Teledyne 401 Instruction Manual Download

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INSTRUCTION MANUAL

MODEL 401

CALIBRATOR

© TELEDYNE INSTRUMENTS

ADVANCED POLLUTION INSTRUMENTATION DIVISION

(T-API)

6565 NANCY RIDGE DRIVE

SAN DIEGO, CA 92121-2251

TOLL-FREE: 800-324-5190

FAX: 858-657-9816

TEL: 858-657-9800

E-MAIL: [email protected]

WEB SITE: www.teledyne-api.com

01124

REV. J1

12/20/04

Summary of Contents for 401

Page 1: ...NTS ADVANCED POLLUTION INSTRUMENTATION DIVISION T API 6565 NANCY RIDGE DRIVE SAN DIEGO CA 92121 2251 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 J1 Copyright 2004 API Inc 12 20 04 ...

Page 2: ...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 All operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTION The analyzer should only be used ...

Page 3: ...4 5 Linearity 1 6 1 4 6 Lag Time 1 6 1 4 7 Rise And Fall Times 1 6 1 4 8 Temperature Range 1 6 1 4 9 Humidity Range 1 6 1 4 10 Flow Rates 1 7 1 4 11 Power 1 7 1 4 12 Weight 1 7 1 5 INSTALLATION AND OVERVIEW 1 7 1 6 ELECTRICAL AND PNEUMATIC CONNECTIONS 1 14 1 6 1 Electrical Connections 1 14 1 6 2 RS 232 1 14 1 6 3 Pneumatic System 1 16 1 6 4 Exhaust Connections See Figure 1 5 1 16 1 6 5 Output Flow...

Page 4: ...HECK CONTACT CLOSURE 3 4 3 8 REMOTE ZERO SPAN CHECK OR ADJUSTMENT RS 232 3 5 3 9 HOLD OFF 3 5 4 SETUP MODE 4 1 4 1 SETUP MODE OPERATION 4 1 4 2 SETTING AUTOMATIC MULTIPOINT ASEQ CHECK 4 1 4 3 SETTING AUTOMATIC ZERO SPAN DURATION 4 1 4 4 EXAMINING THE OZONE FORMULA SLOPE AND OFFSET 4 2 4 5 SETTING THE O3 GENERATION MODE 4 3 4 5 1 BNCH Mode 4 3 4 5 2 REF Mode 4 3 4 5 3 CNST Mode 4 3 4 6 SETTING THE ...

Page 5: ... 11 DARK CURRENT SIGNAL ADJUST PROCEDURE 8 9 8 12 BENCH FEEDBACK OPTION 8 10 9 TROUBLESHOOTING 9 1 9 1 OVERVIEW 9 1 9 2 TROUBLESHOOTING FUNDAMENTAL CALIBRATOR OPERATION 9 1 9 2 1 Checking The Power Sub Systems 9 2 9 2 2 Checking The CPU And Display 9 3 9 2 3 Checking The Keyboard 9 3 9 3 TROUBLESHOOTING USING WARNING MESSAGES 9 3 9 4 TROUBLESHOOTING USING TEST FUNCTION VALUES 9 5 9 5 TROUBLESHOOTI...

Page 6: ...ARRANTY REPAIR QUESTIONNAIRE 9 18 10 ROUTINE MAINTENANCE 10 1 10 1 MAINTENANCE SCHEDULE 10 1 10 2 LEAK CHECKING 10 2 10 3 CLEANING OF SAMPLE CELL 10 2 10 4 CHANGING THE PROM 10 3 11 MODEL 401 SPARE PARTS AND EXPENDABLES KITS 11 1 11 1 SPARE PARTS FOR CE MARK UNITS 11 1 11 2 SPARE PARTS FOR NON CE MARK UNITS 11 3 Appendix A LIST OF AVAILABLE MODEL 401 OPTIONS A 1 Appendix B RECOMMENDED ZERO AIR SYS...

