Teledyne 401 User Manual

INSTRUCTION MANUAL

MODEL 401

CALIBRATOR

ADVANCED POLLUTION INSTRUMENTATION DIVISION

9480 CARROLL PARK DRIVE

SAN DIEGO, CA 92121-5201

TOLL-FREE: 800-324-5190

E-MAIL: api-sales@teledyne.com

WEB SITE: www.teledyne-api.com

Instrumentation

(T-API)

FAX: 858-657-9816

TEL: 858-657-9800

01124

REV. J2

11 July, 2005

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

SAFETY MESSAGES

Your safety and the safety of others is very important. We have provided many important safety messages in this manual. Please read these messages carefully.

A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the instrument. The definition of these symbols is described below:

GENERAL WARNING/CAUTION specific danger.

CAUTION

Technician Symbol by qualified maintenance personnel only.

The analyzer should only be used for the purpose

and in the manner described in this manual.

If you use the analyzer in a manner other than that for which

it was intended, unpredictable behavior could ensue with

: Hot Surface Warning

: Electrical Shock Hazard

: All operations marked with this symbol are to be performed

CAUTION

possible hazardous consequences.

: Refer to the instructions for details on the

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

SAFETY MESSAGES .......................................................................................... II

TABLE OF CONTENTS...................................................................................... III

LIST OF FIGURES.............................................................................................VII

LIST OF TABLES..............................................................................................VIII

1 INTRODUCTION............................................................................................ 1-1

PREFACE .........................................................................................................................................1-1

1.1

1.2

WARRANTY.....................................................................................................................................1-1

1.3 PRINCIPLE OF OPERATION ..............................................................................................................1-2

1.3.1 Interferent Rejection...............................................................................................................1-4

1.4 SPECIFICATIONS ..............................................................................................................................1-5

1.4.1 Noise (PPB RMS)....................................................................................................................1-6

1.4.2 Lower Detectable Limit (LDL) PPB.......................................................................................1-6

1.4.3 Zero Drift (PPB).....................................................................................................................1-6

1.4.4 Span Drift................................................................................................................................1-6

1.4.5 Linearity..................................................................................................................................1-6

1.4.6 Lag Time .................................................................................................................................1-6

1.4.7 Rise And Fall Times................................................................................................................1-6

1.4.8 Temperature Range.................................................................................................................1-6

1.4.9 Humidity Range ......................................................................................................................1-6

1.4.10 Flow Rates ............................................................................................................................1-7

1.4.11 Power....................................................................................................................................1-7

1.4.12 Weight...................................................................................................................................1-7

1.5

INSTALLATION AND OVERVIEW......................................................................................................1-7

1.6 ELECTRICAL AND PNEUMATIC CONNECTIONS ..............................................................................1-14

1.6.1 Electrical Connections..........................................................................................................1-14

1.6.2 RS-232...................................................................................................................................1-14

1.6.3 Pneumatic System .................................................................................................................1-16

1.6.4 Exhaust Connections (See Figure 1-5).................................................................................1-16

1.6.5 Output Flow Adjustment.......................................................................................................1-16

OPERATION VERIFICATION............................................................................................................1-20

1.7

1.7.1 Final Test And Calibration Values.......................................................................................1-21

1.8 OPTIONS........................................................................................................................................1-22

1.8.1 Rack Mount With Slides........................................................................................................1-22

1.8.2 Status Outputs.......................................................................................................................1-22

2 OPERATION .................................................................................................. 2-1

KEY FEATURES ...............................................................................................................................2-1

2.1

2.1.1 O

Readout..............................................................................................................................2-1

iii

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

2.1.2 O

Analog Output....................................................................................................................2-1

2.1.3 E2 ROM Backup Of Software Configuration..........................................................................2-1

2.1.4 Adaptive Filter........................................................................................................................2-1

2.1.5 Data Acquisition .....................................................................................................................2-2

2.1.6 RS-232 Interface .....................................................................................................................2-2

2.1.7 Password Protection...............................................................................................................2-2

FRONT PANEL .................................................................................................................................2-4

2.2

2.2.1 Front Panel Display................................................................................................................2-4

2.2.2 Programmable Pushbuttons ...................................................................................................2-7

2.2.3 Status LEDs.............................................................................................................................2-9

3 CALIBRATION............................................................................................... 3-1

MANUAL ZERO AIR SUPPLY............................................................................................................3-1

3.1

3.2

MANUAL O3 GENERATION ..............................................................................................................3-1

3.3

AUTOMATIC ZERO/SPAN (OR MULTIPOINT) CHECK ........................................................................3-2

3.4

MANUAL ZERO/SPAN (OR MULTI-POINT) CHECK ...........................................................................3-2

3.5

SUMMARY OF FRONT PANEL CALIBRATION CONTROLS..................................................................3-3

3.6

PHOTOMETER CALIBRATION ...........................................................................................................3-3

