Teledyne Frozen Dessert Maker 450H User manual

INSTRUCTION MANUAL
MODEL 450H
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: [email protected]
WEB SITE: www.teledyne-api.com
02826
Rev. B1
5/15/06
Printed: 05/15/06
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. The definition of these 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 monitor in a manner other than that for which it
was intended, unpredictable behavior could ensue with possibly
hazardous consequences.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page ii
TABLE OF CONTENTS
SAFETY MESSAGES.................................................................................................................................... II
TABLE OF CONTENTS ............................................................................................................................... III
FIGURES ........................................................................................................................................................V
TABLES........................................................................................................................................................ VI
1.0 INTRODUCTION..................................................................................................................................7
1.1 PREFACE ....................................................................................................................................................7
1.2 WARRANTY POLICY.............................................................................................................................8
1.3 PRINCIPLE OF OPERATION .........................................................................................................................9
1.4 SPECIFICATIONS ......................................................................................................................................11
1.5 INSTALLATION AND OVERVIEW................................................................................................................11
1.6 ELECTRICAL I/O CONNECTIONS...............................................................................................................19
1.6.1
Analog Output .......................................................................................................................19
1.6.2
Relay Outputs ........................................................................................................................19
1.6.3
Digital Outputs ......................................................................................................................19
1.6.4
Control Inputs .......................................................................................................................20
1.6.5
RS232 Output ........................................................................................................................21
1.7 OPERATION VERIFICATION .......................................................................................................................23
1.8 OPTIONS ...................................................................................................................................................26
2.0 OPERATION.........................................................................................................................................27
2.1 KEY FEATURES .........................................................................................................................................27
2.1.1 O3 readout.......................................................................................................................................27
2.1.2 Concentration Alarms .....................................................................................................................27
2.1.3 O3 analog output.............................................................................................................................27
2.1.4 E2 ROM backup of software configuration.....................................................................................27
2.1.5 RS-232 interface ..............................................................................................................................27
2.2 FRONT PANEL DISPLAY ............................................................................................................................28
2.2.1 Front panel display fields................................................................................................................28
2.2.2 Status LED’s....................................................................................................................................30
2.3 SOFTWARE OPERATION ............................................................................................................................30
2.3.1 Main Menu ......................................................................................................................................30
2.3.3 Alarm Status Menu ..........................................................................................................................31
3.0 SETUP MODE ......................................................................................................................................33
3.1 SETTING THE CONCENTRATION ALARMS (ALRM)...................................................................................34
3.2 SETTING THE CONCENTRATION UNITS (UNIT) ........................................................................................34
3.3 SETTING THE TIME-OF-DAY AND DATE (CLK) ..........................................................................................34
3.4 SETTING THE RS-232 BAUD RATE (COMM).............................................................................................35
3.5 SETUP VARIABLES (VARS) ......................................................................................................................36
4.0 MAINTENANCE ..................................................................................................................................39
4.1 REPLACING THE GAS FILTER ELEMENT......................................................................................................39
4.2 CLEANING EXTERIOR SURFACES OF THE M450H .....................................................................................39
4.3 CLEANING THE OPTICAL CELL .................................................................................................................39
4.4 DEGREE OF PROTECTION
5.0 ADJUSTMENTS ...................................................................................................................................40
5.1 CALIBRATION ...........................................................................................................................................41
5.2 CHANGING THE ANALOG OUTPUT RANGE .................................................................................................41
5.2.1
Voltage output .......................................................................................................................41
5.2.2
Current Output (Optional) ....................................................................................................41
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page iii
5.3 A/D - D/A CALIBRATION PROCEDURE… ............................................................................................42
5.4 CURRENT LOOP CALIBRATION ............................................................................................................43
6.0 MODEL 450H SPARE PARTS………………………………………………………………………….
APPENDIX A - ELECTRICAL SCHEMATIC INDEX ...........................................................49
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page iv
FIGURES
FIGURE 1.1 – NEMA 4X MOUNTING HOLE DIMENSIONS ............................................................16
FIGURE 1.2 – NEMA 4X ELECTRICAL POWER CONNECTIONS .................................................17
FIGURE 1.3 – NEMA 4X PNEUMATIC CONNECTIONS...................................................................18
FIGURE 1.4 - ELECTRICAL SIGNAL I/O CONNECTIONS ..............................................................19
FIGURE 1.5 - CONNECTING DIGITAL OUTPUTS ............................................................................20
FIGURE 1.6 – NEMA4X ASSEMBLY LAYOUT ...................................................................................22
FIGURE 1.7 - M450H PNEUMATIC BLOCK DIAGRAM ...................................................................22
FIGURE 1.9 - RACK ASSEMBLY LAYOUT .........................................................................................23
FIGURE 2.1 - MODEL 450H FRONT PANEL .......................................................................................28
FIGURE 2.2 - MAIN MENU......................................................................................................................30
FIGURE 2.3 - ALARM STATUS MENU .................................................................................................31
FIGURE 3.1 - SETUP MENU....................................................................................................................33
FIGURE 4.1 - MEASUREMENT CELL DISASSEMBLY.....................................................................40
FIGURE 4.2 - ANALOG OUTPUT JUMPERS .......................................................................................42
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page v
TABLES
TABLE 1.1 DIGITAL OUTPUTS ..............................................................................................................20
TABLE 1.2 CONTROL INPUTS ...............................................................................................................21
TABLE 1.3 FINAL TEST AND CALIBRATION VALUES ...................................................................25
TABLE 2.1 SYSTEM MODES ...................................................................................................................28
TABLE 2.2 TEST MEASUREMENTS......................................................................................................29
TABLE 2.3 WARNING MESSAGES ........................................................................................................29
TABLE 2.4 STATUS LED'S .......................................................................................................................30
TABLE 3.1 CONCENTRATION UNITS ..................................................................................................34
TABLE 4.2 V/F BOARD DIP SWITCH - RANGES FOR ANALOG OUTPUT...................................41
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page vi
1.0 INTRODUCTION
1.1 Preface
Teledyne API is pleased that you have purchased the Model 450H. We offer a full oneyear warranty (see Section 1.2) and we at Teledyne API will be pleased to provide you
with any support required so that you may utilize our equipment to the fullest extent.
