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: api-sales@teledyne.com WEB SITE: www.teledyne-api.com 02826 Rev.
SAFETY MESSAGES Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument.
TABLE OF CONTENTS SAFETY MESSAGES.................................................................................................................................... II TABLE OF CONTENTS ............................................................................................................................... III FIGURES ........................................................................................................................................................V TABLES.........................
5.3 A/D - D/A CALIBRATION PROCEDURE… ............................................................................................42 5.4 CURRENT LOOP CALIBRATION ............................................................................................................43 6.0 MODEL 450H SPARE PARTS…………………………………………………………………………. APPENDIX A - ELECTRICAL SCHEMATIC INDEX ...........................................................
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 .............................
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 ..........................................................................................
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.
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 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.
P/N 02826B1 Teledyne API Model 450H O3 Monitor Instruction Manual - Page 10
1.
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.
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.
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.
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.
FIGURE 1.
FIGURE 1.
FIGURE 1.
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).
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.
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.
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.
POWER SUPPLY MODULE Figure 1.
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.
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.
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.
2.0 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.
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.
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.
2.2.2 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.
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.
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.
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.
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".
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 Pr