Page 7: ... 1 13 FIGURE 1 4 RS 232 PIN ASSIGNMENTS 1 15 FIGURE 1 5 M401 CALIBRATOR PNEUMATIC CONNECTIONS 1 17 FIGURE 1 6 M401 REAR PANEL EXTERNAL DRY ZERO AIR 1 18 FIGURE 1 7 M401 CALIBRATOR CHASSIS LAYOUT 1 19 FIGURE 2 1 MODEL 401 FRONT PANEL 2 4 FIGURE 2 2 ILLUSTRATION OF NORMAL DISPLAY 2 8 FIGURE 8 1 ELECTRICAL BLOCK DIAGRAM 8 2 FIGURE 8 2 FLOW AND PRESSURE READOUT ADJUSTMENT 8 5 FIGURE A 1 MODEL 401 SAMP...

Page 8: ...ANDS 7 7 TABLE 7 7 DIAGNOSTIC REPORTS 7 7 TABLE 7 8 TEST MEASUREMENT REQUEST COMMANDS 7 8 TABLE 7 9 RS 232 VARIABLE NAMES 7 10 TABLE 8 1 THE CALIBRATOR HAS THE FOLLOWING STATUS CONDITIONS 8 7 TABLE 9 1 WARNING MESSAGES 9 4 TABLE 9 2 TEST FUNCTION VALUES 9 5 TABLE 9 2 TEST FUNCTION VALUES CONTINUED 9 6 TABLE 9 3 V F BOARD JUMPERS FACTORY SETTINGS 9 12 TABLE 9 4 V F BOARD DIP SWITCHES RANGES FOR ANA...

Page 9: ...tomers 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 is to be performed by the customer NON TELEDYNE API MANUFACTURED EQU...

Page 10: ...ple 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 regulator provides very stable flow of zero air through the O3 generator while the light...

Page 11: ... 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 is a number tha...

Page 12: ...ht intensity to obtain Io Measurement of the Io 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 1 3 1 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 t...

Page 13: ...c Sample Flow Rate 800 cc min 10 Temperature Range 5 40 C Humidity Range 0 95 RH Non Condensing Temp Coefficient 0 05 per C Voltage Coefficient 0 05 per V Dimensions HxWxD 7 x 17 x 27 178 mm x 432 mm x 686 mm Weight Analyzer 60 lb 27 kg Power Analyzer 110v 60Hz 220v 50Hz 250 watts Environmental Conditions Installation Category Overvoltage Category II Pollution Degree 2 Recorder Instantaneous 100 m...

Page 14: ...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 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 ...

Page 15: ...oid 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 API 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 anot...

Page 16: ...ator 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...

Page 17: ... 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 Enter the 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 digit s button until desired range is selected and press ENTR g Press EXIT 3 times to return to the ...

Page 18: ...minate or press O3GN to continue to generate O3 span gas 15 Generate the O3 Span Gas a Press O3GN from the main menu and enter the password 512 b Enter the O3 concentration value desired 0 05 1 ppm range c Press CONC in order to change O3 gas concentration while generating specified O3 gas d Press STBY to terminate O3 gas generation or press zero to continue to generate zero air 1 10 ...

Page 19: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 1 Model 401 Ozone Calibrator Block Diagram 1 11 ...

Page 20: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 8 7 Figure 1 2 M401 Rear Panel Electrical Connections 1 12 ...

Page 21: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 3 Rear Panel Electrical and Pneumatic Connections CE Version 1 13 ...

Page 22: ...est 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 deta...

Page 23: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 4 RS 232 Pin Assignments 1 15 ...

Page 24: ...tical 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 sh...

Page 25: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 5 M401 Calibrator Pneumatic Connections 1 17 ...

Page 26: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 6 M401 Rear Panel External Dry Zero Air 1 18 ...

Page 27: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 1 7 M401 Calibrator Chassis Layout 1 19 ...

Page 28: ...tmost 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 4 O3 REF O3 MEAS TEST function values should be between 4200 mv and 4700 mv 5 Pressure 29 to 30 Inches Mercury Absolute at sea level Other values will be displayed depending on altitude of analyzer 6 Sample Flow 800 cc min 10 7 S...

Page 29: ...MP DEG C O3 OFFSET PPB O3 SLOPE REG PRESSURE IN HG A O3 GEN TMP DEG C O3 GEN FLOW L MIN ANA LAMP TMP DEG C SAMPLE TEMP DEG C SAMPLE FLOW SCC MIN SAMPLE PRESS IN HG A O3 DRIVE MV O3 GEN REF MV O3 REF MV O3 MEAS MV O3 SET PPB PPM Options RACK MOUNTS SLIDES POWER VOLTS Hz STATUS OUTPUT RS 232 OUTPUT Calibration Settings O3 SPAN SETTING PPB O3 ZERO SETTING PPB O3 SLOPE O3 OFFSET PROM Serial Date Techn...