The Model 450H is a microprocessor based high concentration ozone monitor for
monitoring process streams in water treatment, food processing, and research
applications. The Model 450H 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 450H
to interface with a broad range of devices for process control and data logging.
The Teledyne API Model 450H keyboard/operator interface with its "talking keys"
makes the Teledyne API a very user-friendly system. We hope you will not experience
any problems with the Teledyne API Model 450H but if you do, the built-in tests and
diagnostics should allow you to quickly and easily find the problem. In addition, our full
time customer service department is always available to answer your questions.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 7
1.2 WARRANTY POLICY
ADVANCED POLLUTION INSTRUMENTATION DIVISION
02024c
Prior to shipment, Teledyne API equipment is thoroughly inspected and tested. Should equipment
failure occur, Teledyne API assures its customers that prompt service and support will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, Teledyne API stands ready to
provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the
industry. All maintenance and the first level of field troubleshooting are to be performed by the
customer.
NON-API MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by Teledyne API is warranted and will be repaired to the
extent and according to the current terms and conditions of the respective equipment manufacturers
warranty.
GENERAL
Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in
material and workmanship under normal use and service for a period of one year from the date of
delivery. All replacement parts and repairs are warranted for 90 days after the purchase.
If a Product fails to conform to its specifications within the warranty period, Teledyne API shall
correct such defect by, in 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 manner other than in accordance with the instruction provided by API or (iii) not properly
maintained.
THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES
THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES
OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER
WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED.
THE
REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES
FOR BREACH OF ANY WARRANTY CONTAINED HEREIN. TELEDYNE API
SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF API'S
PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR
OTHERWISE.
TERMS AND CONDITIONS
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 8
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 Model 450H uses a mercury lamp
constructed so that a large majority of the light emitted is at the 254nm wavelength. Light
from the lamp shines through an absorption cell through wich the sample gas being
measured is passed. The ratio of the intensity of light passing through the gas to a
reference measurement which does not pass through the gas forms the ratio I/Io. This
ratio forms the basis for the calculation of the ozone concentration.
The Beer-Lambert equation, shown below, calculates the concentration of ozone from the
ratio of light intensities.
CO3 = −
Τ
Ι
10 6
14.695 psi
×
×
× ln
o
Ρ
Ιo
α × l 273 Κ
Where:
I = Intensity of light passed through the sample
Io = Intensity of light through sample free of ozone
α = absorption coefficient
l = path length
CO3 = concentration of ozone in parts per million
T = sample temperature in degrees Kelvin
P = pressure in pounds per square inch (absolute)
As can be seen the concentration of ozone depends 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 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 coefficient is a number that reflects the inherent ability of ozone to absorb 254
nm light. Most current measurements place this value at 308 cm-1 atm-1 at STP. The
value of this number reflects the fact that ozone is a very efficient absorber of UV
radiation which is why stratospheric ozone protects the life forms lower in the
atmosphere from the harmful effects from solar UV radiation. Lastly, the absorption path
length determines how many molecules are present in the column of gas in the absorption
cell.
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.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 9
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 10
1.4 Specifications
Measurement Principle
Ranges
Measurement Units
Precision/Repeatability
Resolution
Linearity
Response Time (95%)
Compensation
Gas Flow Rate
Temperature Range
Alarm Relay Mode
19” Rack Mount Enclosure
Dimensions (H x W x D)
NEMA 4X Enclosure
Dimensions (H x W x D)
Weight
Power
Environmental Conditions
Maximum Operating Altitude
Analog Output Voltage Mode
Isolated Analog Output 4-20mA
Mode*
Degree of Protection (IP Code)
UV Absorption (Beer Lambert Law)
0-5%, 0-10%, 0-15% w/w
0-100 g/m3, 0-200 g/m3, 0-300 g/m3
wt%, g/m3, g/Nm3 (Operator selectable)
±0.5% of full scale range
0.1 % w/w
1%
<5 sec to 95%
Pressure, temperature, gas molecular weight
0.5 - 2 LPM
5-45oC
Latching or Non-Latching (Operator selectable)
7" x 17" x 18.2"
(178 mm x 432 mm x 463 mm)
19.50” x 17.25” x 9.63”
(495 mm x 438 mm x 245 mm)
28 lb. (12.7 kg) - 19” Rack Mount Enclosure
33 lb. (15 kg) - NEMA 4X Enclosure
110V/60 Hz, 220V/50 Hz, 240V/50Hz 250 watts
230V~, 50Hz, 2.5A
Installation Category (Overvoltage Category) II
Pollution Degree 2
2000 meters
100mV, 1V, 5V, 10V (User Selectable)
Maximum voltage between outputs and ground
60V peak
IPX0 (450 Rack Mount)
IPX66 (450 Nema)
*Optional
1.5 Installation (19” Rack Mount Enclosure)
The Model 450H 19” Rack version is shipped with the following standard equipment:
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 11
1. Instruction manual.
2. Power Cord
CAUTION
To avoid personal injury, always use two persons to lift and
carry the Model 450H.
Upon receiving the Model 450H please do the following:
1. Verify no apparent shipping damage. (If damage has occurred please advise shipper
first, then Teledyne API.)
2. Before connecting power to the instrument, check the serial number tag to verify that
the instrument has been configured for the correct line voltage and frequency
connections.
CAUTION
Verify that the instrument is set up for proper line voltage and
frequency.
3. Connect an exhaust line to the fitting labeled ‘Exhaust.’ If the M450H has been
configured with the ozone killer option, this line should be vented to an outside area,
since the exhaust gas may still contain trace levels of ozone. If the M450H has not
been equipped with an ozone killer, this line should be vented to an ozone destruct
unit or other appropriate device.