3.7

REMOTE ZERO/SPAN CHECK (CONTACT CLOSURE)........................................................................3-4

3.8

REMOTE ZERO/SPAN CHECK OR ADJUSTMENT (RS-232)...............................................................3-5

3.9

HOLD OFF .......................................................................................................................................3-5

4 SETUP MODE................................................................................................ 4-1

SETUP MODE OPERATION ...............................................................................................................4-1

4.1

4.2

SETTING AUTOMATIC MULTIPOINT (ASEQ) CHECK.......................................................................4-1

4.3

SETTING AUTOMATIC ZERO/SPAN DURATION.................................................................................4-1

4.4

EXAMINING THE OZONE FORMULA SLOPE AND OFFSET.................................................................4-2

4.5

SETTING THE O3 GENERATION MODE .............................................................................................4-3

4.5.1 BNCH Mode............................................................................................................................4-3

4.5.2 REF Mode...............................................................................................................................4-3

4.5.3 CNST Mode.............................................................................................................................4-3

SETTING THE TIME-OF-DAY...........................................................................................................4-3

4.6

4.7

SETTING THE DATE.........................................................................................................................4-3

4.8

ADJUSTING THE CLOCK SPEED .......................................................................................................4-4

SETTING THE O3 CONCENTRATION RANGE .....................................................................................4-4

4.9

4.10

SETTING THE ANALOG OUTPUT OFFSET .......................................................................................4-4

4.11

SETTING THE RS-232 BAUD RATE................................................................................................4-4

4.12

SETTING THE ANALYZER I.D........................................................................................................4-5

DISABLING THE CALIBRATION PASSWORD ...................................................................................4-5

4.13

4.14

SETTING THE FAULT LED TIMEOUT.............................................................................................4-5

4.15

SOFTWARE CONFIGURATION.........................................................................................................4-6

SUMMARY OF SETUP VARIABLES .................................................................................................4-6

4.16

5 DIAGNOSTICS............................................................................................... 5-1

TEST MEASUREMENTS ....................................................................................................................5-1

5.1

5.2 DIAGNOSTIC TESTS .........................................................................................................................5-1

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

5.2.1 D/A Output..............................................................................................................................5-2

6 HANDLING WARNINGS................................................................................ 6-1

7 RS-232 COMMUNICATIONS......................................................................... 7-1

7.1 DAS REPORTING.............................................................................................................................7-2

7.2

WARNINGS......................................................................................................................................7-3

7.3

STATUS/CONTROL...........................................................................................................................7-4

7.4

DIAGNOSTICS..................................................................................................................................7-6

7.5 TEST MEASUREMENTS ....................................................................................................................7-7

7.6

VIEWING AND MODIFYING VARIABLES ..........................................................................................7-8

8 ADJUSTMENTS............................................................................................. 8-1

8.1

POWER SUPPLY BOARD ADJUSTMENT.............................................................................................8-1

8.1.1 Box Temperature Limits..........................................................................................................8-1

A/D - D/A CALIBRATION PROCEDURE ............................................................................................8-3

8.2

8.3

OUTPUT VOLTAGE RANGE CHANGES..............................................................................................8-4

8.4

FLOW READOUT ADJUSTMENT........................................................................................................8-4

8.5

DC POWER SUPPLY.........................................................................................................................8-6

8.6

CPU................................................................................................................................................8-6

8.7

STATUS LINES.................................................................................................................................8-7

8.8

UV LAMP POWER SUPPLY ADJUSTMENT ........................................................................................8-7

8.9

OZONE GENERATOR LAMP SETUP...................................................................................................8-8

8.10

OZONE GENERATOR CALIBRATION...............................................................................................8-9

8.11

DARK CURRENT SIGNAL ADJUST PROCEDURE..............................................................................8-9

8.12

BENCH FEEDBACK OPTION..........................................................................................................8-10

9 TROUBLESHOOTING ................................................................................... 9-1

OVERVIEW ......................................................................................................................................9-1

9.1

9.2

TROUBLESHOOTING FUNDAMENTAL CALIBRATOR OPERATION ......................................................9-1

9.2.1 Checking The Power Sub-Systems..........................................................................................9-2

9.2.2 Checking The CPU And Display.............................................................................................9-3

9.2.3 Checking The Keyboard..........................................................................................................9-3

TROUBLESHOOTING USING WARNING MESSAGES...........................................................................9-3

9.3

9.4

TROUBLESHOOTING USING TEST FUNCTION VALUES .....................................................................9-5

TROUBLESHOOTING DYNAMIC PROBLEMS ......................................................................................9-6

9.5

9.5.1 Noisy Or Unstable Readings At Zero .....................................................................................9-7

9.5.2 Noisy, Unstable, Or Non-Linear Span Readings....................................................................9-7

9.5.3 Slow Response To Changes In Concentration........................................................................9-7

