 5 4 5 SETADDR Syntax lt address gt SETADDR lt new_address gt lt CR gt Description Changes the communications address to a new value Data Parameters Sent new address 15 the new address for the monitor Range for new address is 1 9 Response address success flag tt checksum CR Example Command 1SETADDR 2 lt CR gt Change address from 1 to 2 Response 1 0K4261 CR Chan
16. fficient is a number that reflects the inherent ability of ozone to absorb 254 nm light Most current measurements place this value at 308 1 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 path length determines how many molecules are present in the column of gas in the absorption cell The intensity of light is converted into a voltage by the detector preamp module The voltage is converted into a number by a voltage to frequency V F converter capable of 80 000 count resolution The digitized signal along with the other variables are used by the CPU to compute the concentration using the above formula P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 9 1 4 Specifications Measurement Principle Ranges Measurement Units Accuracy Precision Repeatability Resolution Response Time 9590 Compensation Gas Inlet Pressure Range Gas Flow Rate Temperature Range Dimensions H x W x D Weight Power Environmental Conditions Maximum Operating Altitude Analog Output Voltage Isolated Analog Output 4 20mA Mode Degree of Protection IP Code Optional UV Absorption Beer Lambert Law 0 596 0 10 0 15 w w 0 20 w w 0 100 g Nm 0 200 g Nm 0 300 g Nm 0 400g Nm wt g Nm t
17. ge Address Successful 1 FAIL 391 CR Change Address Failed Notes Note that monitor response is from previous address but any further commands must be at new address In the example above after sending back the OK response the monitor will no longer respond to commands with address 1 P N 03662D Teledyne API Model 460H Os Monitor Operator Manual Page 27 5 4 6 TDUMP Syntax address TDUMP CR Description Returns the current measured parameters O3 Concentration Cell Pressure psia Cell Temperature Kj Lamp Temperature K Measure Detector mV Calibrated Refererence Detector mV Reference Detector mV Data Parameters Sent None Response lt address gt lt o3_conc gt lt pressure gt lt cell_temp gt lt lamp_temp gt lt measure gt lt cal_ref gt lt ref erence gt lt checksum gt lt CR gt Example Command 1TDUMP lt CR gt Response 1 0 0282144 14 77461 300 7179 324 7713 2881 437 2940 903 4412 52 3228 lt CR gt Notes Note that the concentration value returned shows more digits after the decimal than the front panel display Concentration values should only be considered valid to 4 significant digits P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 28 5 4 7 TLIST Syntax address TLIST CR Description Returns a verbose list of the current measured parameters with labels for each parameter O3 Concentration Cell Pressure psia Cell Temperat
18. heck the serial number tag on the instrument to determine Analog Output configuration P N 03662D Teledyne API Model 460H Os Monitor Operator Manual Page 14 2 4 2 Digital Status Outputs The M460H has four digital status outputs for indicating error and operational status conditions These outputs are in the form of opto isolated open collector transistors They can be used to drive status LED s on a display panel or interface to a digital device such as a Programmable Logic Controller PLC Figure 2 4 shows the most common way of connecting the digital outputs to an external device such as PLC Note Most devices such as PLC s have internal provision for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature external dropping resistors must be used to limit the current through the transistor output to 50mA or less See Chapter 7 for details on using the Status Outputs for diagnosing sensor and system level malfunctions Table 2 1 below describes the function of the status outputs Table 2 1 Digital Status Output Pins Label Name Operation STATUS OUT 1 Sensor O K Normally On STATUS OUT 2 Invalid Reading Normally Off STATUS OUT 3 Lamp Low Normally Off STATUS OUT 4 Cell Dirty Normally Off STATUS OUT 5 Auto Zero Error Normally Off STATUS OUT 6 Spare Undefined STATUS COM Common Pin for N A all Status Outputs Programmab
19. ify that concentration has not exceeded full scale range of sensor Calibrate at Zero 1 X 1 X Lamp adjustment useful though not required 1 X X 1 Calibrate at zero Clean Cell P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 36 Appendix A Serial Port Configuration To configure the com port for RS232 or RS485 move the 4 shunts on JP3 of the Controller PCA 03492 to the proper position as shown in Figure 1 IN rj E CI E mees T RS232 RS485 Figure A 1 RS232 RS485 Jumpers Controller PCA 03492 eG P N 03662D Teledyne API Model 460H Os Monitor Operator Manual Page 37 Appendix B Pneumatic Diagram O3 Gas In p 1 gt Filler Flow Control Flow Meter Azero Valve Orifice O3 O3 Destruct Zero GasIn Measurement Cell Exhaust Out P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 38