CAUTION
Exhaust gas from the M450H may contain dangerous levels of
ozone!
4. Connect the ozone delivery line to the ¼” inlet fitting on the filter assembly on the
rear panel. The ozone delivery pressure should be regulated to no more than 30psig.
All tubing used should be made of ozone resistant material such as PTFE(Teflon™)
or PFA. If new, unconditioned tubing is used for the ozone delivery line, the ozone
concentration may be affected until the tubing becomes conditioned. Pre-conditioned
¼” tubing can be purchased from Teledyne API. Contact the Teledyne API sales
department and reference part number 02639.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 12
5. If the M450H has been configured with the auto-zero valve option, connect the
oxygen or other zero gas source to the ¼” tube fitting labeled ‘Zero Gas Inlet.’ Do
not exceed 30 psig in the zero air delivery line.
NOTE
The zero gas used must be clean and free of particles. If the gas
contains particulate contamination, install a particulate filter in
the zero air line. You can purchase an appropriate filter from
Teledyne API.
6. With the ozone delivery line pressurized, adjust the ozone flow rate using the needle
valve mounted inside the front panel of of the monitor. To access the needle valve,
pop out the two black plastic fasteners at the top of the front panel. The panel will
now hinge down, allowing access to the needle valve. The flow-rate should be set
from 0.5 to 2.0 liters/min. The flow-rate required will depend on your system. As a
general guideline, the flow should be set to the lowest value that will still achieve an
acceptable response time from the instrument. The lower the flow, the slower the
response will be. If a long length of tubing is used for the ozone delivery line then
the flow-rate may need to be increased so that the ozone concentration will not
degrade in the sample line.
7. Turn on the M450H by switching the power switch on the front panel. The front
panel display should light with a sequence of messages, -API - M450H - software
version number, then a normal display as shown in Figure 2.2.
8. Allow about 10 minutes for the UV lamp temperature to come up to it’s set-point 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
1.3. The values observed should closely match the Table 1.3 values.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 13
1.6 Installation (NEMA 4X Wall Mount Enclosure)
The Model 450H NEMA 4X 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 450H.
Upon receiving the Model 450H please do the following:
2. Verify no apparent shipping damage. (If damage has occurred please advise
shipper first, then Teledyne API.)
3. Mount the 450H to a vertical surface using four 5/16” bolts. See Figure 1.1
for mounting hole dimensions.
4. PVC piping of ½” or the metric equivalent must be placed on the bulkhead
conduits.
If a bulkhead conduit is not used it must be plugged to assure the watertight
seal on the unit. If this is not done the protection rating of the unit will be
greatly compromised
If the fittings are not the correct type for your application consult an
electrician to wire the unit according to the local electrical code.
5. Before connecting power to the instrument, check the serial number tag to
verify that the instrument has been configured for the correct line voltage and
frequency. The AC power line should be routed through one of the three ½”
conduit bulkheads on the bottom face of the enclosure. A barrier strip inside
the inside the enclosure is provided for wiring the AC line to the instrument.
See Figure 1.2 for details on these connections.
CAUTION
Verify that the instrument is set up for proper line voltage and
frequency.
6. Connect an exhaust line to the fitting labeled ‘Exhaust.’ If the M450H has
been configured with the ozone killer option, this line should be vented to an
outside area, since the exhaust gas may still contain trace levels of ozone. If
the M450H has not been equipped with an ozone killer, this line should be
vented to an ozone destruct unit or other appropriate device.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 14
CAUTION
Exhaust gas from the M450H may contain dangerous levels of
ozone!
7. Connect the ozone delivery line to the ¼” inlet fitting on the bottom of the
filter assembly. This assembly is located on the bottom face of the enclosure
(See Figure 1.3.) The ozone delivery pressure should be regulated to no more
than 30psig. All tubing used should be made of ozone resistant material such
as PTFE(Teflon™) or PFA. If new, unconditioned tubing is used for the
ozone delivery line, the ozone concentration may be affected until the tubing
becomes conditioned. Pre-conditioned ¼” tubing can be purchased from
Teledyne API. Contact the API sales department and reference part number
02639.
8. If the M450H has been configured with the auto-zero valve option, connect
the oxygen or other zero gas source to the ¼” tube fitting labeled ‘Zero Gas
Inlet.’ Do not exceed 30 psig in the zero air delivery line.
NOTE
The zero gas used must be clean and free of particles. If the gas
contains particulate contamination, install a particulate filter in
the zero air line. You can purchase an appropriate filter from
Teledyne API.
9. With the ozone delivery line pressurized, adjust the ozone flow rate using the
needle valve mounted below the sensor inside the instrument. The flow-rate
should be set from 0.5 to 2.0 liters/min. The flow-rate required will depend
on your system. As a general guideline, the flow should be set to the lowest
value that will still achieve an acceptable response time from the instrument.
The lower the flow, the slower the response will be. If a long length of tubing
is used for the ozone delivery line then the flow-rate may need to be increased
so that the ozone concentration will not degrade in the sample line.
10. Turn on the M450H by switching the power switch on the front panel. The
front panel display should light with a sequence of messages, -API - M450H software version number, then a normal display as shown in Figure 2.2.
11. Allow about 10 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 1.3. The values observed should closely match the
Table 1.3 values.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 15
FIGURE 1.1 – NEMA 4X MOUNTING HOLE DIMENSIONS
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 16
FIGURE 1.2 – NEMA 4X ELECTRICAL POWER CONNECTIONS
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 17
FIGURE 1.3 – NEMA 4X PNEUMATIC CONNECTIONS
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 18
FIGURE 1.4 - ELECTRICAL SIGNAL I/O CONNECTIONS
1.6 Electrical I/O Connections
1.6.1 Analog Output
The analog output is a two pin connector (See Figure 1.4). The analog output can be
configured for voltage or current output. The standard is a 0-5 volt output. 0-100mV, 01V, 0-10V, and 4-20 mA outputs are also available. See Section 5.2 for information on
setting other output ranges.
