Teledyne 400E User Manual
TECHNICAL MANUAL
MODEL 400E
PHOTOMETRIC OZONE ANALYZER
© TELEDYNE INSTRUMENTS
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 O
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 O
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 O
3.7.2. Setting the O
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 O
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 O
4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY .................................................. 41
4.1. FAQ’s ...........................................................................................................................................................41
4.2. Glossary .......................................................................................................................................................43
Measurement ...........................................................................................................30
3
Span Gas Concentration:..........................................................................32
3
Span Concentration Settings:.............................................34
Generator Low-Span (Mid Point) Output Level ..............................................................35
3
Scrubber Conditioning .....................................................................................................37
3
3
..................................38
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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 O
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
Filter ........................................................................................................53
3
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 O
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
Concentration .................................................................................70
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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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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 O
Span Gas concentration....................................................................... 153
3
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 O
Span Gas Concentration with the Z/S Option Installed ....................... 160
3
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. O
Photometer Gas Flow Calibration.................................................................................................. 168
3
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. O
Loss Correction Factor ................................................................................................................ 179
3
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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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. I
2
C 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. O
Photometer UV Lamp Power Supply ................................................................................... 212
3
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. I
13.3.2.2. O
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. I
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 O
13.10. Repair Procedures ............................................................................................................................... 256
13.10.1. Repairing Sample Flow Control Assembly ..................................................................................... 256
13.10.2. Replacing The Standard Reference O
13.10.3. Replacing the IZS O
13.10.4. Metal Wool Scrubber Option........................................................................................................... 258
13.10.5. Disk-On-Chip Replacement Procedure .......................................................................................... 258
13.11. Technical Assistance............................................................................................................................ 258
2
C Bus Watchdog Status LEDs ................................................................................................ 240
Option Status LED s............................................................................................................. 241
3
2
C Bus.............................................................................................................................................. 247
Generator UV Lamp Power Supply...................................................................... 255
3
Scrubber .......................................................................... 257
3
Scrubber ...................................................................................................... 257
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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
04315 Rev. C1 vii
Table of Contents M400E Ozone Analyzer Operator’s Manual
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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M400E Ozone Analyzer Operator’s Manual Table of Contents
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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Table of Contents 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:
x 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual General Information
SECTION I
–
GENERAL INFORMATION
04315 Rev. C1 1
General Information M400E Ozone Analyzer Operator’s Manual
USER NOTES
2 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual 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
or
Via the internet at http://www.teledyne-api.com/
04315 Rev. C1 3
Introduction 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
4 04315 Rev. C1
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.
M400E Ozone Analyzer Operator’s Manual 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.
04315 Rev. C1 5
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:
6 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual Specifications, Approvals and Warranty
2. SPECIFICATIONS, APPROVALS AND
WARRANTY
2.1. SPECIFICATIONS
Table 2-1: Model 400E Basic Unit Specifications
Min/Max Range
(Physical Analog Output)
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
Temperature Range
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
Dimensions (H x W x D) 7” x 17” x 23.5”
Weight 30.6lbs. (13.8Kg) with IZS Option
AC Power
Environmental Conditions Installation Category (Over voltage Category) II Pollution Degree 2
Analog Outputs Four (4) Outputs, Three (3) defined
Analog Output Ranges
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
Certifications USEPA: Equivalent Method Number EQOA-0992-087
Min: 0-100 PPB
Max: 0-10,000 PPB
800 80 cc/min
5 - 40C
< 0.05% per Volt AC (RMS) over range of nominal 10%
100V 50/60Hz (3.25A),
115V 60Hz (3.0A),
220 – 240 V 50/60 Hz (2.5A)
All Outputs: 100 mV, 1 V, 5 V, 10 V
Two concentration outputs convertible to 4-20 mA isolated current loop
All Ranges with 5% Under/Over Range
COM1: RS-232; COM2: RS-232 or RS-485
Baud Rate : 300 – 115200
CE Mark
04315 Rev. C1 7
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
8 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual 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 cc
Gas flow supplied by Internal or External pump.
Following Software Setting:
3
/min at sea level.
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.
04315 Rev. C1 9
Specifications, Approvals and Warranty 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:
10 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual Getting Started
3. GETTING STARTED
3.1. MODEL 400E ANALYZER LAYOUT
MODE FIELD
MESSAGE FIELD
CONCENTRATION FIELD
FASTENERFASTENER LOCKING SCREW
KEY DEFINITION FIELD
KEYBOARD
ON / OFF SWITCH
Figure 3-1: M400E Front Panel Layout
Table 3-1: Front Panel Nomenclature
NAME SIGNIFICANCE
Mode Field
Message Field
Concentration
Field
Keypad
Definition Field
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
SAMPLE Green
CAL Yellow
FAULT Red
Off
On
Blinking
Off
On
Blinking
Off
Blinking
Unit is not operating in sample mode, iDAS is disabled.
