Teledyne 400E User Manual

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TECHNICAL MANUAL

MODEL 400E

PHOTOMETRIC OZONE ANALYZER

ADVANCED POLLUTION INSTRUMENTATION DIVISION (TAPI)

9480 CARROLL PARK DRIVE

SAN DIEGO, CALIFORNIA 92121-5201

USA

Toll-free Phone:	800-324-5190
Phone:	858-657-9800
Fax:	858-657-9816
Email:	api-sales@teledyne.com
Website:	http://www.teledyne-api.com/
Copyright 2007
Teledyne Advanced Pollution Instrumentation	04316 Rev. E
	DCN 5473
	16 June 2009

THIS PAGE IS INTENTIONALLY LEFT BLANK

M400E Ozone Analyzer Operator’s Manual	Table of Contents
TABLE OF CONTENTS
GENERAL INFORMATION ..................................................................................		1
1. INTRODUCTION ..................................................................................................................		3
1.1. Safety Messages............................................................................................................................................		3
1.2. M400E Overview............................................................................................................................................		4
1.3. Using This Manual .........................................................................................................................................		5
2. SPECIFICATIONS, APPROVALS AND WARRANTY .........................................................		7
2.1. Specifications.................................................................................................................................................		7
2.2. EPA Equivalency Designation .......................................................................................................................		9
2.3. CE Mark Compliance .....................................................................................................................................		9
2.4. Warranty.......................................................................................................................................................		10
3. GETTING STARTED ..........................................................................................................		11
3.1. Model 400E Analyzer Layout .......................................................................................................................		11
3.2. Unpacking the M400E analyzer...................................................................................................................		15
3.2.1.1. Ventilation Clearance .....................................................................................................................		16
3.3. Electrical Connections .................................................................................................................................		16
3.3.1. Power Connection..................................................................................................................................		16
3.3.2. Analog Output Connections...................................................................................................................		17
3.3.3. Connecting the Status Outputs..............................................................................................................		18
3.3.4. Connecting the Control Inputs ...............................................................................................................		19
3.3.5. Connecting the Serial Ports ...................................................................................................................		20
3.3.6. Connecting to a LAN or the Internet ......................................................................................................		20
3.3.7. Connecting to a Multidrop Network........................................................................................................		20
3.4. Pnenumatic Connections .............................................................................................................................		21
3.4.1. About Zero Air and Calibration Gas.......................................................................................................		21
3.4.2. Basic Pneumatic Setup for the M400E analyzer ...................................................................................		22
3.4.3. Pneumatic Setup for the M400E Analyzer with Internal Zero/Span Option (IZS) .................................		23
3.4.4. Pneumatic Setups for Ambient Air Monitoring with the M400E analyzer ..............................................		24
3.4.4.1. Pneumatic Set Up for M400E’s Located in the Same Room Being Monitored..............................		24
3.4.4.2. Pneumatic Set Up for M400E’s Monitoring Remote Locations ......................................................		25
3.5. Initial Operation............................................................................................................................................		26
3.5.1. Start Up..................................................................................................................................................		26
3.5.2. Warm Up................................................................................................................................................		27
3.5.3. Warning Messages ................................................................................................................................		27
3.5.4. Functional Check ...................................................................................................................................		29
3.6. Initial Calibration of the M400E Analyzer....................................................................................................		30
3.6.1. Interferents for O3 Measurement ...........................................................................................................		30
3.6.2. Initial Calibration Procedure for M400E analyzers without Options ......................................................		31
3.6.2.1. Verifying the M400E Reporting Range Settings.............................................................................		31
3.6.2.2. Verify the Expected O3 Span Gas Concentration:..........................................................................		32
3.6.2.3. Initial Zero/Span Calibration Procedure: ........................................................................................		33
3.7. Configuring the Internal Zero/Span Option (IZS).........................................................................................		34
3.7.1. Verify the O3 Generator and Expected O3	Span Concentration Settings:.............................................	34
3.7.2. Setting the O3 Generator Low-Span (Mid Point) Output Level ..............................................................		35
3.7.3. Turning on the Reference Detector Option............................................................................................		36
3.7.4. Initial Calibration and Conditioning OF M400E analyzers with the IZS Option Installed.......................		37
3.7.4.1. Initial O3 Scrubber Conditioning .....................................................................................................		37
3.7.4.2. Verifying the M400E Reporting Range Settings.............................................................................		38
3.7.4.3. Initial Zero/Span Calibration Procedure: ........................................................................................		38
3.7.4.4. Initiate Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3..................................		38
4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY ..................................................		41
4.1. FAQ’s ...........................................................................................................................................................		41
4.2. Glossary .......................................................................................................................................................		43