1.6.2 Relay Outputs
Three form C relay outputs are provided on three pin connectors (See Figure 1.1). These
outputs correspond to the ‘HI’ and ‘HI-HI’ concentration alarms and a System OK status
output that is used to indicate a fault or error condition in the instrument. The relay
contacts are rated to 3A at 240VAC. Do not exceed these ratings when connecting
equipment to the instrument.
1.6.3 Digital Outputs
There are 12 digital output. These outputs are optically isolated NPN transistors which
can pass 50 mA of DC current. These outputs can be used to interface to devices that
accept logic-level digital inputs, such as Programmable Logic Controllers(PLC’s).
The outputs labeled ‘STATUS OUT’ are used to indicate instrument operational status
and fault conditions. Table 1.1 below summarizes the functions of all the digital outputs.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 19
Output
1
2
3
4
5
6
7
8-11
12
Description
Power OK
Diagnostics Mode(Instrument not
monitoring)
Temperature Fault
Pressure Fault
UV Lamp Fault
Flow Fault
Performing Auto-Zero Calibration
Not Used
System OK(no faults)
TABLE 1.1
Normal Operating State
ON
OFF
OFF
OFF
OFF
OFF
OFF
N/A
ON
DIGITAL OUTPUTS
Each digital output is configured as a Collector/Emitter pair. The labels are ‘C’ and ‘E’
for these contacts, respectively. Figure 1.2 below shows the most common way of
connecting the digital outputs to an external device such as PLC. Note: Most devices,
such as PLC’s, have internal provision for limiting the current that the input will draw
from an external device. When connecting to a unit that does not have this feature,
external dropping resistors must be used to limit the current through the transistor output
to 50mA or less.
FIGURE 1.5 - CONNECTING DIGITAL OUTPUTS
1.6.4 Control Inputs
There are 6 digital control inputs on the rear panel; they are labeled ‘CONTROL IN’ (See
Figure 1.4.) The control inputs are used for remote control of the M450H by a device
such as a PLC. These inputs are triggered by providing a contact closure or low
impedance current path between the + and ground contacts. This can be done by using a
mechanical switch or isolated transistor type output from another device, such as a PLC.
Never connect a voltage level output from another device to these contacts. The
functions of the control inputs is summarized below in Table 1.2:
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 20
Input
1
2
3
4
5
6
Description
Zero Calibrate
Undefined (Spare)
Undefined (Spare)
Undefined (Spare)
Undefined (Spare)
Undefined (Spare)
TABLE 1.2
CONTROL INPUTS
Zero Calibrate:
The zero calibration input is used to initiate zero calibration from an external device.
This control input only functions when the instrument has been configured with the
Auto-Zero option. To perform the Auto-Zero calibration using the control input, this
input should be closed for at least 2 seconds and released. The instrument will then
automaticall perform the zero calibration and return to normal monitoring afterwards.
See Section 3.5 for details on configuring the Auto-Zero feature.
1.6.5 RS232 Output
The RS232 output is provided on the 9-pin D-Sub connector shown in Figure 1.4. 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 remotely using a computer. Almost any function that can be done
through the front panel interface can also be done remotely through the RS232 interface.
To use the RS232 for instrument control, all that is needed is a PC(personal computer)
with an available serial communications port(COM port), a serial cable, and terminal
emulation software. The serial cable must have a female DB-9 connector on one end and
an appropriate connector on the other end to interface with the COM port on a PC.
For more details on the use of the RS232 interface, please contact Teledyne API and
request document number 01350.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 21
UV LA M P
S E NS O R
NE E D LE
O ZO NE
M O THE RB
A U T O - ZE R O
V /F
C P U
A C P OW E R
A C L IN E
D C P OW E R
S
O
G A S F IL TE R
FIGURE 1.6 – NEMA4X ASSEMBLY LAYOUT
AUTO ZERO
VALVE
OZONE INLET
SAMPLE
FILTER
OZONE
SENSOR
ZERO GAS INLET
NEEDLE VALVE
(0.5 - 2.0 L/Min)
PRESSURE
SENSOR
EXHAUST
FLOW-METER
OZONE
KILLER
FIGURE 1.7 - M450H PNEUMATIC BLOCK DIAGRAM
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 22
POWER SUPPLY
MODULE
Figure 1.8 - 19” Rack Assembly Layout
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 23
1.7 Operation verification
The Model 450H Monitor is now ready for operation.
1. Read Sections 1.3 and all of Section 2 of the manual to understand the
Monitor's operation.
2. Turn on the power by pressing the on/off switch (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 temperatures and voltages are
within operating limits. Clear the fault messages.
3. Sample Flow - Adjust to 0.5-2.0 L/min using needle valve (See Figure 1.6)
4. After a 20 minute warm-up, review the TEST function values in the front
panel display by pushing the keyboard button labeled TST>. Not every
TEST function is a diagnostic of correct monitor operation, therefore TEST
functions not covered below can be ignored for now.
5. O3 REF, O3 MEAS - TEST function values should be between 4200 mV and
4700 mV.
6. Pressure – 14.5-15.2 psia at sea level. Other values will be displayed
depending on altitude of monitor.
7. Sample Temp - 20 -50oC
8. Box Temp - Ambient +10 oC
9. If the TEST functions are within the limits given above the instrument should
function correctly. If there is a problem please read the manual and check
your set-up.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 24
TEST Values
O3 MEAS
O3 REF
PRESS
GAS TEMP
FLOW
Noise at Zero(rms)
Observed
Value
Units
mV
mV
in-Hg-A
o
C
L/MIN
Noise Values
G/Nm3
Factory Installed Options
Power Voltage/Frequency
Auto-Zero Valve
Ozone Killer
Flow-Meter
Flow Switch
Rack Mount, w/ Slides
Isolated 4-20mA Output
Voltage Range
PROM Rev #
Date
TABLE 1.3
Nominal Range
4200-4700
4200-4700
25 - 35
20-50
0.5-2
.5-1.5
Option Installed
0-
V
Serial #
Technician
FINAL TEST AND CALIBRATION VALUES
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 25
1.8 Options
1.8.1 Auto-Zero Option
This option consists of a three way valve that is used to admit customer supplied oxygen
or zero gas into the instrument for performing an automatic or manual zero calibration.
