INSTRUCTION MANUAL MODEL 450 OZONE MONITOR © Teledyne Instruments Advanced Pollution Instrumentation Division (T-API) 9480 Carroll Park Drive San Diego, CA 92121-5201 TOLL-FREE: 800-324-5190 TEL: 858-657-9800 FAX: 858-657-9816 EMAIL: api-sales@teledyne.com WEB SITE: www.teledyne-api.
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.........................
5.1 CALIBRATION ...........................................................................................................................................47 5.2 ADJUSTING UV LAMP AND DETECTOR ......................................................................................................47 5.3 CHANGING THE ANALOG OUTPUT RANGE ..................................................................................................49 5.3.1 Voltage output........................................................
FIGURES FIGURE 1.1 - REAR PANEL PNEUMATIC CONNECTIONS............................................................13 FIGURE 1.2 – NEMA 4X ENCLOSURE DIMENSIONS.......................................................................16 FIGURE 1.3 – NEMA 4X AC LINE POWER CONNECTION .............................................................17 FIGURE 1.4 – NEMA 4X FRONT PANEL..............................................................................................18 FIGURE 1.
TABLES TABLE 1.1 DIGITAL OUTPUTS ..............................................................................................................21 TABLE 1.2 FINAL TEST AND CALIBRATION VALUES ...................................................................28 TABLE 2.1 SYSTEM MODES ...................................................................................................................33 TABLE 2.2 TEST MEASUREMENTS....................................................................................
1.0 INTRODUCTION 1.1 Preface Teledyne API is pleased that you have purchased the Model 450. 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 450 keyboard/operator interface with its "talking keys" makes the Teledyne API a very user-friendly system.
1.2 WARRANTY POLICY ADVANCED POLLUTION INSTRUMENTATION DIVISION (T-API) 02024b 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.
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 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 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.
1.4 Specifications Ranges Measurement Units Zero Noise Span Noise Lower Detectable Limit Linearity Response Time (95%) Minimum Stream Duration (Cycle Time)* Sample Flow Rate Temperature Range Humidity Range Dimensions (H x W x D) Weight Power Environmental Conditions Maximum Operating Altitude Analog Output Voltage Mode Isolated Analog Output 0-20mA Mode** *Multi-Channel Monitor only **Optional User selectable to any full scale range from 1ppm to 1000 ppm ppbv, ppmv, ppmw, pphm, µg/m3, mg/ m3 < .
1.5 Installation (19” Rack Mount Enclosure) The Model 450 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 450. Upon receiving the Model 450 please do the following: 1. Verify no apparent shipping damage. (If damage has occurred please advise shipper first, then Teledyne API.) 2. Remove all red colored shipping screws from the inside and bottom of the instrument.
CAUTION Verify that the instrument is set up for proper line voltage and frequency. 6. Turn on the M450 by switching the switch on the lower right corner of the front panel. The front panel display should light with a sequence of messages, -API - M450 - software version number, then a normal display as shown in Figure 2.2. 7. Allow about 20 minutes for the UV lamp temperature to come up to it’s setpoint then press the TST> button on the front keyboard to scroll through the TEST values.
1.6 Installation (NEMA 4X, Wall Mount Enclosure) The Model 450 is shipped with the following standard equipment: 1. Instruction manual. CAUTION To avoid personal injury, always use two persons to lift and carry the Model 450. Upon receiving the Model 450 please do the following: 1. Verify no apparent shipping damage. (If damage has occurred please advise shipper first, then Teledyne API.) 2. Mount the NEMA 4X enclosure to a vertical surface using four 5/16” bolts.
10. Allow about 20 minutes for the UV lamp temperature to come up to it’s setpoint then press the TST> 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 1.2. The values observed should closely match the Table 1.2 values.
FIGURE 1.
FIGURE 1.
FIGURE 1.
FIGURE 1.
FIGURE 1.6 - ELECTRICAL SIGNAL CONNECTIONS 1.7 Electrical and pneumatic connections 1.7.1 Analog Output The analog output is a two pin connector on the rear panel (See Figure 1.6). The analog output can be configured for voltage or current output. The standard is a 0-5 volt output. 0-100mV, 0-1V, 0-10V, and 4-20 mA outputs are also available. See Section 5.3 for information on setting other output ranges. 1.7.
