INSTRUCTION MANUAL MODEL 460H NEMA OZONE MONITOR © Teledyne Instruments Advanced Pollution Instrumentation Division (T-API) 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.
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.
TABLE OF CONTENTS SAFETY MESSAGES.................................................................................................................................... II TABLE OF CONTENTS ............................................................................................................................... III FIGURES ........................................................................................................................................................V TABLES.........................
6.2 CLEANING EXTERIOR SURFACES OF THE M460H .....................................................................................33 6.3 DEGREE OF PROTECTION ..........................................................................................................................33 7.0 SENSOR AND SYSTEM TROUBLESHOOTING ............................................................................34 7.1 STATUS OUTPUT SUMMARY .......................................................................................
FIGURES Figure 2-1 Mounting Hole Locations........................................................................................................11 Figure 2-2 Pneumatic Connections ...........................................................................................................12 Figure 2-3 Electrical Connections.............................................................................................................14 Figure 2-4 Digital Output Connections .....................................
TABLES Table 2-1 Digital Status Output Pins ........................................................................................................15 Table 2-2 Control Inputs.............................................................................................................................16 Table 2-3 Serial Port Pins ...........................................................................................................................17 Table 4-1 Auto-Zero Function............................
I.0 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.
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.
1.3 Principle of Operation The detection of ozone molecules is based on absorption of 254 nm UV light due to an internal electronic resonance of the O3 molecule. The 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.
1.
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.
2.2 Pneumatic Connections 1. Connect a ¼” 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 to the ¼” inlet fitting labeled “Ozone Inlet” on the bottom face of the enclosure (See Figure 2-2.
2.3AC Power Connection Connect AC power to the instrument. A hole is provided on the bottom face of the enclosure for installing a ½” 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.
I/O CONNECTOR EARTH GROUND AC LINE AC NEUTRAL AC POWER CONNECTOR Figure 2-3 Electrical Connections 2.4 Electrical I/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.
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.
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.
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.
3.0 Startup Perform the following 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 the “API” logo followed by the software version. The display will then begin showing ozone concentration. 2. Establish a flow of zero gas to the monitor. Zero gas can be oxygen or clean, dry air.
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 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.
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.
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.
Examples of valid Commands with no data: Checksum Included: 1O3#179 No Checksum: 1O3 Examples of valid Commands with data: Checksum Included: 1VSET:1,20#620 No Checksum: 1VSET:1,20 5.3 Command Summary Table 5-2 below lists the commands available and a summary of their function.
5.4 Command Reference 5.4.1 CAUTO Syntax
CAUTO Description Perform an Auto-Zero Calibration. monitor.5.4.2 CZERO Syntax
CZERO 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.5.4.3 DACSTEP Syntax
DACSTEP Description Puts instrument in the Analog Output setup mode. The Analog Output steps from zero to full-scale in 20% 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.5.4.4 O3 Syntax
O3 Description Returns the current ozone concentration measured by the monitor. Data Parameters Sent None Response :# Example Command: 1O3 Response: 1:12.01898#518 - Current O3 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.5.4.5 SETADDR Syntax
SETADDR: Description Changes the communications address to a new value. Data Parameters Sent new_address is the new address for the monitor; Range for new_address is 1-9.5.4.6 TDUMP Syntax
TDUMP Description Returns the current measured parameters: O3 Concentration, Cell Pressure(psia,) Cell Temperature (K,) Lamp Temperature (K,) Measure Detector (mV,) Calibrated Refererence Detector (mV,) Reference Detector (mV) Data Parameters Sent None Response :,,,,,,[# Example Command: 1TDUMP Response: 1:0.0282144,14.77461,300.7179,324.7713,2881.437,2940.903,4412.]5.4.7 TLIST Syntax
TLIST Description Returns a verbose list of the current measured parameters with labels for each parameter: O3 Concentration, Cell Pressure(psia,) Cell Temperature (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 Response: O3 = 0.0226168 Press = 14.7753 Cell Temp = 300.7116 Lamp Temp = 324.7965 Ref = 2881.52 Meas = 2941.5.4.8 VGET Syntax
VGET: Description Returns value of an internal configuration variable (VAR.) Data Parameters Sent var_index is index number for internal VAR as follows: Var Index Name Description 0 analog_range 1 azero_enable 2 azero_period 3 carrier_weight 4 5 comm_mode iir_filt 6 conc_units Full-Scale concentration range for Analog Output scaling Auto-Zero Enable VAR.5.4.9 VLIST Syntax
VLIST Description Returns a verbose list of an internal configuration variables (VARs.) Data Parameters Sent None Response Var List (See Below) Example Command: 1VLIST Response: #0 #1 #2 #3 #4 #5 #6 analog_range = 15.0 azero_enable = 0.0 azero_period = 720.0 carrier_weight =32.0 comm_mode = 0.0 iir_filt = 0.4 conc_units = 0.0 Notes Note that no checksum is sent in the response to the VLIST command.5.4.10 VSET Syntax
VSET:, 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 :# Example Command: 1VSET:0,15.0 - Set analog_range VAR to 15.6.0 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.
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.
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.
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.
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 A-1.
Appendix B – Pneumatic Diagram O3 Gas In Filter Azero Valve Zero Gas In Flow Control Orifice Flow-Meter O3 Measurement Cell O3 Destruct Exhaust Out P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 38