This calibration can be done automatically once a day or at some other pre-set interval, or
can be controlled by an external system, such as a PLC.
1.8.2 Isolated Current Output (4-20mA or 2-20mA)
This option converts the M450H’s voltage output to an isolated 4-20mA driver with an
integral loop power supply. It is programmable for 4-20mA or 0-20mA and has a 1500 V
common mode voltage isolation and 240 V RMS normal mode voltage protection. Vloop =
28V max which is sufficient to drive up to a 1000 ohm load.
1.8.3 Flow-meter
A variable area flowmeter can be included on the front panel to give a visual indicator of
gas flow through the instrument.
1.8.4 Ozone Killer
This option consists of a catalytic ozone scrubber that converts most of the ozone back
into oxygen before it is exhausted from the instrument.
1.8.5 Flow Switch
This option is an on/off type flow switch that is used to send a signal to the CPU in case
the flow drops below the minimum required for proper operation of the instrument. In
case of flow failure, the instrument will issue a warning on the front panel and will turn
on the flow warning status bit, indicating an instrument error.
1.8.6 Rack mount with slides
This option, including slides and rack mounting ears, permits the Monitor to be mounted
in a standard 19" wide x 30" deep RETMA rack. This option is not available for the
NEMA 4X enclosure.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 26
2.0 OPERATION
2.1 Key features
The important features of the Teledyne API Model 450H Ozone Monitor are listed
below.
2.1.1 O3 readout
The Teledyne API Model 450H O3 Monitor constantly displays the current ozone
reading (in units selected) in the upper right hand corner of the alphanumeric display.
2.1.2 Concentration Alarms
The Teledyne API O3 Monitor provides two concentration alarms, HI and HI-HI. The
concentrations corresponding to each alarm levels can easily be set using the front panel
interface. Two form C relays for the two alarm level are provided on the rear panel. In
addition, the alarms can operate in either latching or non-latching modes.
2.1.3 O3 analog output
The M450H provides an analog output of the current ozone reading on the rear panel (see
Figure 1.2). The output can be configured for 0-100mV, 0-1V, 0-5V, 0-10V. Isolated 420mA or 2-20mA current output is available as an option. The voltage outputs are bipolar and also provide for 20% over-range.
2.1.4 E2 ROM backup of software configuration
The Teledyne API O3 Monitor has few DIP switches or jumpers that need to be set by
the operator. Configuration of the Monitor is done under software control and the
configuration options are stored in electrically erasable (E2) ROM. Thus, configuration
options are saved even when the Monitor is powered off.
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 5.2.
2.1.5 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.
For more details on the use of the RS232 interface, please contact Teledyne API and
request document number 01350.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 27
2.2 Front Panel Display
This section describes the operator interface from the point of view of the front panel.
The front panel consists of a 2-line by 40-character alphanumeric display, 8 pushbuttons,
and 3 status LED’s. Each of these features is described below.
2.2.1 Front panel display fields
The display is divided into 4 main "fields": the Mode field in the upper left, the
Message/Test Function field in the top center, the ozone Concentration field consisting
of the most recent instantaneous ozone value field in the upper right, and the Menu field
which occupies the entire bottom line of the display. The Menu field is used to define the
function of the 8 pushbuttons directly below the display. The buttons are then used for
selecting menu items and are also used for entering values such as alarm levels. A
typical display is shown in Figure 2.1.
MODE
FIELD
SAMPLE
<TST
MESSAGE/TEST
MEASUREMENT FIELD
CONCENTRATION
FIELD
TIME=15:58:21
12.0 wt%
TST>
ALRM
MSG
CLR
SETUP
BUTTON DEFINITIONS
FIGURE 2.1 - MODEL 450H FRONT PANEL
Mode Field
The mode field indicates the current mode of the Monitor. Table 2.1 lists all the possible
modes in the Monitor and their meanings.
TABLE 2.1
Mode
SAMPLE
ALARM STATUS
SETUP xxx (1)
DIAG CAL
DIAG D/A
DIAG AOUT
DIAG CFG
SYSTEM MODES
Meaning
Monitoring
Display of Alarm Status
Configuring monitor (monitoring continues)
Calibration Menu
Configure and Calibrate Digital to Analog converters
Test analog output
Instrument Configuation List
(1) xxx = software revision (e.g. A.9)
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 28
Message/Test Measurement Field
The message field shows warning messages or test measurements. Tables 2.2 and 2.3
summarize the test measurements and warning messages and their meanings. Refer to
Section 2.3 for detailed information on viewing test measurements and warning messages
and clearing warnings.
Test Message
TIME=xx:xx:xx
RANGE = xxxx wt%
O3 MEAS=xxxxx MV
O3 REF=xxxxx MV
PRESS=xxx PSIA
GAS TEMP=xxx C
LAMP TEMP=xxx C
BOX TEMP=xxx C
TABLE 2.2
Warning Message
SYSTEM RESET
RAM INITIALIZED
UV LAMP WARNING
UV LAMP SHUTDOWN
SAMPLE FLOW WARNING
SAMPLE PRESSURE WARN
GAS TEMP WARNING
BOX TEMP WARNING
ANA LAMP TEMP WARN
V/F NOT INSTALLED
TABLE 2.3
Meaning
Current time-of-day (HH:MM:SS)
Full-Scale concentration for analog
output
Current UV reading, measure channel
Current UV reading, reference channel
Absorption cell pressure - psia
Temperature of the sample gas(deg. C)
UV Lamp Temperature (deg C)
Internal box temperature (deg. C)
TEST MEASUREMENTS
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
Gas temp < 10 or > 50 deg. C
Box temp. < 12 deg. C or > 55 deg. C
UV lamp temp < 51 or > 61 deg. C
V/F card not installed or bad
WARNING MESSAGES
Menu Field
The menu field changes depending on the mode of the Monitor and the buttons that have
been pressed. It indicates the current function of each of the 8 pushbuttons below the
display.