20. interface with a broad range of devices for process control and data logging We hope you will not experience any problems with the Teledyne API Model 460H but if you do our full time customer service department is always available to answer your questions P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 7 1 2 WARRANTY POLICY ADVANCED POLLUTION INSTRUMENTATION DIVISION 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 All maintenance and the first level of field troubleshooting are 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 All replacement parts and repairs are warranted for 90 days after the purchase If a P
21. le Logic Controller or other device Digital Output 1 4 Collector t E Input 7 Digital Output Common Emmiter Ground Provided Opto Isolator by PLC Figure 2 4 Digital Output Connections P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 15 2 4 3 Control Inputs There are 2 digital control inputs on the I O connector they are labeled Zero Input and Aux Input The control inputs are used for remote control of the M460H by a device such as a PLC These inputs are triggered by providing a contact closure or low impedance current path between the Input and the Gnd pin This can be done by using a mechanical switch or isolated transistor type output from another device such as a PLC Never connect a voltage level output from another device to these contacts The functions of the control inputs is summarized below in Table 2 2 Table 2 2 Control Inputs Zero Calibration Pressure Display Zero Calibration Input The zero calibration input is used to initiate zero calibration from an external device This input performs exactly the same function as the Zero buttons on the front panel Pressure Display Input The pressure display input is used to display the pressure on the front panel This input performs exactly the same function as the Pressure buttons on the front panel P N 03662D Teledyne API Model 460H Monitor Operator Manual Page
22. mal State 7 2 Sensor OK The normal state for the Sensor OK output in ON During the warm up period on start up this output will stay off until the UV lamp reaches a minimum intensity If this output remains off after the 15 minute warm up period or goes off during normal operation then the M460H is in need of servicing If the Sensor O K output turns off AND the Lamp Low output is on this indicates that the lamp intensity has below the minimum level required for proper operation If the Sensor O K output turns off and the Lamp Low output is also off then one of the analog voltages in the sensor has exceeded the range of the internal A D converter Adjustment by qualified service personnel is required P N 03662D Teledyne API Model 460H Os Monitor Operator Manual Page 34 7 3 Invalid Reading The normal state for the Invalid Reading output is OFF If this output turns on this indicates that the M460H is still operational but a system fault or calibration fault exists that may make the current ozone reading invalid The Invalid Reading output is turned on for any of the following conditions 1 When the measured pressure in the measurement cell exceeds 45 psia 2 When the measured concentration has exceeded the full scale concentration range of the sensor Check the serial number tag for the full scale concentration range 3 The sensor is indicating an excessive negative reading 7 4 Lamp Low The normal state for the L
23. nse 1 0K4261 CR VSET Successful 1 FAIL 391 lt CR gt VSET Failed P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 32 6 0 Maintenance 6 1 Replacing the gas filter element The Model 460H is equipped with a gas filter on the ozone inlet These filters accept 25mm diameter glass fiber elements Only filter elements of borosilicate glass or quartz fibers should be used When the instrument is first installed the sample filters should be checked at least once a week for particulate loading and replaced if necessary Once the replacement frequency is determined a regular schedule for filter replacement should be instituted For replacement 25mm filter elements please contact API s sales department and request part number 02851 Filter Replacement Procedure l Goo First ensure that the gas delivery line is not under pressure and has been purged of ozone Remove the four screws securing the gas filter assembly Remove the bottom half of the filter housing Examine the internal sealing o ring and replace if necessary Pull out the stainless steel screen securing the filter element The element can now be removed and replaced When re assembling filter make sure that the top stainless steel screen is pushed into the filter cavity securing the element in place After re assembly the gas line should be pressurized with oxygen or dry air and checked for leaks using a bubble solution 6 2