Page 30: ...d rack mounting ears permits the Analyzer to be mounted in 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 ...

Page 31: ...output voltage jumpers In addition TEST function values can be routed to a third analog output 2 1 3 E2 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 done under software control and the configuration options are stored in electrically erasable E2 ROM Thus configurat...

Page 32: ...stantaneous and or average O3 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 Calibra...

Page 33: ...or 512 1 ZERO 03GN ASEQ 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 Setup 717 3 SETUP MISC O3 SLPE SETUP MISC 03 OFFS NOTE All passwords can be disabled To do this enter setup password enter 818 and turn enable off If the wrong password is entered the analyzer will beep when enter is pressed 2 3 ...

Page 34: ...ield 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 ...

Page 35: ...n calibration SETUP xxx 4 Configuring analyzer operation continues 1 xxxx AZS Auto Zero Span programmed AZ2S Auto Zero 2 span points 25 100 of O3 set concentration programmed AZ5S Zero 5 span points 20 40 60 80 100 of O3 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 warni...

Page 36: ...nce channel in mV O3 GEN xxxx MV O3 GEN ref channel feedback voltage PRES xxx IN HG A Absolute pressure inches Hg SMP FLW xxx CC M Sample flow through Photometer cc min SAMPLE TEMP xxx C Temperature in the absorption tube ANA LAMP TMP xxx C Analytical Lamp Housing Temperature O3 FLOW x x L M Gas flow through O3 generator O3 LAMP TMP xx C O3 GEN Lamp Housing temp deg C REG xx x IN HG A Regulator pr...

Page 37: ...eg C BOX TEMP WARNING Box temp 12 deg C or 48 deg C O3 GEN LAMP TEMP WARN O3 lamp 43 or 53 deg C ANA LAMP TEMP WARN Analyzer lamp 51 or 61 deg C V F NOT INSTALLED A D I O card not installed bad or no handshake The menu field changes depending on the mode of the Analyzer and the buttons that have been pressed It indicates the current function of each of the 8 pushbuttons below the display See Secti...

Page 38: ...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 ...

Page 39: ...D 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 State Meaning Green Off On Not monitoring should never be off Monitoring normally STBY ZERO O3GN ASEQ MODE Yellow Off On Blinking Auto cal disabled Auto cal enabled Calibrating Red Off Blinkin...

Page 40: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK 2 10 ...

Page 41: ...provided into the inlet of rear panel for internal zero air supply 3 2 Manual O3 Generation Press O3GN then enter the password 512 to generate the O3 span gas Specify O3 gas concentration up to 1000 ppb and minimum of 50 ppb and press enter to select Again the O3 generator pump will start to run and the flow control system will maintain stable flowrate through the O3 generator Supply flowrate shou...

Page 42: ...d span See Section 3 2 or 3 4 How To preset O3 concentration which is specified in O3 GN or ASEQ of main menu AZ2S for zero and two span points 25 AND 100 of preset O3 concentration and AZ5S for zero and five span multipoint 20 40 60 80 and 100 of preset O3 concentration sequence O3 generator has three different modes of lamp feedback control Press sequence of SETUP MISC O3 GEN MODE to select cons...

Page 43: ...ETUP MISC O3 GEN MODE Select lamp control mode Bench 60 min CNST REF BNCH 3 6 Photometer Calibration Model 401 is capable of accurately reproducing O3 span gas However it should be quantitatively verified by relating to a master standard such as certified Model 400 O3 photometric analyzer The calibration of Model 401 photometer can be verified by periodic recommended every 3 months intercomparison...

Page 44: ...ivated 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 a positive transition i e 0 1 on either signal If a positive transition occurs on EXT ZERO CAL the M401 will perform a zero check If a positive transiti...

Page 45: ...ecked 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...

Page 46: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK 3 6 ...

Page 47: ...O3 concentration select AS2S for zero and two span points 25 and 100 of selected O3 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 minut...

Page 48: ...nalyzer waits 2 seconds to purge 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 Io 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 ne...

Page 49: ...he 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 re...

Page 50: ...he 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 20 000 ppb Whatever range is 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...