The outputs labeled ‘STATUS OUT’ are used to indicate instrument operational status and fault conditions. The outputs labeled ‘CHANNEL ID’ are used to indicate which channel(stream), the instrument is currently monitoring. The outputs labeled ‘ALARM OUT’ are used to indicate the status of the HI and HI-HI alarms for each channel. Table 1.1 below summarizes the functions of all the digital outputs.
FIGURE 1.7 - CONNECTING DIGITAL OUTPUTS TO AN EXTERNAL DEVICE 1.7.4 RS232 Output The RS232 output is provided on the 9-pin D-Sub connector shown in Figure 1.6. The RS232 output can be connected to a computer or serial printer. The RS232 output can be used to record alarm events with a time and date stamp or can be used to control the instrument’s operation. Almost any function that can be done through the front panel interface can also be done remotely through the RS232 interface.
FIGURE 1.8 - FLOW DIAGRAM 1.7.6 Sample gas connection 1/4" O.D. PTFE or FEP (Teflon™) tubing is needed to connect the sample source to the monitor. Any fittings used in the sample lines should be constructed of stainless steel or PTFE. Teledyne API recommends that the length of tubing connecting the sample points to the monitor should be kept to 100 feet or less. When running long sample lines, maintaining a high sample flow near 2 L/min will aid in reducing ozone loss in these lines.
constructed of PTFE or other inert material to avoid degradation of the ozone concentration. Contact Teledyne API’s sales department for additional information on particulate filters. Care must be taken in the design of the sampling system to ensure that water vapor does not condense in the sampling lines or in the instrument itself. The sample lines should be routed to avoid large temperature gradients along the lines.
FIGURE 1.
FIGURE 1.
1.7 Operation verification The Model 450 Monitor is now ready for operation. 1. Read Sections 1.3 and all of Section 4 of the manual to understand the Monitor's operation. 2. 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 yellow "fault" light may also be on until the flows, temperatures and voltages are within operating limits. Clear the fault messages. 3. Sample Flow - Adjust to 1-2.
TEST Values O3 MEAS O3 REF PRESS SAMPLE TEMP FLOW Observed Value Units mV mV in-Hg-A o C L/MIN Span Values PPB PPB Noise at Zero(rms) Noise at Span(rms) Factory Installed Options Power Voltage/Frequency Stream Selector (3 channel) Stream Selector (6 channel) Sample Filter Flow Switch All SS Fittings Rack Mount, w/ Slides Isolated 4-20mA Output Voltage Range PROM Rev # Date TABLE 1.2 Nominal Range 4200-4700 4200-4700 25 - 35 20-50 1-2.5 .5-1.5 .
1.8 Options 1.8.1 Stream Selector (3 or 6 Channel) This option allows the M450 to measure ozone at up to six different sampling points by using an internal stream selector. 3 or 6 channel stream selectors are available. This option includes digital outputs for HI and HI-HI alarms and a channel ID for each channel in the stream selector. 1.8.2 Sample Filter This option consists of a 47mm diameter PTFE particulate filter inside the instrument.
2.0 OPERATION 2.1 Key features The important features of the Teledyne API Model 450 O3 Monitor are listed below. 2.1.1 O3 readout The Teledyne API Model 450 O3 Monitor constantly displays the current ozone reading (in units specified) in the upper right hand corner of the alphanumeric display. If a multi-channel option has been installed, the reading represents the ozone concentration for the stream currently being monitored.
There is one exception to this. The analog output voltage range is set by DIP Switches on the A/D-I/O board as shown in Section 5.3. 2.1.6 RS-232 interface The Teledyne API O3 Monitor features an RS-232 interface which can output the instantaneous and/or average O3 data to another computer. It can also be used as a command and status channel to allow a computer to control the Monitor. 2.2 Front Panel Display This section describes the operator interface from the point of view of the front panel.
Mode Field The mode field indicates the current mode of the Monitor. If it shows "AUTO #1", the instrument is in the automatic sequence mode(multi-stream instruments only) and that stream #1 is the active stream. Table 2.1 lists all the possible modes in the Monitor and their meanings.
Warning Message SYSTEM RESET RAM INITIALIZED ANA LAMP WARNING ANA LAMP SHUTDOWN SAMPLE FLOW WARNING SAMPLE PRESSURE WARN SAMPLE TEMP WARNING BOX TEMP WARNING ANA LAMP TEMP WARN V/F NOT INSTALLED TABLE 2.3 Meaning Issued whenever Monitor is powered on RAM was erased UV lamp < 2500mV OR => 5000mV UV lamp temp control not working Sample flow < 700 cc/m Sample pressure < 15 or > 35 In-Hg-A Sample temp < 10 or > 50 deg. C Box temp. < 12 deg. C or > 55 deg. C UV lamp temp < 51 or > 61 deg.