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Table of Contents	M400E Ozone Analyzer Operator’s Manual
5. OPTIONAL HARDWARE AND SOFTWARE.....................................................................		45
5.1. Optional Pumps (OPT 10 thr Opt 13)...........................................................................................................		45
5.2. Rack Mount Kits (OPT 20 to OPT 23)..........................................................................................................		46
5.3. Carrying Strap Handle (OPT 29)..................................................................................................................		46
5.4. Current Loop Analog Outputs (Opt 41)	........................................................................................................	47
5.4.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs...............................................		47
5.5. Spare Parts kits............................................................................................................................................		48
5.5.1. M400E Expendables Kit (OPT 42A) ......................................................................................................		48
5.5.2. M400E Spare Parts Kit for the IZS Option (OPT 43).............................................................................		48
5.6. Calibration Valve Options ............................................................................................................................		48
5.6.1. Zero/Span VALVES (Opt 50A) ..............................................................................................................		48
5.6.1.1. Pneumatic Setup for the M400E Analyzer with Zero/Span Valve Option ......................................		50
5.6.2. InternaL Zero Span (IZS) Option (OPT 51A).........................................................................................		52
5.6.2.1. Disposable Charcoal O3 Filter	........................................................................................................	53
5.6.3. Metal Wool Scrubber (Opt 68) ...............................................................................................................		53
5.6.4. IZS Desiccant (Option 56) .....................................................................................................................		53
5.7. Communication Options...............................................................................................................................		54
5.7.1. Extra COMM Cables..............................................................................................................................		54
5.7.1.1. RS232 Modem Cables (OPTs 60A and 60B).................................................................................		54
5.7.1.2. ETHERNET Cable (OPT 60C) .......................................................................................................		54
5.7.2. RS-232 Multidrop (OPT 62) ...................................................................................................................		54
5.7.3. Ethernet (OPT 63)..................................................................................................................................		55
5.7.4. Ethernet + Multidrop (OPT 63C)............................................................................................................		56
5.8. Additional Manual (OPT 70A & OPT 70B)...................................................................................................		56
OPERATING INSTRUCTIONS...........................................................................		57
6. BASIC OPERATION OF THE M400E ANALYZER...........................................................		59
6.1. Overview of Operating Modes .....................................................................................................................		59
6.2. Sample Mode...............................................................................................................................................		60
6.2.1. Test Functions .......................................................................................................................................		60
6.2.2. Warning Message Display .....................................................................................................................		61
6.3. Calibration Mode..........................................................................................................................................		63
6.4. SETUP Mode ...............................................................................................................................................		64
6.4.1. SETUP  CFG: Configuration Information ...........................................................................................		65
6.4.2. SETUP  PASS: Enabling/Disabling Passwords .................................................................................		66
6.4.3. SETUP  CLK: Setting the M400E Analyzer’s Internal Clock..............................................................		68
6.4.3.1. Setting the internal Clock’s Time and Day .....................................................................................		68
6.4.3.2. Adjusting the internal Clock’s speed ..............................................................................................		69
6.4.4. SETUP  RNGE: Analog Output Reporting Range Configuration.......................................................		70
6.4.4.1. Physical Range versus Analog Output Reporting Ranges.............................................................		70
6.4.4.2. Analog Output Ranges for O3	Concentration .................................................................................	70
6.4.4.3. RNGE  MODE  SNGL: Configuring the M400E analyzer for Single Range Mode..................		72
6.4.4.4. RNGE  MODE  DUAL: Configuring the M400E analyzer for Dual Range Mode ...................		73
6.4.4.5. RNGE  MODE  AUTO: Configuring the M400E analyzer for Auto Range Mode ....................		74
6.4.4.6. SETUP  RNGE  UNIT: Setting the Reporting range Unit Type...............................................		75
7. ADVANCED FEATURES OF THE M400E ANALYZER ....................................................		77
7.1. Using Using the Data Acquisition System (iDAS)........................................................................................		77
7.1.1. IDAS STATUS .......................................................................................................................................		77
7.1.2. iDAS Structure .......................................................................................................................................		78
7.1.3. iDAS Channels.......................................................................................................................................		78
7.1.3.1. Default iDAS Channels...................................................................................................................		79
7.1.4. SETUP DAS VIEW: Viewing iDAS Channels and Individual Records ..........................................		81
7.1.5. SETUP DAS EDIT: Accessing the iDAS Edit Mode ......................................................................		82
7.1.5.1. Editing iDAS Data Channel Names................................................................................................		83
7.1.5.2. Editing iDAS Triggering Events ......................................................................................................		84
7.1.5.3. Editing iDAS Parameters................................................................................................................		85
7.1.5.4. Editing Sample Period and Report Period......................................................................................		87
7.1.5.5. Report periods in Progress when Instrument Is Powered Off........................................................		88
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7.1.5.6. Editing the Number of Records ......................................................................................................	89
7.1.5.7. RS-232 Report Function.................................................................................................................	90
7.1.5.8. Enabling / Disabling the HOLDOFF Feature..................................................................................	91
7.1.5.9. The Compact Report Feature.........................................................................................................	92
7.1.5.10. The Starting Date Feature............................................................................................................	92
7.1.6. Disabling/Enabling Data Channels ........................................................................................................	92
7.1.7. Remote iDAS Configuration...................................................................................................................	93
7.2. SETUP  MORE  VARS: Internal Variables (VARS)..............................................................................	94
7.3. SETUP  MORE  DIAG :The Diagnostic Menu ......................................................................................	96
7.4. Using the Model 400E Analyzer’s Analog Outputs......................................................................................	98
7.4.1. Adjusting & Calibrating the Analog Output Signals ...............................................................................	98
7.4.2. Calibration of the Analog Outputs.......................................................................................................	100
7.4.2.1. Enabling or Disabling the AutoCal for an Individual Analog Output............................................	100
7.4.2.2. Automatic Calibration of the Analog Outputs ..............................................................................	101
7.4.2.3. Manual Calibration of the Analog Outputs configured for Voltage Ranges.................................	103
7.4.2.4. Manual Adjustment of Current Loop Output Span and Offset ....................................................	105
7.4.3. Analog Output Voltage / Current Range Selection .............................................................................	108
7.4.4. Turning an analog output Over-Range Feature ON/OFF...................................................................	109
7.4.5. Adding a Recorder Offset to an analog output ...................................................................................	110
7.4.6. Selecting a Test Channel Function for Output A4 ..............................................................................	111
7.4.7. AIN Calibration....................................................................................................................................	113
8. REMOTE OPERATION OF THE M400E..........................................................................	115
8.1. Using the Analyser’s Communication Ports..............................................................................................	115
8.1.1. RS-232 DTE and DCE Communication..............................................................................................	115
8.1.2. COMM Port Default Settings and Connector Pin Assignments..........................................................	116
8.1.3. COMM Port Baud Rate.......................................................................................................................	118
8.1.4. COMM Port Communication Modes...................................................................................................	119
8.1.5. COMM Port Testing ............................................................................................................................	121
8.1.6. Machine ID..........................................................................................................................................	122
8.1.7. Terminal Operating Modes .................................................................................................................	123
8.1.7.1. Help Commands in Terminal Mode.............................................................................................	123
8.1.7.2. Command Syntax ........................................................................................................................	124
8.1.7.3. Data Types ..................................................................................................................................	124
8.1.7.4. Status Reporting..........................................................................................................................	125
8.1.7.5. COMM Port Password Security...................................................................................................	126
8.2. Remote Access by Modem .......................................................................................................................	127
8.2.1. Multidrop RS-232 Set Up....................................................................................................................	129
8.3. RS-485 Configuration of COM2................................................................................................................	131
8.4. Remote Access via the Ethernet...............................................................................................................	133
8.4.1. Ethernet Card COM2 Communication Modes and Baud Rate...........................................................	133
8.4.2. Configuring the Ethernet Interface Option using DHCP .....................................................................	133
8.4.2.1. Manually Configuring the Network IP Addresses........................................................................	136
8.4.3. Changing the Analyzer’s HOSTNAME ...............................................................................................	138
8.5. Using the M400E with a Hessen Protocol Network ..................................................................................	139
8.5.1. General Overview of Hessen Protocol................................................................................................	139
8.5.2. Hessen COMM Port Configuration .....................................................................................................	139
8.5.3. Activating Hessen Protocol.................................................................................................................	140
8.5.4. Selecting a Hessen Protocol Type......................................................................................................	141
8.5.5. Setting The Hessen Protocol Response Mode...................................................................................	142
8.5.6. Hessen Protocol Gas List Entries .......................................................................................................	143
8.5.6.1. Gas List Entry Format and Definitions.........................................................................................	143
8.5.6.2. Editing or Adding HESSEN Gas List Entries...............................................................................	144
8.5.6.3. Deleting HESSEN Gas List Entries .............................................................................................	145
8.5.7. Setting Hessen Protocol Status Flags ................................................................................................	146
8.5.8. Instrument ID Code.............................................................................................................................	147
8.6. APICOM Remote Control Program...........................................................................................................	148