The 8 pushbuttons below the display are programmable by the CPU in that their
functions change depending on the mode of the Monitor or the operations being
performed. The legend above a button identifies its current function. If there is no
legend above a button, it has no function and will be ignored if pressed.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 29
2.2.2 Status LED’s
The three status LED’s to the right of the display indicate the general status of the Model
450H Monitor. The green SAMPLE LED indicates the sampling status. The yellow
FAULT LED indicates the fault status. The red ALARM LED indicates the
concentration alarm status. Table 2.4 below summarizes the meanings of the status
LED’s.
LED
Green
State
Off
On
Off
Blinking
Off
Blinking
Yellow
Red
Meaning
Not monitoring(1)
Monitoring normally
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. The instrument software has been designed to
be easy to use, yet powerful enough to allow the user to customize the instrument for a
particular application.
2.3.1 Main Menu
Figure 2.2 below shows the shows a typical main menu for a Model 450H.
SAMPLE
<TST
TIME=15:58:21
TST>
ALRM
12.0 %
MSG
CLR
SETUP
FIGURE 2.2 - MAIN MENU
If <TST or TST> are pushed, the upper center display cycles through list of available
test functions (see Table 2.3).
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 30
When the MSG button is displayed, it indicates that one or more warnings have been
issued. To view the warning messages, press the MSG button. Repeatedly pressing this
button will cycle through all available warning messages. Pressing CLR will clear the
warning message from the display. Note: If the conditions that caused the warning
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.
2.3.3 Alarm Status Menu
Pressing the ALRM button from the main menu when alarms have been triggered will
bring up the alarm status menu as shown below in Figure 2.3.
ALARM STATUS
CLR
HI=ACTIVE, HI HI=OK
BEEP
EXIT
FIGURE 2.3 - ALARM STATUS MENU
Clearing Alarms
If the monitor is configured for Latching type alarms, and either of the alarms can be
cleared (ie. The concentration has dropped below the alarm threshold,) then a CLR
button will appear as shown in Figure 2.3 above. The CLR button will clear the alarm
condition.
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
the ‘HI’ alarm has been triggered, and a fast beep indicates that the ‘HI-HI’ alarm has
been triggered. Pressing the BEEP button from the alarm menu will silence the audible
beeper for 5 minutes. Note: Pressing the BEEP button does not clear any of the alarms,
it simply silences the audible alarm. If the alarms are not cleared, the audible alarm will
automatically resume in 5 minutes.
See Sections 3.1 and 3.5 for details on configuring concentration alarms.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 31
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. The top level setup menu is shown in Figure 3.1 below.
SETUP A.8
ALRM
UNIT
CLK COMM VARS DIAG
EXIT
FIGURE 3.1 - SETUP MENU
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 33
3.1 Setting the Concentration Alarms (ALRM)
To configure the concentration alarms, press ALRM from the SETUP menu. The
software will now show a series of prompts for configuring the HI and HI-HI alarms.
Each alarm can be independantly enabled and disabled as follows:
HI ALARM:OFF
Pressing the leftmost button on the display will toggle the HI Alarm on and off.
Setting the alarm to off disables the alarm. Press ENTR to proceed to the next
prompt. If the HI Alarm is set to ON then the next prompt will show:
HI ALARM LIMIT: 5.00 wt%
The concentration threshold for the HI alarm is shown. To change this value,
edit the number shown on the lower line of the display by pressing the button
below the digit you want to change. When you are done, press ENTR to store the
new value. The next set of prompts sets the HI-HI alarm as follows:
HI-HI ALARM:OFF
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: 10.00 wt%
Edit the HI-HI alarm value and press ENTR to store the value.
3.2 Setting the Concentration Units (UNIT)
To set the concentration units, press UNIT from the setup menu. The default
concentration units are weight %. Table 3.1 below lists the units available.
Software Abbreviation
GM3
WT%
GNM3
Unit
Grams per m (g/m )
Percent by weight (wt%)
Grams per normal m3 (g/Nm3)
TABLE 3.1
CONCENTRATION UNITS
3
3
3.3 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
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 34
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). The operator may change the time-of-day and then press ENTR to
accept the new time, or press EXIT to leave the time unchanged.
To set the current date, which is used for time-stamping the RS-232 reports, press
SETUP-CLK-DATE. The CPU will display the current date as "DD MMM YY". For
example, April 1, 1990 would be displayed as "01 APR 90". Change the date by pressing
the button under each field until the desired date is shown. Then press ENTR to accept
the new date or press EXIT to leave the date unchanged.
3.4 Setting the RS-232 baud rate (COMM)
To set the baud rate for the RS-232 channel, press SETUP-COMM-BAUD. Press 300,
1200, 2400, 4800, 9600, or 19.2 followed by ENTR to accept the new baud rate, or
EXIT to leave the baud rate unchanged.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 35
3.5 Setup variables (VARS)
The setup variables are global settings that can be configured by the user. Note: Do not
arbitrarily change these settings since these variables affect the fundamental operation of
the instrument. The setup variables are accessed from the main menu by pressing
SETUP-VARS. Use the PREV or NEXT buttons to scroll to the desired variable and
press EDIT to change the variable. Set the desired value for the variable and press
ENTR to save the value. Pressing EXIT aborts the edit screen without changing the
value. The setup variables available to the user are listed below along with their
description.
0) LATCH_ALARMS
This variable sets the operation of the concentration alarms to either latched or nonlatched mode. In latched mode, when a concentration alarm is triggered, the alarm will
stay on, or latch, until the user resets the alarm through the ALRM menu on the front
panel. When the alarms are set to non-latching mode(LATCH_ALARMS = OFF) the
alarms will automatically turn off when the concentration drops back below the alarm
threshold value.