LED Green State Off On Blinking Yellow Off Blinking Off Blinking Red Meaning Not monitoring(1) Monitoring normally Monitoring, Manual Mode No warnings exist Warnings exist No Alarms active Alarms active (1) This occurs during all diagnostics modes TABLE 2.4 STATUS LED'S 2.3 Software Operation This section describes the operation of the instrument software through the front panel interface described in the previous section.
messages are still in effect, the warning messages will re-appear after they have been cleared. The ALRM button is displayed when concentration alarms have been triggered. See Section 2.3.3 for operation of the Alarm menu. The MODE button will toggle the instrument between Auto and Manual modes. The current mode is shown in the upper left-hand corner of the display. In Auto mode, the instrument will continuously cycle through a user defined sequence of streams(See Section 3.2 for sequence configuration.
that has been sitting in the sample line while that stream was inactive. During the dwell phase the Concentration field on the display (see Figure 2.1) will blink and the instrument will display the last concentration recorded for that stream. After the 30 seconds has elapsed, the concentration field will stop blinking and the current concentration will be displayed. The current stream will now be monitored for the rest of the Monitoring Duration that has been set for that stream (see Section 3.
condition, provided that the concentration for that stream has dropped below the alarm threshold. If the monitor is configured for Non-Latching alarms, the CLR button will not appear, and all alarms will automatically clear when the concentration drops below the alarm threshold. Audible Beeper An audible beeper is sounded when any alarm is activated. A slow beep indicates that one ore more ‘HI’ alarms has been triggered, and a fast beep indicates that one or more ‘HI-HI’ alarms has been triggered.
3.0 SETUP MODE This section describes the setup variables which are used to configure the Monitor. All the setup variables are stored in the Monitor'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 monitor will beep when exit is pressed. The setup menus are accessed by pressing the SETUP button from the instrument’s main menu.
SETUP A.8 SEQUENCE:[1]23456 INS DEL [1] ENTR EXIT FIGURE 3.2 - SEQUENCE EDITING The current sequence is shown at the top center of the display as a string of digits. Each digit in the sequence represents a stream number. To edit a digit, press the buttons until the digit you wish to edit is shown in brackets []. As you scroll through the steps in the sequence, the digit in brackets is displayed above one of the buttons on the display.
3.2 Stream Configuration (STRM) The stream configuration menu is used to set alarm thresholds, monitoring duration, and analog output ranges for each individual stream. This menu is accessed by pressing the STRM button from the setup menu. The stream configuration menu is shown in Figure 3.3 below. SETUP A.8 PREV NEXT STRM 1)H=0.10,HH=0.30 PPM EDIT PRNT EXIT FIGURE 3.3 - STREAM CONFIGURATION MENU Pressing PREV or NEXT will cycle through the available streams.
Pressing the leftmost button on the display will toggle the HI Alarm on and off. Press ENTR to proceed to the next prompt. If the HI-HI Alarm is set to ON then the next prompt will show: HI-HI ALARM LIMIT:0.300 PPM Edit the HI-HI alarm value and press ENTR to store the value. The next prompt is: ANA. OUT RANGE: 1.000 PPM This is the analog output range setting.
3.4 Setting the time-of-day and date (CLK) 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-CLK-TIME. The CPU will display the current time-of-day as four digits in the format "HH: MM", where "HH" is the hour in 24-hour format (i.e. hours range from 00 to 23) and "MM" is the minute (00 - 59).
1) ALARM_BEEPER This variable enables or disables the audible beeper that sounds whenever one of the alarms has been triggered. The beeper sounds a slow beep if any of the ‘HI’ alarms are active and sounds a fast beep if any of the ‘HI-HI’ alarms are active. 2) ANA_OUTPUT_MODE This variable sets the Analog Output Mode for the Model 550 relay box accessory, if this is installed. This variable has no effect on the analog output of the M450 itself. The possible selections are: CURR (0-20mA or 4-20mA), 0.1V, 1.