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Table of Contents	M400E Ozone Analyzer Operator’s Manual
9. M400E CALIBRATION PROCEDURES...........................................................................			149
9.1. Before Calibration .....................................................................................................................................			150
9.1.1. Required Equipment, Supplies, and Expendables .............................................................................			150
9.1.2. Zero Air and Span Gas .......................................................................................................................			150
9.2. Basic Manual Calibration Checks And Calibration of the M400E analyzer ..............................................			151
9.2.1. Setup for Basic Calibration Checks and Calibration of the M400E analyzer......................................			151
9.2.2. Performing a Basic Manual Calibration Check ...................................................................................			152
9.2.3. Performing a Basic Manual Calibration ..............................................................................................			153
9.2.3.1. Setting the expected O3	Span Gas concentration.......................................................................		153
9.2.3.2. Zero/Span Point Calibration Procedure.......................................................................................			154
9.2.4. Manual Calibration Checks and Calibrations Using AUTO RANGE or DUAL RANGE Modes			.......... 155
9.3. Manual Calibration Check and Calibration with Valve Options Installed..................................................			156
9.3.1. Setup for Calibration Checks and Calibration with Valve Options Installed. ......................................			156
Manual Calibration Checks with Valve Options Installed .............................................................................			158
9.3.2. Manual Calibration Using Valve Options ............................................................................................			159
9.3.2.1. Setting the Expected O3	Span Gas Concentration with the Z/S Option Installed .......................		160
9.3.2.2. Zero/Span Point Calibration Procedure the Z/S Option Installed................................................			161
9.3.2.3. Use of Zero/Span Valve with Remote Contact Closure ..............................................................			162
9.4. Automatic Zero/Span Cal/Check (AutoCal) ..............................................................................................			162
9.4.1. SETUP  ACAL: Programming and AUTO CAL Sequence..............................................................			164
9.5. O3 Photometer Electronic Calibration ......................................................................................................			167
9.5.1. Photometer Dark Calibration	..............................................................................................................		167
9.5.2. O3 Photometer Gas Flow Calibration..................................................................................................			168
9.6. Calibration the IZS Option O3 Generator ..................................................................................................			169
10. EPA PROTOCOL CALIBRATION .................................................................................			171
10.1.1. M400E Calibration – General Guidelines .........................................................................................			171
10.1.2. Calibration Equipment, Supplies, and Expendables.........................................................................			172
10.1.3. Calibration Gas and Zero Air Sources..............................................................................................			172
10.1.4. Recommended Standards for Establishing Traceability...................................................................			173
10.1.5. Calibration Frequency.......................................................................................................................			174
10.1.6. Data Recording Device.....................................................................................................................			174
10.1.7. Record Keeping ................................................................................................................................			174
10.2. Level 1 Calibrations versus Level 2 Checks...........................................................................................			175
10.3. Multipoint Calibration ..............................................................................................................................			175
10.3.1. General information ..........................................................................................................................			175
10.3.2. Multipoint Calibration Procedure.......................................................................................................			176
10.3.3. Dynamic Multipoint Calibration Check..............................................................................................			177
10.3.4. Linearity Test ....................................................................................................................................			177
10.3.5. O3 Loss Correction Factor ................................................................................................................			179
10.3.6. Span Drift Check...............................................................................................................................			179
10.4. Auditing Procedures ...............................................................................................................................			179
10.4.1. Multipoint Calibration Audit ...............................................................................................................			180
10.4.2. Data Processing Audit ......................................................................................................................			180
10.4.3. System Audit.....................................................................................................................................			181
10.4.4. Assessment of Monitoring Data for Precision and Accuracy............................................................			181
10.5. Summary of Quality Assurance Checks .................................................................................................			181
10.6. References .............................................................................................................................................			185
TECHNICAL INFORMATION...........................................................................			186
11. THEORY OF OPERATION ............................................................................................			189
11.1. Measurement Method.............................................................................................................................			189
11.1.1. Calculating O3 Concentration...........................................................................................................			189
11.1.2. The Photometer UV Absorption Path ...............................................................................................			191
11.1.3. The Reference / Measurement Cycle...............................................................................................			192
11.1.4. Interferent Rejection .........................................................................................................................			193
11.2. Pneumatic Operation ..............................................................................................................................			194
11.2.1. Sample Gas Air Flow ........................................................................................................................			194
11.2.2. Flow Rate Control .............................................................................................................................			195
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M400E Ozone Analyzer Operator’s Manual	Table of Contents
11.2.2.1. Critical Flow Orifice....................................................................................................................	195
11.2.3. Particulate Filter................................................................................................................................	196
11.2.4. Pneumatic Sensors...........................................................................................................................	196
11.2.4.1. Sample Pressure Sensor ..........................................................................................................	196
11.2.4.2. Sample Flow Sensor .................................................................................................................	196
11.3. Electronic Operation ...............................................................................................................................	197
11.3.1. Overview ...........................................................................................................................................	197
11.3.2. CPU ..................................................................................................................................................	198
11.3.3. Motherboard......................................................................................................................................	198
11.3.3.1. A to D Conversion .....................................................................................................................	198
11.3.3.2. Sensor Inputs ............................................................................................................................	199
11.3.3.3. Thermistor Interface ..................................................................................................................	199
11.3.3.4. Analog Outputs..........................................................................................................................	200
11.3.3.5. External Digital I/O.....................................................................................................................	200
11.3.3.6. I2C Data Bus..............................................................................................................................	200
11.3.3.7. Power Up Circuit........................................................................................................................	200
11.3.4. Relay PCA ........................................................................................................................................	200
11.3.4.1. Status LED’s..............................................................................................................................	203
11.3.4.2. Watchdog Circuitry ....................................................................................................................	203
11.3.4.3. Valve Control .............................................................................................................................	204
11.3.4.4. Heater Control ...........................................................................................................................	204
11.3.4.5. Thermocouple Inputs and Configuration Jumper (JP5) ............................................................	205
11.3.5. Power Supply/Circuit Breaker...........................................................................................................	206
11.3.5.1. Power Switch/Circuit Breaker....................................................................................................	206
11.3.6. AC Power Configuration ...................................................................................................................	207
11.3.6.1. AC configuration – Internal Pump (JP7)....................................................................................	208
11.3.6.2. AC Configuration – Heaters for Option Packages (JP6)...........................................................	209
11.3.7. Photometer Layout and Operation....................................................................................................	210
11.3.7.1. Photometer Electronic Operation ..............................................................................................	211
11.3.7.2. O3 Photometer UV Lamp Power Supply ...................................................................................	212
11.3.7.3. Photometer Temperature ..........................................................................................................	213
11.3.7.4. Photometer Gas Pressure and Flow Rate.................................................................................	213
11.4. Interface..................................................................................................................................................	214
11.4.1. Front Panel .......................................................................................................................................	214
11.4.1.1. Front Panel Display ...................................................................................................................	215
11.4.1.2. Keypad ......................................................................................................................................	215
11.4.1.3. Front Panel States LED’s ..........................................................................................................	215
11.5. Software Operation.................................................................................................................................	216
11.5.1. Adaptive Filter ...................................................................................................................................	216
11.5.2. Calibration - Slope and Offset...........................................................................................................	217
12. MAINTENANCE SCHEDULE & PROCEDURES ..........................................................	219
12.1. Predicting Failures Using the Test Functions.........................................................................................	219
12.2. Maintenance Schedule ...........................................................................................................................	220
12.3. Maintenance Procedures........................................................................................................................	223
12.3.1. Replacing the Sample Particulate Filter............................................................................................	223
12.3.2. Rebuilding the Sample Pump ...........................................................................................................	224
12.3.3. Replacing the IZS Option Zero Air Scrubber ....................................................................................	224
12.3.4. Performing Leak Checks ..................................................................................................................	225
12.3.4.1. Vacuum Leak Check and Pump Check.....................................................................................	225
12.3.4.2. Pressure Leak Check ................................................................................................................	225
12.3.5. Performing a Sample Flow Check ....................................................................................................	226
12.3.6. Maintenance of the Photometer Absorption Tube............................................................................	227
12.3.6.1. Cleaning or Replacing the Absorption Tube .............................................................................	227
12.3.6.2. UV Lamp Adjustment.................................................................................................................	228
12.3.6.3. UV Lamp Replacement .............................................................................................................	229
12.3.7. Adjustment or Replacement of Optional IZS Ozone Generator UV Lamp .......................................	230