Page 51: ... 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 wi...

Page 52: ...UP 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 is 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 4 6 ...

Page 53: ...GEN lamp setup adjust OFF ON OFF SETUP MISC O3 GEN CAL O3 GEN calibration OFF ON OFF SETUP MISC O3 GEN MODE Feedback mode selection BNCH SETUP MISC O3 OFFS Offset adjust parameter 0 0 1000 0 SETUP MISC DARK VIEW Dark current offset 0 mV 1000 mV SETUP MISC CLK TIME Current time of day 00 00 00 00 23 59 SETUP MISC CLK DATE Current date 01 JAN 00 31 DEC 99 SETUP MISC CLK ADJ Clock speed adjust 0 sec ...

Page 54: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK 4 8 ...

Page 55: ... 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...

Page 56: ...chassis temp 11 DCPS VOLT Outputs DC power Table 5 2 Diagnostic Tests Test Name Type Purpose 1 D A OUTPUT Analog 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 change...

Page 57: ...e 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...

Page 58: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK 6 2 ...

Page 59: ... 7 1 RS 232 Message Types Character Message Type R DAS Report W Warning C Control Status D Diagnostic T Test Measurement V Variable Value HELP Screen 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 HH as a number from 00 to 23 and the minute MM as a number from 00 to 59 The IIII is a 4 digit Analyzer I D number The MESSAGE field contains v...

Page 60: ...agnostics mode no O3 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 O3 readings The host computer can request the DAS reports stored in the battery backed RAM by means of the command R NNN CRLF where NNN is the number of reports requested starting from the most recent one The CPU wil...

Page 61: ... message format is W DDD HH MM IIII WARNING MESSAGE CRLF An example of an actual warning message is W 194 11 03 0000 SAMPLE FLOW WARN CRLF Warnings may be cleared via the RS 232 interface by issuing a command of the form W COMMAND CRLF where COMMAND indicates which warning message to clear For example to clear the SAMPLE FLOW WARN message the host computer can issue the command W WSMPFLOW CRLF To ...

Page 62: ...MP WARNING W WALMPTMP CRLF ANA LAMP TEMP WARNING W WVFINS CRLF V F NOT INSTALLED 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 ...

Page 63: ...a zero check C O3GEN CRLF Do a span check C ASEQ CRLF Do a multi point check C STBY CRLF 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 C ASEQ is enabled only if ASEQ is pre selected When a control command is issued the CPU will respond by issuing a status report For example if the host computer issues the c...

Page 64: ...D NEXT CRLF Go to next test D ON CRLF Turn test signal ON D OFF CRLF Turn test signal OFF D PAUSE CRLF Pause analog output test D RESUME CRLF Resume analog output test These commands may be used whether the diagnostics have been entered from the keyboard SETUP DIAG or the RS 232 D ENTER CRLF However when the diagnostics are entered via the keyboard no feedback is sent to the RS 232 channel This pr...

Page 65: ... Test Measurements All 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 is T DDD HH MM IIII TEST MEASUREMENT CRLF ...

Page 66: ...r 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 CRLF The CPU will respond by sending a message of the following format to the RS 232 output V VARIABLE VALUE WARNLO WARNHI DATALO DATAHI CRLF In...

Page 67: ... 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 V VARIABLE VALUE WARNLO WARNHI DATALO DATAHI CRLF which should reflect the new value The values in squa...

Page 68: ...ETUP DAS FREQ 1 60 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 20 70 LAMP PCT SETUP MISC O3 GEN 0 100 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 DA RANGE SETUP MISC D A RNGE 0 100 1 500 2 1000 3 5000 4 10000 DA OFFSET SETUP MISC D ...

Page 69: ... 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 one leg A feedback circuit performs the required linearization Zero adjust pots have been factory set and no field adjustment should be requir...

Page 70: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 8 1 Electrical Block Diagram 8 2 ...

Page 71: ...tput 3 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 t...

Page 72: ...ge ranges are set by jumper placement 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 B6 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...

Page 73: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure 8 2 Flow And Pressure Readout Adjustment 8 5 ...

Page 74: ...dividual regulators should be measured Test points 1 2 3 and 4 provide connection to the temperature outputs on drawing no 00016 in Appendix D 8 6 CPU If the display is operating and the green sample light is on the CPU should be operating If not check the red LED on 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 the 5 ...