Sample Mode active; Front Panel Display being updated; iDAS data being stored.
Unit is operating in sample mode, front panel display being updated, iDAS hold-off mode is ON,
iDAS disabled
Auto Cal disabled
Auto Cal enabled
Unit is in calibration mode
O
warnings exist
3
Warnings exist
STATUS LED’s
04315 Rev. C1 11
Getting Started M400E Ozone Analyzer Operator’s Manual
Cooling Fan
Power Receptacle
Serial I/O LEDs
Sample Gas Inlet
Exhaust Gas
Outlet
DCE – DTE Switch Serial Number
COM Port A
(RS-232 Only)
Status Outputs Analog Outputs
COM Port B
(RS-232 or RS-485)
Control
Inputs
Tag
Figure 3-2: M400E Rear Panel Layout – Basic Version
Power Receptacle
Cooling Fan
Serial I/O LEDs
Sample Gas Inlet
Exhaust Gas
Outlet
Dry Air Inlet
DCE – DTE Switch Serial Number
COM Port A
(RS-232 Only)
Status Outputs Analog Outputs
COM Port B
(RS-232 or RS-485)
Control
Inputs
Tag
Figure 3-3: M400E Rear Panel Layout with Internal Zero/Span (IZS) Option (OPT-51A)
12 04315 Rev. C1
M400E Ozone Analyzer Operator’s Manual Getting Started
/
Table 3-2: M400E Analyzer Gas Inlet/Outlet Nomenclature
REAR PANEL
LABEL
SAMPLE
EXHAUST
SPAN
ZERO AIR
DRY AIR
Front Panel
FUNCTION CONFIGURATION VARIATIONS
Calibration gasses are also inlet here on:
Connect the source of sample gas here.
Base configuration and;
Analyzers with the internal zero/span valve
option installed (OPT-51A)
Connect exhaust gas line here (must be <10
meters).
All configurations
Connect the source of calibrated span gas here. Only present with Zero/Span valves (OPT-50A)
Connect the source of zero air here. Only present with Zero/Span valves (OPT-50A)
Attach the source of dry air here (< -20ºc dew
point).
Only present with the internal zero/span option
(OPT-51A)
Particulate Filter
IZS O3 Generator
(Optional)
104 Card
PC
Mother
Board
Measure /
Reference
Valve
Optical
Bench
Gas Flow
Sensor Assy
ON/OFF
SWITCH
Pump Assy
Critical Flow
Orifice
PS2
(+12 VDC)
PS1
(+5 VDC; 15VDC)
Rear Panel
Relay Board
Power
Receptacle
Figure 3-4: M400E Internal Layout – Top View with IZS Option
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Getting Started M400E Ozone Analyzer Operator’s Manual
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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M400E Ozone Analyzer Operator’s Manual Getting Started
3.2. UNPACKING THE M400E ANALYZER
CAUTION
General Safety Hazard
TO AVOID PERSONAL INJURY, ALWAYS USE TWO PERSONS TO LIFT AND CARRY
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
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.
THE MODEL 400E.
(P/N 04314) is an
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
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.
WHILE UNDER POWER.
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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Getting Started M400E Ozone Analyzer Operator’s Manual
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
Above and below the instrument
Various rack mount kits are available for this analyzer. See Section 5.1 of this manual for more information.
1 in.
1 in.
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.
16 04315 Rev. C1
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.
M400E Ozone Analyzer Operator’s Manual Getting Started
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).
nnels A1 and A2 output a signal that is proportional to the O
Cha
concentration of the sample gas.
3
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 a
nd 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
1 V Out I Out +
2
3 V Out I Out +
4
5
6
7 V Out Not Available
8
A1
A2
A3 NOT USED
A4
Standard Voltage
Output
Ground I Out -
Ground I Out -
Ground Not Available
To change the settings for the analog output channels, see Section 7.4
Current
Loop Option
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Getting Started M400E Ozone Analyzer Operator’s Manual
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 +
ZERO CAL
SPAN CAL
SYSTEM OK
CONC VALID
HIGH RANGE
DIAG MODE
Figure 3-8: Status Output Connector
Table 3-5: Status Output Pin Assignments
OUTPUT #
1
2
3
4
5
6
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).
STATUS
DEFINITION
SYSTEM OK
CONC VALID
HIGH RANGE
ZERO CAL
SPAN CAL
DIAG MODE
CONDITION
On if no faults are present.
On if O3 concentration measurement is valid.
If the O
On if unit is in high range of DUAL or AUTO Range Modes.
On whenever the instrument is in CALZ mode.
On whenever the instrument is in CALS mode.
On whenever the instrument is in DIAGNOSTIC mode.
concentration measurement is invalid, this bit is OFF.
3
Digital Ground The ground level from the analyzer’s internal DC power supplies.
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