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Table of Contents	M400E Ozone Analyzer Operator’s Manual
13. GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER................		233
13.1. General Troubleshooting ........................................................................................................................		233
13.1.1. Fault Diagnosis with WARNING Messages......................................................................................		234
13.1.2. Fault Diagnosis With Test Functions ................................................................................................		236
13.1.3. DIAG  SIGNAL I/O: Using the Diagnostic Signal I/O Function ....................................................		237
13.2. Using the Analog Output Test Channel ..................................................................................................		239
13.3. Using the Internal Electronic Status LEDs..............................................................................................		240
13.3.1. CPU Status Indicator ........................................................................................................................		240
13.3.2. Relay PCA Status LED s ..................................................................................................................		240
13.3.2.1. I2C Bus Watchdog Status LEDs ................................................................................................		240
13.3.2.2. O3 Option Status LED s.............................................................................................................		241
13.4. Gas Flow Problems ................................................................................................................................		242
13.4.1. Typical Flow Problems......................................................................................................................		242
13.4.1.1. Flow is Zero ...............................................................................................................................		242
13.4.1.2. Low Flow ...................................................................................................................................		242
13.4.1.3. High Flow...................................................................................................................................		243
13.4.1.4. Actual Flow Does Not Match Displayed Flow ...........................................................................		243
13.4.1.5. Sample Pump ............................................................................................................................		243
13.5. Calibration Problems ..............................................................................................................................		243
13.5.1. Mis-Calibrated...................................................................................................................................		243
13.5.2. Non-Repeatable Zero and Span.......................................................................................................		243
13.5.3. Inability to Span – No Span Key (CALS) ..........................................................................................		244
13.5.4. Inability to Zero – No Zero Key (CALZ) ............................................................................................		244
13.6. Other Performance Problems.................................................................................................................		244
13.6.1. Temperature Problems .....................................................................................................................		244
13.6.1.1. Box Temperature.......................................................................................................................		244
13.6.1.2. Sample Temperature.................................................................................................................		244
13.6.1.3. UV Lamp Temperature..............................................................................................................		245
13.6.1.4. IZS Ozone Generator Temperature (Optional) .........................................................................		245
13.7. Subsystem Checkout..............................................................................................................................		246
13.7.1. AC Main Power.................................................................................................................................		246
13.7.2. DC Power Supply..............................................................................................................................		246
13.7.3. I2C Bus..............................................................................................................................................		247
13.7.4. Keyboard/Display Interface...............................................................................................................		248
13.7.5. Relay PCA ........................................................................................................................................		248
13.7.6. Photometer Pressure /Flow Sensor Assembly .................................................................................		249
13.7.7. Motherboard......................................................................................................................................		250
13.7.7.1. Test Channel / Analog Outputs Voltage....................................................................................		250
13.7.7.2. A/D Functions ............................................................................................................................		251
13.7.7.3. Status Outputs...........................................................................................................................		251
13.7.7.4. Control Inputs ............................................................................................................................		252
13.7.8. CPU ..................................................................................................................................................		252
13.7.9. RS-232 Communications..................................................................................................................		253
13.7.9.1. General RS-232 Troubleshooting..............................................................................................		253
13.7.9.2. Troubleshooting Analyzer/Modem or Terminal Operation ........................................................		253
13.8. Trouble Shooting the photometer ...........................................................................................................		254
13.8.1. Checking Measure / Reference Valve ..............................................................................................		254
13.8.2. Checking The Photometer UV Lamp Power Supply.........................................................................		254
13.9. Trouble Shooting the IZS Options O3 generator.....................................................................................		255
13.9.1. Checking The O3 Generator UV Lamp Power Supply......................................................................		255
13.10. Repair Procedures ...............................................................................................................................		256
13.10.1. Repairing Sample Flow Control Assembly .....................................................................................		256
13.10.2. Replacing The Standard Reference O3 Scrubber ..........................................................................		257
13.10.3. Replacing the IZS O3 Scrubber ......................................................................................................		257
13.10.4. Metal Wool Scrubber Option...........................................................................................................		258
13.10.5. Disk-On-Chip Replacement Procedure ..........................................................................................		258
13.11. Technical Assistance............................................................................................................................		258

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14. A PRIMER ON ELECTRO-STATIC DISCHARGE.........................................................			259
14.1. How Static Charges are Created............................................................................................................			259
14.2. How Electro-Static Charges Cause Damage .........................................................................................			260
14.3. Common Myths About ESD Damage .....................................................................................................			261
14.4. Basic Principles of Static Control............................................................................................................			261
14.4.1. General Rules ...................................................................................................................................			261
14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance .................................................			263
14.4.2.1. Working at the Instrument Rack ................................................................................................			263
14.4.2.2. Working at an Anti-ESD Work Bench........................................................................................			263
14.4.2.3. Transferring Components from Rack to Bench and Back.........................................................			264
14.4.2.4. Opening Shipments from Teledyne Instruments’ Customer Service. .......................................			264
14.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service..........................			265
LIST OF FIGURES
Figure 3-1:	M400E Front Panel Layout ..........................................................................................................		11
Figure 3-2:	M400E Rear Panel Layout – Basic Version ................................................................................		12
Figure 3-3:	M400E Rear Panel Layout with Internal Zero/Span (IZS) Option (OPT-51A).............................		12
Figure 3-4:	M400E Internal Layout – Top View with IZS Option....................................................................		13
Figure 3-5:	M400E Pneumatic Diagram – Basic Unit.....................................................................................		14
Figure 3-6:	M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) ...........................		14
Figure 3-7:	M400E Analog Output Connector................................................................................................		17
Figure 3-8:	Status Output Connector .............................................................................................................		18
Figure 3-9:	Energizing the M400E Control Inputs..........................................................................................		19
Figure 3-10:	Gas Line Connections for the M400E Analyzer – Basic Configuration .......................................		22
Figure 3-11:	Gas Line Connections for the M400E Analyzer with IZS Option (OPT-51A) ..............................		23
Figure 3-12:	Gas Line Connections when the M400E Analyzer is Located in the Room Being Monitored.....		24
Figure 3-13:	Gas Line Connections when the M400E Analyzer is Monitoring a Remote Location .................		25
Figure 5-1:	M400E with Carrying Strap Handle and Rack Mount Brackets...................................................		46
Figure 5-2:	Current Loop Option Installed......................................................................................................		47
Figure 5-3:	M400E Pneumatic Diagram with Zero/Span Valve Option (OPT-50A) .......................................		48
Figure 5-4:	M400E Rear Panel Layout with Zero/Span Valve Option (OPT-50A) .........................................		49
Figure 5-5:	Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) .........		50
Figure 5-6:	M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) ...........................		52
Figure 5-7:	M400E Multidrop Card.................................................................................................................		54
Figure 5-8:	M400E Ethernet Card ..................................................................................................................		55
Figure 5-9:	M400E Rear Panel with Ethernet Installed..................................................................................		55
Figure 6-1:	Location of Mode field on M400E Analyzer Display ....................................................................		59
Figure 6-2:	Viewing M400E Test Functions ...................................................................................................		60
Figure 6-3:	Analog Output Connector Pin Out ...............................................................................................		70
Figure 7-1:	Default M400E iDAS Channels Setup .........................................................................................		80
Figure 7-2:	APICOMuser interface for configuring the iDAS..........................................................................		93
Figure 7-3:	Accessing the DIAG Submenus ..................................................................................................		97
Figure 7-4:	Accessing the Analog I/O Configuration Submenus....................................................................		99
Figure 7-5:	Setup for Calibrating An............................................................................................................		103
Figure 7-6:	Setup for Checking Current Output Signal Levels....................................................................		105
Figure 7-7:	Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ...............		107
Figure 8-1:	Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) .......		116
Figure 8-2:	Defaul Pin Assignments for CPU COM Port connector (RS-232). ...........................................		117
Figure 8-3:	Location of JP2 on RS232-Multidrop PCA (option 62) .............................................................		129
Figure 8-4:	RS232-Multidrop PCA Host/Analyzer Interconnect Diagram ...................................................		130
Figure 8-5:	CPU card Locations of RS-232/485 Switches, Connectors and Jumpers................................		131
Figure 8-6:	Back Panel connector Pin-Outs for COM2 in RS-485mode.....................................................		132
Figure 8-7:	CPU connector Pin-Outs for COM2 in RS-485 mode...............................................................		132
Figure 8-8:	APICOM Remote Control Program Interface ...........................................................................		148
Figure 9-1:	Pneumatic connections for Manual Calibration Checks without Z/S Valve	or IZS Options.....	151
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Figure 9-2:	Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) ......		157
Figure 9-3:	Gas Line Connections for the M400E Analyzer with IZS Options (OPT-51A)..........................		157
Figure 11-1:	O3	Absorption Path ...................................................................................................................	191
Figure 11-2:	Reference / Measurement Gas Cycle.......................................................................................		192
Figure 11-3:	M400E Pneumatic Diagram – Basic Unit..................................................................................		194
Figure 11-4:	Flow Control Assembly & Critical Flow Orifice .........................................................................		195
Figure 11-5:	M400E Electronic Block Diagram .............................................................................................		197
Figure 11-6:	Relay PCA Layout (P/N 04523-0100).......................................................................................		201
Figure 11-7:	Relay PCA P/N 045230100 with Safety Shield In Place ..........................................................		202
Figure 11-8:	Relay PCA P/N 045230200 with AC Relay Retainer in Place..................................................		202
Figure 11-9:	Status LED Locations – Relay PCA..........................................................................................		203
Figure 11-10:	Heater Control Loop Block Diagram.........................................................................................		204
Figure 11-11:	Thermocouple Configuration Jumper (JP5) Pin-Outs...............................................................		205
Figure 11-12:	Power Distribution Block Diagram ............................................................................................		206
Figure 11-13:	Location of AC power Configuration Jumpers ..........................................................................		207
Figure 11-14:	Pump AC Power Jumpers (JP7)...............................................................................................		208
Figure 11-15:	Typical Jumper Set (JP2) Set Up of Optional Metal Wool Scrubber Heater ............................		209
Figure 11-16:	O3 Photometer Layout – Top Cover Removed.........................................................................		210
Figure 11-17:	O3 Photometer Electronic Block Diagram.................................................................................		211
Figure 11-18:	O3	Photometer UV Lamp Power Supply Block Diagram ..........................................................	212
Figure 11-19:	Interface Block Diagram ...........................................................................................................		214
Figure 11-20:	Front Panel ...............................................................................................................................		214
Figure 11-21:	Basic Software Operation .........................................................................................................		216
Figure 12-1	Replacing the Particulate Filter.................................................................................................		223
Figure 12-2	Replacing the IZS Zero Air Scrubber........................................................................................		224
Figure 12-3:	Optical Bench – Lamp Adjustment/ Installation ........................................................................		229
Figure 12-4:	O3 Generator Temperature Thermistor and DC Heater Locations...........................................		230
Figure 12-5:	Location of O3 Generator Reference Detector Adjustment Pot ................................................		230
Figure 13-1:	Example of Signal I/O Function ................................................................................................		238
Figure 13-2:	CPU Status Indicator ................................................................................................................		240
Figure 13-3:	Relay PCA Status LEDS Used for Troubleshooting .................................................................		241
Figure 13-4:	Location of DC Power Test Points on Relay PCA ....................................................................		247
Figure 13-5:	Critical Flow Orifice Assembly (Instruments without IZS).........................................................		256
Figure 13-6:	IZS O3 Generator Zero Air Scrubber Location..........................................................................		257
Figure 14-1:	Triboelectric Charging...............................................................................................................		259
Figure 14-2:	Basic anti-ESD Work Station ....................................................................................................		261