Page 75: ...ator 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 a 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 O3 REF XXXXX ...

Page 76: ...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 O3 generator and its feedback circuit 1 Enter the SETUP menu by pressing SETUP MISC O3 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 mi...

Page 77: ...ngs 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 calibration 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 n...

Page 78: ...equired 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 mode for stable and precise O3 calibration gas 8 10 ...

Page 79: ...ms 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 ma...

Page 80: ...fety 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 is 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 repla...

Page 81: ...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 warning message or messages being displayed on t...

Page 82: ...GEN lamp heater and thermistor as described in Section 8 10 SAMPLE PRESSURE The Sample Pressure is less than 15 Hg or is greater than 35 Hg Check for pressure transducer problems as described in Sections 9 6 1 and 9 6 5 SAMPLE FLOW WARNING The sample flow is less than 500 cc min or greater than 1000 cc min Check for pneumatic system problems as described in Section 9 6 1 Check for flow transducer ...

Page 83: ... of all Test Functions at the time the analyzer left the factory Table 9 2 Test Function Values Test Function Meaning Acceptable Values Corrective Action for Unacceptable Values RANGE The Full Scale Range of the analyzer s analog outputs in PPB Any between 100 10000 PPB None required O3 MEAS The most recent detector reading taken in Measure mode i e with sample gas bypassing the Ozone Scrubber 250...

Page 84: ...nce A composite of all voltages provided by the DC Power Supply 2400 2600 mV See Section 9 6 4 O3 FLOW The flow rate of O3 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 is monitoring sample gas can be the most difficult and time consuming to isolate and resolve Additi...

Page 85: ...r Span Readings 1 Check for leaks in the pneumatic systems as described in Section 10 3 2 Check for proper operation of the Main Switching Valve as described in Section 9 6 7 3 Check for dirty absorption cell and or 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 procedu...

Page 86: ...m 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...

Page 87: ...t 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...

Page 88: ... Temperature 4 O3 GEN Lamp Temperature The instrument controls the temperatures of two components by heating 1 Source Lamp 2 O3 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 ...

Page 89: ...r 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 A...

Page 90: ...ed B15 Set to match power line frequency JP1 1 2 JP2 1 2 Table 9 4 V F Board Dip Switches Ranges For Analog Output User Set DIP Switches Switch 100 mV Full Scale 1 V Full Scale 5 V Full Scale 10 V Full Scale S1 DAC 0 REC 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 ON S3 DAC 2 TEST 1 6 7 ON 1 5 7 ON 1 4 7 ON 1 3 7 ON S3 DAC 2 O3 GEN N A N A 1 4 7 ON N A 3 If Voltages and Jumpe...

Page 91: ...owing 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 J8 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 38VAC between J13 pins 6 and 7 WARNING Hazardous voltage present on the power supply module If any of these voltages is not present the Pow...

Page 92: ...0403 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 measuremen...

Page 93: ...y 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 Det...

Page 94: ...the analyzer to stabilize 2 Observe the O3 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 O3 REF Test Function and note its value If the O3 REF value has decreased by more than 5 MV from its value with Zero gas then there is a cross port leak in the main switching valve NOTE If desired th...

Page 95: ... 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 TP14 and TP2 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 ...

Page 96: ...N 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 O3 OFFSET PPB 10 20PPB O3 SLOPE 1 0 15 REG PRESSURE IN HG A 10 21 Hg A O3 GEN TMP DEG C 48 1 C O3 GEN FLOW L MIN 2 5 LPM ANA LAMP TMP DEG C 52 1 C SAMPLE TEMP DEG C 10 50 C SAMPLE FLOW SCC MIN 700 900 cc min SAMPLE...

Page 97: ...ient pollutant levels some maintenance procedures may need to be performed more often than shown Table 10 1 Maintenance Schedule Date Instrument Was Recieved ___________________ Item Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Recommended Action Zero Air Scrubber Replace charcoal quarterly Pump Diaphragms Replace every 6 months DFU particulate filter for zero air Replace annually Sample Cell I...

Page 98: ... Cell 1 Remove the center cover from the optical bench 2 Loosen the screws that hold the retaining rings at each end of the glass tube 3 Using 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 m...