24. of ozone molecules is based on absorption of 254 nm UV light due to an internal electronic resonance of the O3 molecule The Model 460H uses a mercury lamp constructed so that a large majority of the light emitted is at the 254nm wavelength Light from the lamp shines through an absorption cell through which the sample gas being measured is passed The ratio of the intensity of light passing through the gas to a reference measurement which does not pass through the gas forms the ratio I Ig This ratio forms the basis for the calculation of the ozone concentration The Beer Lambert equation shown below calculates the concentration of ozone from the ratio of light intensities 10 T 14 695 psi I x tn ZI KP L Where I Intensity of light passed through the sample I Intensity of light through sample free of ozone absorption coefficient path length concentration of ozone in parts per million T sample temperature in degrees Kelvin P pressure in pounds per square inch absolute As can be seen the concentration of ozone depends on more than the intensity ratio Temperature and pressure influence the density of the sample The density of the gas changes the number of ozone molecules in the absorption cell 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 coe
25. rmed up the green Sensor OK LED should be on and all other Status LED s should be off For information on troubleshooting using the Status LED s see Chapter 7 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 19 4 2 Auto Zero Operation The Auto Zero feature allows the monitor to operate unattended for extended periods of time This feature automatically performs a Zero Calibration at specific intervals default interval is 12hrs The monitor does this by opening a solenoid valve to allow externally supplied Zero Gas to purge the monitor and then automatically performs a Zero Calibration 4 2 1 Auto Zero Installation In order for this feature to function properly external pressurized zero gas must be supplied to the monitor as detailed in Section 2 2 4 2 2 Auto Zero Function When the Auto Zero function is triggered the monitor performs the steps outlined in Table 4 1 below Table 4 1 Auto Zero Function Step Function Display Reads Switch Auto Zero valve on Purge cell for 20 seconds IS nc m M NN and Concentration Value Perform Zero Calibration Switch Auto Zero valve off 5 Hold Off for 3 sec to return Dashes Measurement Gas to cell l6 Return to Measurement Mode Normal Concentration Display 4 2 3 Auto Zero Error When performing an Auto Zero Calibration the monitor checks to make sure the ozone concentration is near zero before calibration If the ozone concentration is
26. roduct 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 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 or ii that has been used in any manner other than in accordance with the instruction provided by Teledyne API or 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 API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE APIS PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE TERMS AND CONDITIONS All units or components returned to 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 P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 8 1 3 Principle of Operation The detection
27. te teet taedet e ag II TABEEOECONTENTS oerte tret E TR Ee REI E eu Ie Ee e n ee E be ep e ee E dee te IEEE Ud III EIGURES nt etus OR ToS ee AS V BBES Heo e Ro eet eb entren i tenis tee ees VI INTRODUCTION estas ee feet oan DU Pene eo Ee uo Ua RT UO Ie S e NGING se Re PNE en da 7 1 1 Es 7 I 2 WARRANTY POLICY peo e ee n a oe eee E E 8 1 32 PRINCIPLE OF OPERATION eee terere eet eee cubo ee ei ea eiie Nga TE A pes eet ome ede eed eer epe Mie 9 1 4 SPECIFICATIONS Linee he ve e T E EPIRI Te Pete Wee e WERTE ENS Dee 10 PB INSTALLATION 5666990596969905 999508 n 11 2 1 MECHANICAL INSTALLATION aa Ga aa a Ka a gg tae ec hie ed ione e rv Pr EY 11 2 2 PNEUMATIC CONNECTIONS v iere estre eese eben de eee va elect te cedevese ces e eee rv We epa edo ee 12 23 AC POWER CONNECTIONS iive rise E ete sec a abas a ariete 13 2 4 ELECTRICAL I O CONNEGTIONS Ag EN Aa Ag a A A E GN SAK A asse ses estate AA ak Ega agan 14 2 4 1 Analog Output sneen ag a ng AE ANE E EEN DEN E SANGED ENG E E NGING A EN GB SA a a Na 14 2 4 2 Digital Status OWlputse ia eter rrt rU HERE RE BA EE RES 15 2 4 3 GNI IEEE 16 2 4 4 RS232 RS485 Serial Communications 17 3 0 M WINE e 18 40 0OPERATION or M 19 4 IL FRONTPANEE DISPLA