LIST OF TABLES
Table 2-1:	Model 400E Basic Unit Specifications ...........................................................................................	7
Table 2-2:	Model 400E IZS Generator Specifications with Reference Feedback Option..............................	8
Table 2-3:	Specifications for Model 400E IZS Generator w/o Reference Feedback Option .........................	8
Table 2-4:	Software Settings for EPA Equivalence.........................................................................................	9
Table 3-1:	Front Panel Nomenclature...........................................................................................................	11
Table 3-2:	M400E Analyzer Gas Inlet/Outlet Nomenclature.........................................................................	13
Table 3-3:	Ventilation Clearance...................................................................................................................	16
Table 3-4:	Analog Output Pin Outs ...............................................................................................................	17
Table 3-5:	Status Output Pin Assignments ...................................................................................................	18
Table 3-6:	Control Input Pin Assignments ....................................................................................................	19
Table 3-7:	Front Panel Display during System Warm-Up.............................................................................	27
Table 3-8:	Possible Warning Messages at Start-Up.....................................................................................	28
Table 3-9:	AUTOCAL Settings for Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3 .....	38
Table 5-1:	Zero/Span Valve Operating States..............................................................................................	49
Table 5-2:	Internal Zero/Span Valve Operating States.................................................................................	53
Table 6-1:	Analyzer Operating Modes ..........................................................................................................	59

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Table 6-2:	Test Functions Defined................................................................................................................		61
Table 6-3:	Warning Messages Defined.........................................................................................................		62
Table 6-4:	Primary Setup Mode Features and Functions .............................................................................		64
Table 6-5:	Secondary Setup Mode Features and Functions ........................................................................		64
Table 6-6:	Password Levels..........................................................................................................................		66
Table 7-1:	Front Panel LED Status Indicators for iDAS................................................................................		77
Table 7-2:	iDAS Data Channel Properties ....................................................................................................		78
Table 7-3:	iDAS Data Parameter Functions..................................................................................................		85
Table 7-4:	Variable Names (VARS) ..............................................................................................................		94
Table 7-5:	Diagnostic Mode (DIAG) Functions .............................................................................................		96
Table 7-6:	DIAG - Analog I/O Functions .......................................................................................................		98
Table 7-7:	Voltage Tolerances for the TEST CHANNEL Calibration.........................................................		103
Table 7-8:	Current Loop Output Check......................................................................................................		107
Table 7-9:	Analog Output Voltage Range Min/Max ...................................................................................		108
Table 7-10:	Test Channels Functions available on the M400E’s Analog Output ........................................		111
Table 8-1:	COMM Port Communication Modes .........................................................................................		119
Table 8-2:	Terminal Mode Software Commands .......................................................................................		123
Table 8-3:	Teledyne Instruments Serial I/O Command Types...................................................................		124
Table 8-4:	Ethernet Status Indicators ........................................................................................................		133
Table 8-5:	LAN/Internet Configuration Properties......................................................................................		134
Table 8-6:	RS-232 Communication Parameters for Hessen Protocol .......................................................		139
Table 8-7:	Teledyne Instruments Hessen Protocol Response Modes ......................................................		142
Table 8-8:	Default Hessen Status Bit Assignments ...................................................................................		146
Table 9-1:	AUTOCAL Modes .....................................................................................................................		162
Table 9-2:	AutoCal Attribute Setup Parameters.........................................................................................		163
Table 9-3:	Example AutoCal Sequence.....................................................................................................		163
Table 10-1:	Daily Activity Matrix...................................................................................................................		183
Table 10-2:	Activity Matrix for Audit Procedure............................................................................................		183
Table 10-3:	Activity Matrix for Data Reduction, Validation and Reporting...................................................		184
Table 10-4:	Activity Matrix for Calibration Procedures.................................................................................		184
Table 11-1:	Relay PCA Status LED’s ..........................................................................................................		203
Table 11-2:	Thermocouple Configuration Jumper (JP5) Pin-Outs...............................................................		205
Table 11-3:	Thermocouple Settings for Optional Metal Wool Scrubber ......................................................		205
Table 11-4:	AC Power Configuration for Internal Pumps (JP7) ...................................................................		208
Table 11-5:	Power Configuration for Optional Metal Wool Scrubber Heater (JP6) .....................................		209
Table 11-6:	Front Panel Status LED’s .........................................................................................................		215
Table 12-1:	Predictive Uses for Test Functions ...........................................................................................		219
Table 12-2:	M400E Maintenance Schedule.................................................................................................		221
Table 13-1:	Front Panel Warning Messages ...............................................................................................		235
Table 13-2:	Test Functions - Indicated Failures...........................................................................................		237
Table 13-3:	Test Channel Outputs as Diagnostic Tools ..............................................................................		239
Table 13-4:	Relay PCA Watchdog LED Failure Indications.........................................................................		240
Table 13-5:	Relay PCA Status LED Failure Indications...............................................................................		241
Table 13-6:	DC Power Test Point and Wiring Color Codes.........................................................................		246
Table 13-7:	DC Power Supply Acceptable Levels .......................................................................................		247
Table 13-8:	Relay PCA Control Devices......................................................................................................		248
Table 13-9:	Analog Output Test Function - Nominal Values Voltage Outputs ............................................		250
Table 13-10:	Status Outputs Check...............................................................................................................		251
Table 13-11:	M400E Control Input Pin Assignments and Corresponding Signal I/O Functions ...................		252
Table 14-1:	Static Generation Voltages for Typical Activities ......................................................................		259
Table 14-2:	Sensitivity of Electronic Devices to Damage by ESD ...............................................................		260

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M400E Ozone Analyzer Operator’s Manual

LIST OF APPENDICES

APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX A-1: Model 400E Software Menu Trees, Revision D.4

APPENDIX A-2: Model 400E Setup Variables Available Via Serial I/O, Revision D.4 APPENDIX A-3: Model 400E Warnings and Test Measurements via Serial I/O, Revision D.4 APPENDIX A-4: Model 400E Signal I/O Definitions, Revision D.4

APPENDIX A-5: Model M400E IDAS Functions, Revision D.4

APPENDIX A-6: Model M400E Terminal Command Designators, Revision D.4 APPENDIX B - M400E SPARE PARTS LIST

APPENDIX C - REPAIR QUESTIONNAIRE - M400E APPENDIX D - ELECTRONIC SCHEMATICS

USER NOTES:

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General Information

SECTION I

–

GENERAL INFORMATION

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General Information

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USER NOTES

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Introduction

1. INTRODUCTION

1.1. SAFETY MESSAGES

Your safety and the safety of others are 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 M400E Photometric Ozone Analyzer. The definition of these symbols is described below:

General Safety Hazard: Refer to the instructions for details on the specific hazard.