4.0 Maintenance 4.1 Replacing the sample filter element If your Model 450 has been equipped with an internal or external sample filter, the Teflon™ filter elements must be replaced on a regular basis to ensure accurate readings from the M450. The frequency of this operation will be determined by the particulate loading from the air being sampled and will vary greatly from location to location.
4.2 Cleaning Exterior Surfaces of the M450 If necessary, the front panel mask and keyboard of the M450 can be cleaned with a damp cloth. Do not attempt to clean any of the other surfaces of the instrument. Do not submerge any part of the instrument in water or cleaning solution.
5.0 ADJUSTMENTS CAUTION RISK OF ELECTRICAL SHOCK. THE OPERATIONS OUTLINED IN THE FOLLOWING SECTIONS OF THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY! 5.1 Calibration The Model 450 is calibrated to NIST traceable standards on the 0-1 ppm range prior to shipment. A calibration certificate for your instrument can be purchased from Teledyne API if required. Teledyne API also recommends that the Model 450 be re-calibrated once a year.
UV Source Lamp and Detector Diagnostics O3 REF Value Meaning 4700 mV to 5000 mV The Source Lamp and Detector are operating, but adjustment is required 4000 mV to 4700 mV The Source Lamp and Detector are operating properly; no adjustment is needed 2500 mV to 4000 mV The Source Lamp and Detector are operating.
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: WARNING UV LIGHT PRESENT DO NOT LOOK DIRECTLY AT THE UV LAMP SINCE UV LIGHT COULD CAUSE EYE DAMAGE. ALAWYS USE UV FILTERING GLASSES OR VIEW THROUGH GLASS. A O3 REF value of approximately 125 mV usually indicates a total failure of either the source lamp or the detector.
Full Scale Output 100 mV 1V 5V 10 V TABLE 4.2 Switch Settings 1,6 = ON 1,5 = ON 1,4 = ON 1,3 = ON V/F BOARD DIP SWITCH - RANGES FOR ANALOG OUTPUT 5.3.2 Current Output (Optional) To configure the M450 for 4-20mA current output, perform the following steps: 1. Set the analog voltage range to the 5 Volt scale as described in Section 5.3.1 above. 2. Install Jumper in J2 on the rear panel PCB assembly. 3. Set Jumpers JP3 and JP4 on the rear panel PCB assembly as shown in Figure 4.2 below. FIGURE 4.
4. The M450 display will read "ADJUST ZERO:A/D=xx.x MV.” Put the probe of a voltmeter between TP3(AGND) and TP9(DAC #0) on the top of the V/F card. 5. The value displayed by the voltmeter should be close(+/- 20 mV) to the value on the M450 display. If they are not close then the V/F card has probably been configured improperly. 6. Adjust the Zero pot(R27) on the V/F card until the value on the M450 display matches the value on the voltmeter to within +/- 2 mV.
4. This indicates that channel 0 is setup for current output and has not been calibrated. If the display shows VOLT instead of CURR then the channel must be setup for current output. To do this, press SET, select CURR as the output type and press ENTR. 5. Next press CAL to begin the calibration. At this point the display should show: DIAG D/A U100 UP10 CAL O3_CONC_1,CURR, ZERO UP DOWN DN10 D100 ENTR EXIT 6. The zero point for current output can now be set.
6.
SW0000026 TU0000009 TU0000018 VA0000034 VA0000035 PRESSURE XDUCER, 0-15 PSIA TUBING, 1/8 X 1/4 TYGON FEP TEFLON TUBING 1/4 OD 5/32 ID VALVE, 2-WAY, SS, MANIFOLD MOUNT VALVE, 3-WAY, SS, 12VDC, VITON, M450 P/N 02395D1 Teledyne API Model 450 O3 Monitor Instruction Manual - Page 54
APPENDIX A - ELECTRICAL SCHEMATIC INDEX Drawing Number 00514 00515 00704 00705 0147802 01479 01561 01562 01930 01931 02028 02029 02322 02323 0236200 02363 02421 02422 Title V/F - I/O Card Assembly V/F - I/O Card Schematic Keyboard Assembly Keyboard Schematic Motherboard Assembly Motherboard Schematic I2C/SubMux Assembly I2C/SubMux Schematic CE Keyboard Assembly CE Keyboard Schematic UV Detector Preamp Assembly UV Detector Preamp Schematic UV Lamp Driver Assembly UV Lamp Driver Schematic M450 Rear Panel Ass