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TABLE OF CONTENTS 

SAFETY MESSAGES....................................................................................................................................

II

 

TABLE

 

OF

 

CONTENTS ...............................................................................................................................

III

 

FIGURES ........................................................................................................................................................

V

 

TABLES........................................................................................................................................................

VI

 

I. 0 INTRODUCTION ..................................................................................................................................7 

1.

 

1

 

P

REFACE

....................................................................................................................................................7 

1.2

  

WARRANTY

 

POLICY ............................................................................................................................8 

1.3

  

P

RINCIPLE OF 

O

PERATION

.........................................................................................................................9 

1.4

  

S

PECIFICATIONS

......................................................................................................................................10 

2.0  INSTALLATION .................................................................................................................................11 

2.1

 

M

ECHANICAL 

I

NSTALLATION

...................................................................................................................11 

2.2

 

P

NEUMATIC 

C

ONNECTIONS

......................................................................................................................12 

2.3

 

AC

 

P

OWER 

C

ONNECTION

.........................................................................................................................13 

2.4 E

LECTRICAL 

I/O

 

C

ONNECTIONS

.......................................................................................................14 

2.4.1 Analog 

Output .......................................................................................................................14 

2.4.2           Digital Status Outputs ...........................................................................................................15 
2.4.3 Control 

Inputs .......................................................................................................................16 

2.4.4 RS232/RS485 

Serial 

Communications Port ..........................................................................17 

3.0 STARTUP ..............................................................................................................................................18 

4.0 OPERATION.........................................................................................................................................19 

4.1

 

F

RONT 

P

ANEL 

D

ISPLAY

............................................................................................................................19 

4.1.1 O3 readout.......................................................................................................................................19 

4.1.2 Pressure Display .............................................................................................................................19 
4.1.3 Zero Calibration..............................................................................................................................19 
4.1.4 Status LED’s....................................................................................................................................19 

4.2

 

A

UTO

-Z

ERO 

O

PERATION 

(O

PTIONAL

) ......................................................................................................20 

4.2.1 Auto-Zero Installation .....................................................................................................................20 
4.2.2 Auto-Zero Function .........................................................................................................................20 
4.2.3 Auto Zero Error...............................................................................................................................20 

5.0 SERIAL COMMUNICATIONS ..........................................................................................................21 

5.1

 

S

ERIAL 

P

ORT 

C

ONFIGURATION

.................................................................................................................21 

5.2

 

C

OMMAND 

S

YNTAX

.................................................................................................................................21 

5.3

 

C

OMMAND 

S

UMMARY

..............................................................................................................................22 

5.4

 

C

OMMAND 

R

EFERENCE

............................................................................................................................23 

5.4.1 CAUTO............................................................................................................................................23 
5.4.2 CZERO ............................................................................................................................................24 
5.4.3 DACSTEP........................................................................................................................................25 
5.4.4 O3 ....................................................................................................................................................26 
5.4.5 SETADDR........................................................................................................................................27 
5.4.6 TDUMP ...........................................................................................................................................28 
5.4.7 TLIST ...............................................................................................................................................29 
5.4.8 VGET ...............................................................................................................................................30 
5.4.9 VLIST...............................................................................................................................................31 
5.4.10 VSET..............................................................................................................................................32 

6.0 MAINTENANCE ..................................................................................................................................33 

6.1

 

R

EPLACING THE GAS FILTER ELEMENT 

(O

PTIONAL

)..................................................................................33 

P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page iii 

Summary of Contents for 460H NEMA

Page 1: ...eledyne 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 ...

Page 2: ... symbols is described below General Warning Caution Refer to the instructions for details on the specific danger Caution Hot Surface Caution Electrical Shock Hazard 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 moni...

Page 3: ...PERATION 19 4 1 FRONT PANEL DISPLAY 19 4 1 1 O3 readout 19 4 1 2 Pressure Display 19 4 1 3 Zero Calibration 19 4 1 4 Status LED s 19 4 2 AUTO ZERO OPERATION OPTIONAL 20 4 2 1 Auto Zero Installation 20 4 2 2 Auto Zero Function 20 4 2 3 Auto Zero Error 20 5 0 SERIAL COMMUNICATIONS 21 5 1 SERIAL PORT CONFIGURATION 21 5 2 COMMAND SYNTAX 21 5 3 COMMAND SUMMARY 22 5 4 COMMAND REFERENCE 23 5 4 1 CAUTO 23...

Page 4: ...NSOR AND SYSTEM TROUBLESHOOTING 34 7 1 STATUS OUTPUT SUMMARY 34 7 2 SENSOR OK 34 7 3 INVALID READING 35 7 4 LAMP LOW 35 7 5 CELL DIRTY 35 7 6 STATUS OUTPUT SUMMARY TABLE 36 APPENDIX A SERIAL PORT CONFIGURATION 37 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page iv ...

Page 5: ... Connections 12 Figure 2 3 Electrical Connections 14 Figure 2 4 Digital Output Connections 15 Figure 2 5 Typical RS232 and RS485 Connections 17 Figure A 1 RS232 RS485 Jumpers Controller PCA 03492 37 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page v ...

Page 6: ... 2 3 Serial Port Pins 17 Table 4 1 Auto Zero Function 20 Table 5 1 Serial Port Configuration 21 Table 5 2 Serial Port Command Summary 22 Table 7 1 Digital Status Outputs 34 Table 7 2 Status Output Truth Table 36 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page vi ...

Page 7: ...reatment 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 interface with a broad range of devices for process control and data logging We hope you will not experience any prob...

Page 8: ...ons 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 i that has been altered or subjected to misuse negligence or accident or ii that has been used in any ma...