CAUTION: Hot Surface Hazard.

CAUTION: Electrical Shock Hazard.

TECHNICIAN SYMBOL: All operations marked with this symbol are to be performed by qualified maintenance personnel only.

NOTE

Technical Assistance regarding the use and maintenance of the M400E or any other Teledyne Instruments product

can be obtained by:

Contacting Teledyne Instruments’ Customer Service Department at 800-324-5190

Via the internet at http://www.teledyne-api.com/

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M400E Ozone Analyzer Operator’s Manual

1.2. M400E OVERVIEW

The Model 400E photometric ozone analyzer is a microprocessor-controlled analyzer that measures low ranges of ozone in ambient air using a method based on the Beer-Lambert law, an empirical relationship that relates the absorption of light to the properties of the material through which the light is traveling over a given distance.

The intensity of an ultra violate light is measured after it passes through a chamber, called the sample cell, where it is absorbed in proportion to the amount of ozone present. Every three seconds, a switching valve alternates measurement between a gas stream containing ozone and a stream that has been scrubbed of ozone.

The analyzer also measures the ambient temperature and pressure of the gas being measured. Using results of these measurements and the Beer-Lambert equation, the M400E analyzer calculates the amount of ozone present in the sampler gas.

The M400E analyzer’s multi-tasking software gives the ability to track and report a large number of operational parameters in real time. These readings are compared to diagnostic limits kept in the analyzers memory and should any fall outside of those limits the analyzer issues automatic warnings.

Built-in data acquisition capability, using the analyzer's internal memory, allows the logging of multiple parameters including averaged or instantaneous concentration values, calibration data, and operating parameters such as pressure and flow rate. Stored data are easily retrieved through the serial port or optional Ethernet port via our APICOM software or from the front panel, allowing operators to perform predictive diagnostics and enhanced data analysis by tracking parameter trends. Multiple averaging periods of one minute to 365 days are available for over a period of one year.

Some of the exceptional features of your M400E photometric ozone analyzer are:

Ranges, 0-100 ppb to 0-10 ppm, user selectable

Single pass ultraviolet absorption

Microprocessor controlled for versatility

Multi-tasking software allows viewing of test variables during operation

Continuous self checking with alarms

Dual bi-directional RS-232 ports for remote operation (optional RS-485 or Ethernet)

Digital status outputs provide instrument operating condition

Adaptive signal filtering optimizes response time

Optional Internal Zero/Span check and dual span points

Temperature & Pressure compensation

Internal data logging with 1 min to 365 day multiple averages

Several options can be purchased for the analyzer that allows the user to more easily supply and manipulate Zero Air and Span Gas. For more information of these options, see Sections 5.6.1and 5.6.2.

CAUTION

General Safety Hazard

The M400E Photometric Ozone Analyzer should only be used for the purpose and in the manner described in this manual. If you use the M400E in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences.

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Introduction

1.3. USING THIS MANUAL

NOTE

Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent messages as they appear on the analyzer’s display.

This manual is organized in the following manner:

TABLE OF CONTENTS:

Outlines the contents of the manual in the order the information are presented. This is a good overview of the topics covered in the manual. There is also a list of appendices, figures and tables.

SECTION I – GENERAL INFORMATION

INTRODUCTION

A brief description of the M400E analyzer architecture as well as a description of the layout of the manual and what information is located in its various sections and chapters.

SPECIFICATIONS AND WARRANTY

A list of the analyzer’s performance specifications and if applicable a description of the conditions and configuration under which EPA equivalency was approved as well as the Teledyne Instruments’ warranty statement.

GETTING STARTED

Instructions for setting up, installing and running your analyzer for the first time.

GLOSSARY:

Answers to the most frequently asked questions about operating the analyzer and a glossary of acronyms and technical terms.

OPTIONAL HARDWARE & SOFTWARE

A description of optional equipment to add functionality to your analyzer.

SECTION II – OPERATING INSTRUCTIONS

BASIC OPERATION OF THE M400E ANALYZER

Step-by-Step instructions for using the display/keyboard to set up and operate the M400E analyzer.

ADVANCED FEATURES OF THE M400E ANALYZER

Step-by-Step instructions for using the M400E analyzer’s more advanced features such as the iDAS system, the DIAG and VARSmenus and the and the TEST channel analog output.

REMOTE OPERATION OF THE M400E Analyzer

Information and instructions for interacting with the M400E analyzer via its several remote interface options (e.g. via RS-232, Ethernet, its built in digital control inputs/outputs, etc.)

M400E VALIDATION AND VERIFICATION

Methods and procedures for verifying the correct operation of your M400E Analyzer as well as step by step instructions for calibrating it

EPA PROTOCOL CALIBRATION

Specific information regarding calibration requirements for analyzers used in EPA monitoring.

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Introduction

M400E Ozone Analyzer Operator’s Manual

SECTION III – TECHNICAL INFORMATION

THEORY OF OPERATION

An in-depth look at the various principals by which your analyzer operates as well as a description of how the various electronic, mechanical and pneumatic components of the analyzer work and interact with each other. A close reading of this section is invaluable for understanding the analyzer’s operation.

MAINTENANCE SCHEDULE AND PROCEDURES

Description of preventative maintenance procedures that should be regularly performed on you analyzer to assure good operating condition.

GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER

This section includes pointers and instructions for diagnosing problems with the analyzer in general and the Terminus as well as instructions on performing repairs of on the Terminus.

A PRIMER ON ELECTRO-STATIC DISCHARGE

This section describes how static electricity occurs; why it is a significant concern and; how to avoid it and avoid allowing ESD to affect the reliable and accurate operation of your analyzer.

APPENDICES

For easier access and better updating, some information has been separated out of the manual and placed in a series of appendices at the end of this manual. These include version-specific software menu trees, warning messages, definitions Modbus registers and serial I/O variables as well as spare part listings, repair questionnaires, interconnect drawing, detailed pneumatic and electronic schematics.