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.
Note: VAR’s 2-6 apply only to instruments with the Auto-Zero valve option
2) USE_ZERO_VALVE
This variable enables the Auto-Zero valve (if installed) during manual zero calibration
(See Section X.X.)
3) AZERO_ENABLE
This variable enables the Auto-Zero function which will perform an automatic zero
calibration at the interval specified by the AZERO_FREQ variable. This calibration is
performed by admitting externally supplied zero gas into the measurement cell for a
period of time specified by the AZERO_DWELL variable and then performing a zero
calibration.
4) AZERO_CAL_ENABLE
This variable enables automatic calibation during the Auto-Zero cycle and should be set
to ON whenever the Auto-Zero function is enabled.
5) AZERO_FREQ
This variable determines the frequency of the Auto-Zero function in hours. The default
value is 24 hours.
6) AZERO_DWELL
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 36
This variable determines length of time that zero gas is admitted into the measurement
cell before the zero calibration is performed. This value must be set to a long enough
interval to ensure that the cell is purged of all ozone before the calibration is performed.
The defaul value is 20 seconds.
7) AZERO_HOLD_OFF
This variable determines the length of time the instrument waits after the Auto-Zero
cycle before normal measurement is resumed. The default value is 5 seconds.
8) GAS_MOLECULAR_WEIGHT
This variable is the molecular weight of the carrier gas that the ozone is being measured
in. This value is used in the calculation of the wt% concentration unit. The default value
is 32.0 (for Oxygen carrier gas.)
9) CONCENTRATION _RANGE
This variable sets the full-scale concentration range for the analog output. A 15 wt%
concentration range means that 0-5 volts on the analog output will coorespond to a
concentration range of 0-15 wt%.
10) TPC_ENABLE
This variable enables temperature and pressure compensation for the calculation of the
ozone concentration. This variable should always be set to ON unless an external
correction is being applied to compensate for temperature and pressure changes.
11) STD_TEMP
12) STD_PRESS
These variables are the standard temperature and pressure that are used to calculate the
concentration when the units are set to grams per normal cubic meter (g/Nm3.)
13) RS232_MODE
This variable set the mode of operation of the RS232 interface. For more details on the
use of the RS232 interface, please contact Teledyne API and request document number
01350.
14) CLOCK_ADJ
This variable is used to make slight adjustments to the instrument’s internal clock so that
it keeps proper time. Setting this variable to a positive value will add that number of
seconds each day to the clock while a negative value will subtract that number of seconds
per day.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 37
3.5 Diagnostics (DIAG)
3.5.1 Zero Calibration
This menu is used for performing manual zero calibration of the M450H. If the
Auto-Zero option has been installed and the USE_ZERO_VALVE variable has
been enabled (See Section 3.5) then this calibration can be done using gas from
the Zero Gas inlet port on the monitor. If this valve is not used, then the zero
calibration gas must be supplied at the Ozone Inlet port. To zero the monitor
press the ZERO button once. This button will now change to ENTR. Press this
button once more to confirm the calibration. The Ozone concentration reading
should now go to zero.
3.5.2 D/A Calibration
This menu is used for the calibration of the internal A/D converter and DACs on
the V/F Card. This procedure is performed at the factory and should not need to
be performed again unless the analog output voltage range is changed or the V/F
Card is replaced. For details on performing this calibration see Section 5.3.
3.5.3 Analog Output
This diagnostic function will step the analog output through it’s full scale range in
20% increments, ie. 0% - 20% - 40% - 60% - 80% - 100%. The function pauses
for several seconds at each level. To freeze the analog output at a particular level,
press and release the button under the % display. Pressing the button again will
resume the cycling. This function is useful for calibrating instruments connected
to the analog output.
3.5.4 RS232 Output
This diagnostic function outputs a string of w’s out the RS232 port and is used for
troubleshooting RS232 connections to a computer. For more details on the use of
the RS232 interface, please contact Teledyne API and request document number
01350.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 38
4.0 Maintenance
4.1 Replacing the gas filter element
The Model 450H comes equipped with a gas filter on the ozone inlet. These filters
accept 25mm diameter glass fiber elements. Only filter elements of borosilicate glass or
quartz fibers should be used. When the instrument is first installed, the sample filters
should be checked at least once a week for particulate loading and replaced if necessary.
Once the replacement frequency is determined, a regular schedule for filter replacement
should be instituted.
For replacement 25mm filter elements, please contact Teledyne API’s sales department
and request part number 02851.
Filter Replacement Procedure:
1. First ensure that the gas delivery line is not under pressure and has been purged of
ozone.
2. Remove the four nuts securing the gas filter assembly.
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 pressurized with oxygen or dry air and
checked for leaks using a bubble solution.
4.2 Cleaning Exterior Surfaces of the M450H
If necessary, the exterior surfaces of M450H 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.
4.3 Cleaning the Optical Cell
Over long periods of time the optical cell windows in the sensor assembly may become
dirty and affect the operation of the instrument. Each time a zero calibration is done, the
instrument can detect changes in the light transmission through the windows and will
issue a warning when this value drops to an unacceptable level. The warning message
“Optical Cell Warning” will be issued on the front panel and the “Cell Dirty” status
output(See Section 1.6.3) will be turned on. The cell assembly should then be cleaned to
avoid any degradation in measurement accuracy of the M450H.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 39
Figure 4.1 below shows the disassembly of the measurement cell for cleaning. The cell
can be easily disassembled after removing the (4) #8-32 screws from the rear of the
sensor assembly. The two sapphire Cell Windows and the Stainless Steel Cell Spacer can
be cleaned with isopropyl alcohol and rinsed with distilled water. Before reassembly,
inspect all three O-Rings to ensure that they are in good condition and replace if
necessary. After reassembly, the sensor should be leak checked.