Page 99: ...ew chip Install the chip in the left end of the socket with the notch facing to the right Make sure that all of the legs insert into the socket correctly 5 Replace the CPU board and re attach the connectors making sure to observe the polarity 6 Re attach the CPU card to the STD BUS 7 Move the power switch to the ON position and observe the front panel display As the analyzer goes through the setup...

Page 100: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK 10 4 ...

Page 101: ...015 Power Supply Board 00276 1401 CPU Board 00402 03 Sensor Board 00508 Absorption Tube 00514 03 V F Board 00526 01 UV Lamp Assy Source 00535 Pre AMP Assy M400 DET 00551 15 Power Supply Module 230 V 50 Hz EU 00551 19 Power Supply Module 230 V 50 Hz UK 00566 02 Assy Optical Bench 00596 Activated Charcoal 00611 Assy Bench Lamp Heater 00612 01 UV Lamp Assy O3 Gen 00628 Assy Heater 50W IZS 00644 M400 ...

Page 102: ...FM004 Flow Meter 0 1000 CC FM05 Flow Restrictor O3 Generator FM06 Flow Restrictor Zero Reference HW020 Spring Flow Control HW036 TFE Thread Tape 48 FT HW037 Tie Cable OP001 UV Detector OR001 O Ring Flow Control OR012 O Ring O3 Gen Lamp OR014 O Ring Optical Bench Lamp Window OR021 O Ring Scrubber OR026 O Ring Absorption Tube OR028 O Ring O3 Gen Base OR030 O Ring IZS Scrubber OR048 O Ring UV Detecto...

Page 103: ...00551 03 Power Supply Module 115 V 60 Hz 00551 13 Power Supply Module 220 V 50 Hz 00551 19 Power Supply Module 240 V 50 Hz 00566 02 Assy Optical Bench 00596 Activated Charcoal 00611 Assy Heater Thermistor 00612 01 UV Lamp Assy IZS Gen 00628 Assy Heater 50 W IZS 00690 01 Scrubber Pads 00704 Keyboard 00728 Display 00815 M400 Valve Module 01061 M401 Pump 01111 M401 Level 1 Spares Kit 01112 M401 Expen...

Page 104: ...Control HW036 TFE Thread Tape 48 FT HW037 Tie Cable OP001 UV Detector OR001 O Ring Flow Control OR012 O Ring O3 Gen Lamp OR014 O Ring Optical Bench Lamp Window OR018 O Ring Sample Filter OR021 O Ring Scrubber OR026 O Ring Absorption Tube OR028 O Ring O3 Gen Base OR030 O Ring Zero Air Scrubber OR048 O Ring UV Detector SW006 Overheat SW IZS OVEN SW008 Vacuum Sensor TU001 Tubing 6 1 8 Clr TU002 Tubin...

Page 105: ...1 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Appendix A LIST OF AVAILABLE MODEL 401 OPTIONS Table A 1 Available Model 401 Options Option 1 RS 232 2 Status Outputs 3 Rack Mount and Slides 4 Rack Mount Only A 1 ...

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Page 107: ...existing NO to NO2 and a large column of activated charcoal removes NO2 O3 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 ...

Page 108: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK B 2 ...

Page 109: ...ystems Vol I EPA 600 9 76 005 March 1976 7 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 8 Appendix A Quality Assurance Requirements for State and Local Air Monitoring Stations SLAMS Code of Federal Regulations Title 40 Part 58 9 Appendix B Quality Assurance Re...

Page 110: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 INTENTIONALLY BLANK C 2 ...

Page 111: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Appendix D SOFTWARE MENU TREES Figure A 1 Model 401 Sample Software Menu Tree D 1 ...

Page 112: ...Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual 01124 Rev J1 Figure A 2 Model 401 Setup Software Menu Tree D 2 ...

Page 113: ...c Sensor Diagram 00514 V F I O Card Assembly 00515 V F I O Card Diagram 00517 Mother Board Assembly 00518 Mother Board Diagram 0053203 Power Supply PCA Assembly 0053303 Power Supply PCA Diagram 00535 UV Detector Assembly 00536 UV Detector Diagram 00704 Keyboard Assembly 00705 Keyboard Diagram 01217 UV Lamp Power Supply PCA 01218 UV Lamp Power Supply Diagram 01916 Rear Panel PCA Assembly 01917 Rear...

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