USER NOTES:

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Specifications, Approvals and Warranty

2.SPECIFICATIONS, APPROVALS AND WARRANTY

2.1. SPECIFICATIONS

Table 2-1: Model 400E Basic Unit Specifications

Min/Max Range	Min: 0-100 PPB
(Physical Analog Output)	Max: 0-10,000 PPB
Measurement Units	ppb, ppm, µg/m3, mg/m3 (user selectable)
Zero Noise	< 0.3 ppb RMS (EPA Definition)
Span Noise	< 0.5% of reading above 100 PPB (EPA Definition)
Lower Detectable Limit	< 0.6 PPB (EPA Definition)
Zero Drift (24 hours)	< 1.0 ppb (at constant temperature and voltage)
Zero Drift (7 days)	< 1.0 ppb (at constant temperature and voltage)
Span Drift (24 hours)	< 1% of reading (at constant temperature and voltage)
Span Drift (7 days)	< 1% of reading (at constant temperature and voltage)
Linearity	< 1% of full scale
Precision	< 0.5% of reading (EPA Definition)
Lag Time	< 10 sec (EPA Definition)
Rise/Fall Time	< 20 sec to 95% (EPA Definition)
Sample Flow Rate	800 80 cc/min
Temperature Range	5 - 40 C
Humidity Range	0-90% RH, Non-Condensing
Pressure Range	25 – 31 “Hg-A
Altitude Range	0-2000m
Temp Coefficient	< 0.05% per deg C
Voltage Coefficient	< 0.05% per Volt AC (RMS) over range of nominal 10%
Dimensions (H x W x D)	7” x 17” x 23.5”
Weight	30.6lbs. (13.8Kg) with IZS Option
AC Power	100V 50/60Hz (3.25A),
	115V 60Hz (3.0A),
	220 – 240 V 50/60 Hz (2.5A)
Environmental Conditions	Installation Category (Over voltage Category) II Pollution Degree 2
Analog Outputs	Four (4) Outputs, Three (3) defined
Analog Output Ranges	All Outputs: 100 mV, 1 V, 5 V, 10 V
Analog Output Ranges	Two concentration outputs convertible to 4-20 mA isolated current loop
	All Ranges with 5% Under/Over Range
Analog Output Resolution	1 part in 4096 of selected full-scale voltage
Status Outputs	8 Status outputs from opto-isolators
Control Inputs	6 Control Inputs, 3 defined, 3 spare
Serial I/O	COM1: RS-232; COM2: RS-232 or RS-485
	Baud Rate : 300 – 115200
Certifications	USEPA: Equivalent Method Number EQOA-0992-087
	CE Mark

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Specifications, Approvals and Warranty			M400E Ozone Analyzer Operator’s Manual
	Table 2-2: Model 400E IZS Generator Specifications with Reference
		Feedback Option

	Maximum Concentration		1.0 PPM
	Minimum Concentration		0.050 PPM
	Initial Accuracy		+/- 5% of target concentration
	Stability (7 Days)		1% of reading

	Repeatability (7 days)		1% of reading

	Response Time		< 5 min to 95%
	Resolution		0.5 ppb

Table 2-3: Specifications for Model 400E IZS Generator w/o Reference

	Feedback Option

Maximum Concentration		1.0 PPM

Minimum Concentration		0.050 PPM
Initial Accuracy		+/- 10% of target concentration
Stability (7 Days)		2% of reading
Repeatability (7 days)		2% of reading

Response Time		< 5 min to 95%

Resolution		0.5 ppb

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Specifications, Approvals and Warranty

2.2. EPA EQUIVALENCY DESIGNATION

Advanced Pollution Instrumentation, Inc., Model 400E photometric ozone analyzer is designated as Equivalent Method Number EQOA-0992-087 as defined in 40 CFR Part 53, when operated under the following conditions:

Range: Any range from 100 ppb to 1 ppm.

Ambient temperature range of 5 to 40ºC.

Line voltage range of 105 – 125 VAC or 200 – 240 VAC, 50/60 Hz.

With 5-micron PTFE filter element installed in the internal filter assembly.

Sample flow of 800 ± 80 cc3/min at sea level.

Gas flow supplied by Internal or External pump.

Following Software Setting:

Table 2-4: Software Settings for EPA Equivalence

Dilution Factor	1.0
AutoCal	ON or OFF
Dynamic Zero	ON or OFF

Dynamic Span	OFF

Dual range	ON or OFF
Auto range	ON or OFF
Temp/Pres compensation	ON

Under the designation, the Analyzer may be operated with or without the following options:

Rack mount with slides.

Rack mount without slides, ears only.

Zero/Span Valves option.

Internal Zero/Span (IZS) generator.

4-20mA, isolated output.

2.3. CE MARK COMPLIANCE

EMISSIONS COMPLIANCE

The Teledyne Instruments Model 400E photometric ozone analyzer was tested and found to be fully compliant with:

EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B section 15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A.

Tested on 7/1/2002 to 7/2/2002 at CKC Laboratories, Inc., Report Number CE02-128.

SAFETY COMPLIANCE

The Teledyne Instruments Model 400E photometric ozone analyzer was tested and found to be fully compliant with:

IEC 61010-1:90 + A1:92 + A2:95,

Tested in 08/2002 to 09/2002 at NEMKO: Report Number 2002-10280.

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M400E Ozone Analyzer Operator’s Manual

2.4. WARRANTY

WARRANTY POLICY (02024D)

Prior to shipment, T-API equipment is thoroughly inspected and tested. Should equipment failure occur, T-API assures its customers that prompt service and support will be available.

COVERAGE

After the warranty period and throughout the equipment lifetime, T-API stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry. All maintenance and the first level of field troubleshooting is to be performed by the customer.

NON-API MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by T-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

During the warranty period, T-API warrants each Product manufactured by T-API to be free from defects in material and workmanship under normal use and service. Expendable parts are excluded.

If a Product fails to conform to its specifications within the warranty period, 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 T-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. API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF T-API'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE

TERMS AND CONDITIONS

All units or components returned to Teledyne Instruments Incorporated 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.

USER NOTES:

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3. GETTING STARTED

3.1. MODEL 400E ANALYZER LAYOUT

FASTENER

MODE FIELD

LOCKING SCREW

MESSAGE FIELD CONCENTRATION FIELD FASTENER

KEY DEFINITION FIELD

KEYBOARD

ON / OFF SWITCH

STATUS LED’s

Figure 3-1: M400E Front Panel Layout

Table 3-1: Front Panel Nomenclature

NAME

Mode Field

Message Field

Concentration

Field

Keypad

Definition Field

SIGNIFICANCE

Displays the name of the analyzer’s current operating mode

Displays a variety of informational messages such as warning messages, operational data, test function values and response messages during interactive tasks.

Displays the actual concentration of the sample gas currently being measured by the analyzer in the currently selected units of measure

Displays dynamic, context sensitive definitions for the row of keys just below the display.

STATUS LED’s

NAME	COLOR	STATE	DEFINITION
		Off	Unit is not operating in sample mode, iDAS is disabled.
SAMPLE	Green	On	Sample Mode active; Front Panel Display being updated; iDAS data being stored.
SAMPLE	Green	Blinking	Unit is operating in sample mode, front panel display being updated, iDAS hold-off mode is ON,
		Blinking
			iDAS disabled
		Off	Auto Cal disabled
CAL	Yellow	On	Auto Cal enabled
		Blinking	Unit is in calibration mode
FAULT	Red	Off	O3 warnings exist
FAULT	Red	Blinking	Warnings exist
		Blinking	Warnings exist

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Cooling Fan

Serial I/O LEDs

Status Outputs

Analog Outputs

Sample Gas Inlet

Exhaust Gas

Outlet

Power Receptacle	DCE – DTE Switch COM Port A	COM Port B	Control	Serial Number
	(RS-232 Only)	(RS-232 or RS-485)	Inputs	Tag

Figure 3-2: M400E Rear Panel Layout – Basic Version

Cooling Fan

Serial I/O LEDs

Status Outputs

Analog Outputs

Sample Gas Inlet

Exhaust Gas

Outlet

Dry Air Inlet

Power Receptacle	DCE – DTE Switch COM Port A	COM Port B	Control	Serial Number
	(RS-232 Only)	(RS-232 or RS-485)	Inputs	Tag

Figure 3-3: M400E Rear Panel Layout with Internal Zero/Span (IZS) Option (OPT-51A)

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Table 3-2: M400E Analyzer Gas Inlet/Outlet Nomenclature

	REAR PANEL			FUNCTION
	LABEL			FUNCTION
	LABEL
	SAMPLE			Connect the source of sample gas here.

	EXHAUST			Connect exhaust gas line here (must be <10
	EXHAUST			meters).
				meters).
	SPAN			Connect the source of calibrated span gas here.
	ZERO AIR			Connect the source of zero air here.
	DRY AIR			Attach the source of dry air here (< -20ºc dew
	DRY AIR			point).
				point).