FIGURE 4.1 MEASUREMENT CELL DISASSEMBLY
4.4 Degree of Protection
The Model 450NEMA has a water ingress rating of IPX66 which indicates that it can
withstand strong jets of water and is totally protected against dust.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 40
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 450H is calibrated using a wet chemistry method (double buffered KI) prior
to shipment. The M450H should operate for extended periods without calibration.
5.2 Changing the analog output range
5.2.1 Voltage output
Output voltage ranges are set by DIP switches on the V/F board. To change the range for
the analog output:
1. Turn off instrument power. Remove instrument cover. Locate the V/F board
near the front of the analyzer using Figure 1.6.
2. Locate switch S1, along the top edge of the card. Select the desired range per
Table 4.2 below.
3. Recalibrate the ADC as described in Section 5.3.
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
5.2.2 Current Output (Optional)
To configure the M450H 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.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 41
FIGURE 4.2- ANALOG OUTPUT JUMPERS
5.3 A/D - D/A Calibration Procedure
This procedure should be performed whenever a circuit board assembly is exchanged or
whenever the analog output voltage range is changed.
To calibrate the ADC, do the following:
1. Press SETUP-DIAG.
2. Enter Diagnostic password and press NEXT until D/A CALIBRATION
appears in the display and press ENTR.
3. Press ADC to perform the A/D Cal.
4. The M450H 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 M450H 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 M450H
display matches the value on the voltmeter to within +/- 2 mV. Note that
when adjusting R27, the value on the M450H display will change, the value
on the voltmeter will remain constant.
7. Press ENTR.
8. The M450H display will now read "ADJUST GAIN:A/D=xx.x MV.”
9. Adjust the Span Pot (R31) on the V/F card until the value on the M450H
display matches the value on the voltmeter to within +/- 2 mV.
10. Press ENTR.
11. The ADC is now calibrated and the M450H will automatically calibrate all the
DAC's. This process takes only a few seconds.
12. Press EXIT 3 times to return to the sample menu.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 42
5.4 Current Loop Calibration
A current loop option can be ordered that will provide a 0-20mA or 4-20mA output on
the analog output. This calibration must be repeated every time an A/D - D/A calibration
is performed. To calibrate the current output, perform the following steps:
1. Perform an A/D - D/A calibration as outlined in Section 5.3.
2. Connect a Multimeter capable of measuring milliamperes to the analog output
on the rear panel. Note: When measuring the current output with a
multimeter or similar low-impedance current measuring device, a 400450 ohm resistor must be placed in series with the meter to simulate a
load. Failure to do this will result in erroneous readings.
3. From the front panel, press SETUP-DIAG. Press NEXT until D/A
CALIBRATION appears and press ENTR. Press CFG and the properties for
analog output Channel 0 will be displayed on the top line. The display should
show something like:
DIAG D/A
NEXT
0) O3_CONC_1,CURR, NOT CAL
CAL
SET
EXIT
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. Pressing UP, UP10 and
U100 will step the zero point up in increments of 1, 10 and 100 steps. The
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 43
zero point can be adjusted anywhere between 0 and 4 milliamps. Press
ENTR when you have reached the desired zero point as measured by your test
meter.
7. The display will now prompt you to adjust the Gain, or full-scale output of the
current loop. Using the UP and DOWN buttons as in step 4, adjust the fullscale (usually 20ma) and press ENTR. This completes the current loop
calibration. Press EXIT several times until you are back at the sample menu.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 44
APPENDIX A – SOFTWARE MENU TREE
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 45
APPENDIX B – SPARE PARTS LIST
PART NO.
030360000
002760451
005140300
007040000
007280000
015610000
023480000
023620100
023900000
024040000
024740000
025710000
026490000
026540000
027010000
027020000
027030000
028260000
028320000
028330000
028340000
028350000
028510000
FM0000016
HW0000036
IC0000055
OP0000019
OR0000070
OR0000071
OR0000072
PS0000011
PS0000012
PU0000020
PU0000022
DESCRIPTION
Teledyne API Model 450H Spare Parts List
CPU Board (450H)
V/F Board
Keyboard
Display
I2C/Sub Mux, M450
Filter PAD, Ozone Scrubber
Rear Panel PCA, Single Channel
UV Lamp Supply
Power Supply Module, M450
Tubing: 6’, 1/4” CLR FEP
Measure Detector Preamp
Heater, Cartridge, 120V, 20W
Reference Detector Preamp
Sensor Assembly, M450
Assy, Auto Zero Valve
Assy, Needle Valve, Kalrez Seals
Manual, Instruction, M450H
Assy, Sample Filter, 25mm
Assy, Oxone Killer w/o Flow Switch
Assy, Thermistor, Cell & Lamp
Assy, UV Lamp (M450H)
Kit, 25mm Glass Filters (50)
Flowmeter, 0-2 LPM
TFE Thread Tape (48 FT)
Isolated Current Loop Driver, AD1B22N
Window Sapphire 3/4" x 2mm
Oring, Sensor Assy M450H
Oring,Sensor Assy M450H
Oring, Sensor Assy M450H
Switching PS, 40W, 5V,
Switching PS, 20W
Pump, 115V 50/60 Hz
Pump Rebuild Kit, KNF Model #NO5ATI
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 47
APPENDIX C - ELECTRICAL
SCHEMATIC INDEX
Drawing Number
00514
00515
00704
00705
0147802
01479
01561
01562
02322
02323
0236200
02363
02571
02572
02654
02655
03186
Title
V/F - I/O Card Assembly
V/F - I/O Card Schematic
Keyboard Assembly
Keyboard Schematic
Motherboard Assembly
Motherboard Schmatic
I2C/SubMux Assembly
I2C/SubMux Schematic
UV Lamp Supply Assembly
UV Lamp Supply Schematic
Rear Panel Assembly
Rear Panel Schematic
UV Detector Preamp PCA
UV Detector Preamp Schematic
O3 Sensor Preamp PCA
O3 Sensor Preamp Schematic
Interconnect Diagram
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 49