28. to inlet fitting labeled Ozone Inlet on the bottom face of the enclosure See Figure 2 2 The ozone delivery should be regulated to no more than 30psig All tubing used should be made of ozone resistant material such as PTFE Teflon or FEP API can supply appropriate tubing for connecting the ozone supply line 3 Connect the oxygen or other zero gas source to the 1 4 tube fitting labeled Zero Gas Inlet Zero Gas supply pressure should be regulated between 5 and 30 psig 4 The gas flow rate through the monitor should be established between 0 5 and 2 0 L min X ee OZONE INLET ZERO GAS INLET WARNING DO NOT EXCEED WARNING DO NOT EXCEED 30 PSIG GAS DELIVERY 30 PSIG GAS DELIVERY PRESSURE PRESSURE EXHAUST WARNING THIS GAS MAY CONTAIN HARMFUL LEVELS OF OZONE Figure 2 2 Pneumatic Connections P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 12 2 3AC Power Connection A A Connect AC power to the instrument A hole is provided on the bottom face of the enclosure for installing a 1 2 conduit fitting for routing the electrical wiring into the instrument In order to maintain the IP NEMA4X rating of the enclosure an appropriate sealed conduit connector should be used Figure 2 3 below shows the location of the three terminal connector for the AC power It is recommended that if multi strand wires are used to make the AC connections the wire ends should first be tinned
29. ure K Lamp Temperature K Measure Detector mV Calibrated Reference Detector mV Reference Detector mV Data Parameters Sent None Response Test Parameter List See Below Example Command 1TLIST lt CR gt Response 03 0 0226168 Press 14 7753 Cell Temp 300 7116 Lamp Temp 324 7965 Ref 2881 52 Meas 2941 092 Raw Ref 4412 646 Notes Note that the concentration value returned shows more digits after the decimal than the front panel display Concentration values should only be considered valid to 4 significant digits Also note that no checksum is sent in the response to the TLIST command P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 29 5 4 8 VGET Syntax address VGET var index CR Description Returns value of an internal configuration variable VAR Data Parameters Sent var index 15 index number for internal VAR as follows Var Name Description Allowable Range Index 0 analog range Full Scale concentration 5 0 400 0 Units are range for Analog Output current unit of measure scaling wt or g Nm3 1 azero enable Auto Zero Enable VAR 0 Off only valid if Auto Zero hardware is installed 2 azero period Period for Auto Zero 5 0 86400 0 Seconds Calibration timer 3 carrier weight Mol weight of carrier gas 27 0 32 0 mol weight for wt calculations 32 0 02 4 comm mode Not Used N A 5
30. wing steps when fist installing the M460H ozone monitor or when bringing the monitor back into service 1 Turn on power to the monitor The display will briefly display logo followed by the software version The display will then begin showing ozone concentration Establish a flow of zero gas to the monitor Zero gas can be oxygen or clean dry air If monitor cannot be disconnected from an ozone generator then establish flow through the generator and monitor with the generator turned off Flow rate through monitor should be between 0 5 2 0 LPM Liters per minute Let monitor warm up and purge for a minimum of 5 minutes Zero the monitor by simultaneously pressing the Zero buttons on the front panel The display should momentarily show dashes after which the display should go quickly to zero Check Status LED s on front panel Sensor OK led should be ON all other LED s should be OFF If the Status LED s are not in this state refer to Chapter 7 for troubleshooting information Observe the monitor for several more minutes at zero to ensure that it is stable The monitor is now ready to measure ozone P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 18 4 0 Operation The M460H has been designed for simple and trouble free operation The Sections below detail the operational features of the M460H 4 1 Front Panel Display 4 1 1 O3 readout The current ozone concentration is
31. with solder to ensure that the screw terminals can make a reliable connection to the wires CAUTION Disconnect power to the AC mains before making any electrical connections to the Model 460H IMPORTANT A proper earth ground connection must be made to the receptacle labeled Earth Ground on the 3 pin AC connector Failure to do so may result in a shock hazard and malfunction of the instrument P N 03662D Teledyne API Model 460H Monitor Operator Manual Page 13 CONNECTOR EARTH GROUND ac Ac NEUTRAL v Sy GN N H AC POWER CONNECTOR Figure 2 3 Electrical Connections 2 4 Electrical l O Connections All user I O connections are available on the 16 pin connector on the mainboard See Figure 2 3 for location This connector can be unplugged from the header on the mainboard for easier access when wiring To disconnect from mainboard loosen the two retaining screws at either end of the connector When connecting multi strand wire to this connector the wire ends should be tinned with solder to ensure a reliable connection This is not necessary if solid core wire is used 2 4 1 Analog Output The analog output is located on the two pins labeled Analog and Analog The analog output can be configured for voltage or current output The standard output is a 0 5 volt output The analog output can also be optionally configured for a 4 20mA Current output C
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