CONFIGURATION VARIATIONS

Calibration gasses are also inlet here on:

Base configuration and;

Analyzers with the internal zero/span valve option installed (OPT-51A)

All configurations

Only present with Zero/Span valves (OPT-50A)

Only present with the internal zero/span option (OPT-51A)

	Particulate Filter		PC/104 Card
	IZS O3	Generator
Front Panel			Mother
	(Optional)
			Board

Measure /

Reference

Valve

Optical

Bench

Gas Flow

Sensor Assy

Relay Board

ON/OFF
SWITCH		Power
Critical Flow	PS2	Power
Critical Flow	(+12 VDC)	Receptacle
Orifice	(+12 VDC)	Receptacle
Orifice
Pump Assy	PS1	Rear Panel
	PS1	Rear Panel
	(+5 VDC; 15VDC)

Figure 3-4: M400E Internal Layout – Top View with IZS Option

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Figure 3-5: M400E Pneumatic Diagram – Basic Unit

Figure 3-6:

M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A)

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3.2. UNPACKING THE M400E ANALYZER

CAUTION

General Safety Hazard

TO AVOID PERSONAL INJURY, ALWAYS USE TWO PERSONS TO LIFT AND CARRY

THE MODEL 400E.

1.Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne Instruments.

2.Included with your analyzer is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet (P/N 04314) is an important quality assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument.

3.Carefully remove the top cover of the analyzer and check for internal shipping damage.

Remove the setscrew located in the top, center of the Front panel.

Remove the two screws fastening the top cover to the unit (one per side towards the rear).

Slide the cover backwards until it clears the analyzer’s front bezel.

Lift the cover straight up.

NOTE

Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty.

See Chapter 12 for more information on preventing ESD damage.

CAUTION

Electrical Shock Hazard

NEVER DISCONNECT PCAS, WIRING HARNESSES OR ELECTRONIC SUBASSEMBLIES

WHILE UNDER POWER.

4.Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated.

5.Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated.

6.Verify that all of the optional hardware ordered with the unit has been installed. These are listed on the paperwork accompanying the analyzer.

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3.2.1.1. Ventilation Clearance

Whether the analyzer is set up on a bench or installed into an instrument rack, be sure to leave sufficient ventilation clearance.

Table 3-3: Ventilation Clearance

AREA	MINIMUM REQUIRED CLEARANCE
Back of the instrument	4 in.
Sides of the instrument	1 in.

Above and below the instrument	1 in.

Various rack mount kits are available for this analyzer. See Section 5.1 of this manual for more information.

3.3. ELECTRICAL CONNECTIONS

3.3.1. POWER CONNECTION

Attach the power cord to the analyzer and plug it into a power outlet capable of carrying at least 10 A current at your AC voltage and that it is equipped with a functioning earth ground.

CAUTION

Electrical Shock Hazard

HIGH VOLTAGES ARE PRESENT INSIDE THE ANALYZERS CASE

POWER CONNECTION MUST HAVE FUNCTIONING GROUND CONNECTION.

DO NOT DEFEAT THE GROUND WIRE ON POWER PLUG.

TURN OFF ANALYZER POWER BEFORE DISCONNECTING OR

CONNECTING ELECTRICAL SUBASSEMBLIES.

DO NOT OPERATE WITH COVER OFF.

CAUTION

General Safety Hazard

THE M400E ANALYZER CAN BE CONFIGURED FOR BOTH 100-130 V AND

210-240 V AT EITHER 50 OR 60 HZ.

TO AVOID DAMAGE TO YOUR ANALYZER, MAKE SURE THAT THE AC POWER VOLTAGE MATCHES THE VOLTAGE INDICATED ON THE ANALYZER’S SERIAL NUMBER LABEL TAG (SEE FIGURE 3-2) BEFORE PLUGGING THE M400E INTO LINE POWER.

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3.3.2. ANALOG OUTPUT CONNECTIONS

The M400E is equipped with several analog output channels accessible through a connector on the back panel of the instrument (see Figure 3-2).

Channels A1 and A2 output a signal that is proportional to the O3 concentration of the sample gas.

The default analog output voltage setting of these channels is 0 to 5 VDC with a reporting range of 0 to 500 ppb.

An optional Current Loop output is available for each.

The output labeled A4 is special. It can be set by the user to output any one a variety of diagnostic test functions.

The default analog output voltage setting of these channels is also 0 to 5 VDC.

See Section 7.4.6 for a list of available functions and their associated reporting range.

There is no optional Current Loop output available for Channel A4.

To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output connections on the rear panel of the analyzer. Pin-outs for the analog output connector are:

		ANALOG OUT
	A1	A2	A3	A4
+ -		+ - +	-	+ -

		Figure 3-7:	M400E Analog Output Connector
		Table 3-4: Analog Output Pin Outs

	Pin	Analog Output		Standard Voltage	Current
	Pin	Analog Output		Output	Loop Option
				Output	Loop Option
1		A1		V Out	I Out +

2				Ground	I Out -
2				Ground	I Out -

3		A2		V Out	I Out +
4		A2		Ground	I Out -
4				Ground	I Out -
	5	A3		NOT USED
	6	A3		NOT USED
	6
7		A4		V Out	Not Available
8		A4		Ground	Not Available
8				Ground	Not Available

To change the settings for the analog output channels, see Section 7.4

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3.3.3. CONNECTING THE STATUS OUTPUTS

The status outputs report analyzer conditions via optically isolated NPN transistors, which sink up to 50 mA of DC current. These outputs can be used interface with devices that accept logic-level digital inputs, such as programmable logic controllers (PLCs). Each Status bit is an open collector output that can withstand up to 40 VDC. All of the emitters of these transistors are tied together and available at D.

NOTE

Most PLC’s have internal provisions for limiting the current that the input will draw from an external device. When connecting to a unit that does not have this feature, an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA. At 50 mA, the transistor will drop approximately 1.2V from its collector to emitter.

The status outputs are accessed via a 12-pin connector on the analyzer’s rear panel labeled STATUS (see Figure 3-2). Pin-outs for this connector are:

STATUS




1		2	3 4	5	6 7 8 D	+


SYSTEM OK	CONC VALID	HIGH RANGE	ZERO CAL	SPAN CAL	DIAG MODE

	Figure 3-8:		Status Output Connector
	Table 3-5: Status Output Pin Assignments

OUTPUT #	STATUS		CONDITION
OUTPUT #	DEFINITION		CONDITION
	DEFINITION
1	SYSTEM OK On if no faults are present.
2	CONC VALID	On if O3 concentration measurement is valid.
2	CONC VALID	If the O3	concentration measurement is invalid, this bit is OFF.
		If the O3	concentration measurement is invalid, this bit is OFF.

3HIGH RANGE On if unit is in high range of DUAL or AUTO Range Modes.

4ZERO CAL On whenever the instrument is in CALZ mode.

5SPAN CAL On whenever the instrument is in CALS mode.

6DIAG MODE On whenever the instrument is in DIAGNOSTIC mode.

7 & 8	Unassigned
D	Emitter BUSS	The emitters of the transistors on pins 1 to 8 are bussed together.

	Spare
+	DC Power	+ 5 VDC, 300 mA source (combined rating with Control Output, if used).

	Digital Ground	The ground level from the analyzer’s internal DC power supplies.

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Table of Contents

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES

LIST OF APPENDICES

1. INTRODUCTION

1.1. SAFETY MESSAGES

1.2. M400E OVERVIEW

Specifications, Approvals and Warranty

2.1. SPECIFICATIONS

2.2. EPA EQUIVALENCY DESIGNATION

2.3. CE MARK COMPLIANCE

2.4. WARRANTY

3. GETTING STARTED

3.1. MODEL 400E ANALYZER LAYOUT

3.2. UNPACKING THE M400E ANALYZER

3.2.1.1. Ventilation Clearance

3.3. ELECTRICAL CONNECTIONS

3.3.1. POWER CONNECTION

3.3.2. ANALOG OUTPUT CONNECTIONS

3.3.3. CONNECTING THE STATUS OUTPUTS