Teledyne 460H manual

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. D 1/8/04[...]

SAFETY MESSAGES Your safety and the safety of others is very important. We have provided m any important safety messages in this m anual. Please read these messages carefully. A safety message alerts you to potential hazar ds that could hurt you or others. Each safety message is associated with a safety alert symbol. These sym bols are found in the[...]

TABLE OF CONTENTS SAFETY MESSAGES ................................................................................................................ .................... II TABLE OF CONTENTS ....................................................................................................................... ........ III FIGURES ....................[...]

6.2 C LEANING E XTERIOR S URFACES OF THE M460H .....................................................................................33 6.3 D EGREE OF P ROTECTION ..........................................................................................................................33 7.0 SENSOR AND SYSTEM TROUBLESHOOTING .........................[...]

FIGURES Figure 2-1 Mounting Hole Locations ............................................................................................ ............ 11 Figure 2-2 Pneumatic Connections .............................................................................................. ............. 12 Figure 2-3 Electri cal Connections ..................[...]

TABLES Table 2-1 Digital Status Output Pins .......................................................................................... ..............15 Table 2-2 Control Inputs....................................................................................................... ......................16 Table 2-3 Serial Port Pins ..................[...]

I.0 INTRODUCTION 1.1 Preface Teledyne API is pleased that you have purch ased 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 th at you may utilize our equipment to the fullest extent. The Model 460H is a microprocessor base d high concent[...]

1.2 WARRANTY POLICY ADVANCED POLLUTION INSTRUMENTATION DIVISION 02024c Prior to shipment, Tel edy ne API equipm ent is thoroughly inspected and tested. Should equipment failure occur, Te led yn e API assures its customers that prompt service and support will be available. COVERAGE After the warranty period and throughout the equipm ent lifetime, Te[...]

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 O 3 molecule. The Model 460H uses a m ercury lamp constructed so that a large majority of the light emitted is at the 254nm wavelength. Light from the lamp shines through an absorpti on cell through wh[...]

1.4 Specifications Measurement Principle UV Absorption (Beer Lambert Law) Ranges 0-5%, 0-10%, 0-15% w/w, 0-20% w/w 0-100 g/Nm 3 , 0-200 g/Nm 3 , 0-300 g/Nm 3 , 0- 400g/ Nm 3 Measurement Units wt%, g/Nm 3 Accuracy ± 1% of Full Scale Precision/Repeatability ± 0.5% of Full Scale Range Resolution 0.1 % w/w or .01 g/Nm 3 Response Time (95%) <5 sec [...]

2.0 Installation Upon receiving the Model 460H please verify th at there is no apparent shipping dam age. (If damage has occurred please advise shipper first, then Teledyne API.) 2.1 Mechanical Installation 1. Mount the enclosure securely to a verti cal surface. Figure 2-1 below shows the locations of the four mounting holes. A ll four mounting hol[...]

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! [...]

2.3AC 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 shoul d be used. Figure 2-3 below shows [...]

AC NEUTRAL EARTH GR OUND AC POWER CONNECTOR AC LINE I/O 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 disconnec[...]

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 di splay panel or interface to a digital device such as a Programmable Logic Controller (PLC). Figure [...]

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 fo r remote control of the M460H by a device such as a PLC. These inputs are trigge red by providing a contact closure or low impedance current path between the Input a nd the Gnd pin. This[...]

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 com puter with a serial communications port (COM port) and terminal software. Three pins are provided on the I/O connector for serial [...]

3.0 Startup Perform the following steps when fist inst alling the M460H ozone monitor or when bringing the monitor back into service. 1. Turn on power to the monitor. The di splay 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 [...]

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 O 3 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, [...]

4.2 Auto-Zero Operation The Auto-Zero feature allows the monitor to operate unattended for extended periods of time. This feature automatically perform s 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 a nd then automat[...]

5.0 Serial Communications The M460H comes equipped with a powerful di gital Serial Comm unications Port that can be used for Data Acquisition and for ch anging 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[...]