Page 9: ...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 coefficie...

Page 10: ... Inlet Pressure Range 3 0 30 0 psig Gas Flow Rate 0 2 2 0 LPM Temperature Range 5 45oC Dimensions H x W x D 12 64 x 11 19 x 6 08 321mm x 284mm x 154mm Weight 9 40lb 4 27kg Power 110 240V 50 60Hz 2 5A Environmental Conditions Installation Category Overvoltage Category II Pollution Degree 2 Maximum Operating Altitude 2000 meters Analog Output Voltage 0 5V 4 20mA Optional Isolated Analog Output 4 20m...

Page 11: ...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 O3 Monitor Operator Manual Page 11 ...

Page 12: ...e 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 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...

Page 13: ...e AC power It is recommended that if multi strand wires are used to make the AC connections the wire ends should first be tinned 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 labele...

Page 14: ...tor 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 Out and Analog Out The analog output can be configured for voltage or current output The standard output is a 0 5 volt output The analog out...

Page 15: ...stors 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 ...

Page 16: ...el 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 Input Description Zero Input Zero Calibration Aux Input 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 f...

Page 17: ... 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 connect...

Page 18: ...enerator turned off Flow rate through monitor should be between 0 5 2 0 LPM Liters per minute 3 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 4 Check Status LED s on front panel Sensor OK led should be ON all other L...

Page 19: ...tor 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 i...

Page 20: ...for 20 seconds Holds and Flashes Concentration Value 3 Perform Zero Calibration Dashes 4 Switch Auto Zero valve off Dashes 5 Hold Off for 3 sec to return Measurement Gas to cell Dashes 6 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...

Page 21: ...dard Ascii characters and all numbers are decimal numbers converted to Ascii text All commands are sent using the following syntax address command data1 data2 checksum CR Where address is the instrument address default 1 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 comman...

Page 22: ... Perform an Auto Zero Calibration if option is installed CZERO Perform a manual zero calibration zero calibration is computed based on current O3 reading in cell DACSTEP Analog Output Test Mode Step Function O3 Returns current O3 concentration SETADDR Set communications address TDUMP Returns a compact list of current measurement parameters TLIST Returns all current measurement parameters VGET Get ...

Page 23: ...tion Valid only 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 Calibration Successful 1 FAIL 391 CR Calibration Failed P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 23 ...

Page 24: ... in measurement cell Instrument should be sufficiently purged with zero gas before issuing this command Data Parameters Sent None Response address success_flag checksum CR Example Command 1CZERO CR Response 1 OK 261 CR Calibration Successful 1 FAIL 391 CR Calibration Failed P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 24 ...

Page 25: ...ameters Sent None Response address success_flag checksum CR Example Command 1DACSTEP CR Response 1 OK 261 CR Calibration Successful 1 FAIL 391 CR Calibration Failed Notes Note that the 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 c...

Page 26: ...cksum CR Example Command 1O3 CR Response 1 12 01898 518 CR 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 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 26 ...

Page 27: ...hecksum CR Example Command 1SETADDR 2 CR Change address from 1 to 2 Response 1 OK 261 CR Change 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 M...

Page 28: ...ne Response address o3_conc pressure cell_temp lamp_temp measure cal_ref ref erence checksum CR Example Command 1TDUMP CR Response 1 0 0282144 14 77461 300 7179 324 7713 2881 437 2940 903 4412 52 3228 CR 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 0...

Page 29: ...Response Test Parameter List See Below Example Command 1TLIST CR Response O3 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 ...

Page 30: ...Auto Zero hardware is installed 0 Off 1 On 2 azero_period Period for Auto Zero Calibration timer 5 0 86400 0 Seconds 3 carrier_weight Mol weight of carrier gas for wt calculations 32 0 O2 27 0 32 0 mol weight 4 comm_mode Not Used N A 5 iir_filt Digital Concentration filter 0 05 1 0 1 0 No Filtering lower values increases filtering 6 conc_units O3 Concentration measurement units 0 wt 1 g Nm3 Respon...

Page 31: ...one 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 iir_filt 0 4 6 conc_units 0 0 Notes Note that no checksum is sent in the response to the VLIST command P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 31 ...

Page 32: ... 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 Example Command 1VSET 0 15 0 CR Set analog_range VAR to 15 0 wt Response 1 OK 261 CR VSET Successful 1 FAIL 391 CR VSET Failed P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 32 ...

Page 33: ... 3 Remove the bottom half of the filter housing 4 Examine the internal sealing o ring and replace if necessary 5 Pull out the stainless steel screen securing the filter element 6 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 7 After re assembly the gas line should be...

Page 34: ...Lamp Low Reference Detector 2500mV Normal State 4 Cell Dirty Measure Reference ratio 0 5 zero gas Normal State 5 Auto Zero Error Auto Zero Failed Normal 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...

Page 35: ...is 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 condi...

Page 36: ...n either state Table 7 2 Status Output Truth Table Sensor OK Invalid Reading Lamp Low Cell Dirty Actions 1 0 0 0 Normal operation no action required 0 X X X Service required 1 1 X X Check Pressure 45 psia Verify 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...

Page 37: ...m 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 Figure A 1 RS232 RS485 Jumpers Controller PCA 03492 RS232 RS485 P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 37 ...

Page 38: ...x B Pneumatic Diagram Exhaust Out Zero Gas In O3 Gas In Filter Flow Control Orifice Azero Valve O3 Measurement Cell Flow Meter O3 Destruct P N 03662D Teledyne API Model 460H O3 Monitor Operator Manual Page 38 ...

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