Examples of valid Commands with no data: Checksum Included: 1O3#179<CR> No Checksum: 1O3<CR> Examples of valid Commands with data: Checksum Included: 1VSET:1,20#620<CR> No Checksum: 1VSET:1,20<CR> 5.3 Command Summary Table 5-2 below lists the commands available and a sum mary of their function. Table 5-2 Serial Port Command [...]

5.4 Command Reference 5.4.1 CAUTO Syntax < address >CAUTO< CR > Description Perform an Auto-Zero Calibration. Valid onl y if Auto-Zero option is installed in monitor. Data Parameters Sent None Response < address > : < success_flag > # < checksum >< CR > Example Command: 1CAUTO<CR> Response: 1:OK#261<CR&g[...]

5.4.2 CZERO Syntax < address >CZERO< CR > Description Perform a Zero Calibration. Note that calib ration is perform ed based on concentration currently in measurement cell. Instrum ent should be sufficiently purged with zero gas before issuing this command. Data Parameters Sent None Response < address > : < success_flag > # [...]

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 20% increments, pausing for 4 s econds at each level. This repeats 5 times, after which the instrument returns to normal operation. This m ode is useful for testing the Analog Outp[...]

5.4.4 O3 Syntax < address >O3< CR > Description Returns the current ozone concentration measured by the monitor. Data Parameters Sent None Response < address > : < o3_conc > # < checksum >< CR > Example Command: 1O3<CR> Response: 1:12.01898#518<CR> - Current O3 Concentration (reading 12.02 wt%) Notes [...]

5.4.5 SETADDR Syntax < address >SETADDR : < new_address >< CR > 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. Response < address > : < success_flag > # < checksum >< CR > Example Command: 1SET[...]

5.4.6 TDUMP Syntax < address >TDUMP< CR > Description Returns the current measured parameters: O3 Concentration, Cell Pressure(psia,) Cell Temperature (K,) Lamp Tem perature (K ,) Measure Detector (mV,) Calibrated Refererence Detector (mV,) Reference Detector (mV) Data Parameters Sent None Response < address > : < o3_conc > [...]

5.4.7 TLIST Syntax <address>TLIST<CR> Description Returns a verbose list of the current measured parameters with labels for each param eter: O3 Concentration, Cell Pressure(psia,) Cell Temperature (K,) Lam p Temperature (K,) Measure Detector (mV,) Calibrated Reference Detector (mV,) Reference Detector (m V) Data Parameters Sent None Res[...]

5.4.8 VGET Syntax <address>VGET :< var_index > <CR> 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 Allowable Range 0 analog_range Full-Scale concentration range for Analog Output scaling 5.0 – 400.0 (Uni[...]

5.4.9 VLIST Syntax <address>VLIST<CR> Description Returns a verbose list of an internal configuration variables (VARs.) Data Parameters Sent None Response Var List (See Below) Example Command: 1VLIST< CR > Response: #0 analog_range = 15.0 #1 azero_enable = 0.0 #2 azero_period = 720.0 #3 carrier_weight =32.0 #4 comm_mode = 0.0 #5 i[...]

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 < address > : < var_value> #< checksum >< CR[...]

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 diam eter glass fiber elements. Only filter elem ents 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[...]

7.0 Sensor and System Troubleshooting This chapter gives guidelines for diagnosing system and sensor m alfunctions using the five digital Status Outputs provided by th e 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 summa[...]

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 pre[...]

7.6 Status Output Summary Table Table 7-2 below is a logic truth table su mm arizing the recommended actions based on the states of the four status out puts. 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 OK Invalid Reading[...]

Appendix A – Serial Port Configuration To configure the com port for RS232 or RS485, m ove the 4 shunts on JP3 of the Controller PCA (#03492) to the proper position as shown in Figure A-1. Figure A-1 RS232/RS485 Jumpers (Controller PCA#03492) RS232 RS485 P/N 03662D Teledyne API Model 460H O 3 Monitor Operator Manual - Page 37[...]

Appendix B – Pneumatic Diagram Exhaust Out Zero Gas In O3 Gas In Filter Flow Contro l Orifice Azero Va lv e O3 Measurement Cell Flow-Meter O3 Destruct P/N 03662D Teledyne API Model 460H O 3 Monitor Operator Manual - Page 38[...]