9.5.4 Analog Outputs Do Not Agree With Front Panel Readings...................................................9-8

9.5.5 Cannot Zero............................................................................................................................9-8

9.5.6 Cannot Span............................................................................................................................9-8

TROUBLESHOOTING INDIVIDUAL SUB-ASSEMBLIES AND COMPONENTS.........................................9-9

9.6

9.6.1 Troubleshooting Flow Problems ............................................................................................9-9

9.6.2 Troubleshooting Temperature Problems..............................................................................9-10

9.6.3 Checking The V/F Card........................................................................................................9-11

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

9.6.4 Checking The DC Power Supply Board................................................................................9-13

9.6.5 Checking The Pneumatic Sensor Board ...............................................................................9-14

9.6.6 Checking The Source Lamp And Detector............................................................................9-14

9.6.7 Checking Main Switching Valve...........................................................................................9-16

9.6.8 Checking The Lamp Power Supply.......................................................................................9-16

9.7

WARRANTY/REPAIR QUESTIONNAIRE.........................................................................................9-18

10 ROUTINE MAINTENANCE........................................................................ 10-1

MAINTENANCE SCHEDULE..........................................................................................................10-1

10.1

10.2

LEAK CHECKING .........................................................................................................................10-2

10.3

CLEANING OF SAMPLE CELL.......................................................................................................10-2

10.4 CHANGING THE PROM.................................................................................................................10-3

11 MODEL 401 SPARE PARTS AND EXPENDABLES KITS........................ 11-1

SPARE PARTS FOR CE MARK UNITS ...........................................................................................11-1

11.1

11.2

SPARE PARTS FOR NON-CE MARK UNITS ..................................................................................11-3

Appendix A LIST OF AVAILABLE MODEL 401 OPTIONS ................................................. A-1

Appendix B RECOMMENDED ZERO AIR SYSTEM............................................................. B-1

Appendix C REFERENCES....................................................................................................... C-1

Appendix D SOFTWARE MENU TREES ................................................................................ D-1

Appendix E ELECTRICAL SCHEMATIC INDEX ...................................................................E-1

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

LIST OF FIGURES

FIGURE 1-1: MODEL 401 OZONE CALIBRATOR BLOCK DIAGRAM..........................................................1-11

IGURE 1-2: M401 REAR PANEL ELECTRICAL CONNECTIONS................................................................1-12

IGURE 1-3: REAR PANEL ELECTRICAL AND PNEUMATIC CONNECTIONS (CE VERSION).......................1-13

IGURE 1-4: RS-232 PIN ASSIGNMENTS.................................................................................................1-15

IGURE 1-5: M401 CALIBRATOR PNEUMATIC CONNECTIONS ................................................................1-17

IGURE 1-6: M401 REAR PANEL (EXTERNAL DRY ZERO AIR)...............................................................1-18

IGURE 1-7: M401 CALIBRATOR CHASSIS LAYOUT...............................................................................1-19

IGURE 2-1: MODEL 401 FRONT PANEL...................................................................................................2-4

FIGURE 2-2: ILLUSTRATION OF NORMAL DISPLAY ..................................................................................2-8

IGURE 8-1: ELECTRICAL BLOCK DIAGRAM ............................................................................................8-2

IGURE 8-2: FLOW AND PRESSURE READOUT ADJUSTMENT....................................................................8-5

IGURE A-1: MODEL 401 SAMPLE SOFTWARE MENU TREE....................................................................D-1

IGURE A-2: MODEL 401 SETUP SOFTWARE MENU TREE.......................................................................D-2

vii

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

LIST OF TABLES

TABLE 1-1: TEST VALUES.......................................................................................................................1-21

ABLE 2-1: PASSWORD LEVELS ...............................................................................................................2-3

ABLE 2-2: SYSTEM MODES ....................................................................................................................2-5

ABLE 2-3: TEST MEASUREMENTS ..........................................................................................................2-6

ABLE 2-4: WARNING MESSAGES............................................................................................................2-7

ABLE 2-5: STATUS LEDS........................................................................................................................2-9

ABLE 3-1: CALIBRATION CONTROLS......................................................................................................3-3

ABLE 4-1: SETUP VARIABLES.................................................................................................................4-7

TABLE 5-1: TEST CHANNEL OUTPUT........................................................................................................5-2

ABLE 5-2: DIAGNOSTIC TESTS ...............................................................................................................5-2

ABLE 7-1: RS-232 MESSAGE TYPES ......................................................................................................7-1

ABLE 7-2: WARNING MESSAGE CLEAR COMMANDS..............................................................................7-4

ABLE 7-3: STATUS REPORTS ..................................................................................................................7-4

ABLE 7-4: CONTROL COMMANDS...........................................................................................................7-5

ABLE 7-5: DIAGNOSTIC COMMANDS ......................................................................................................7-6

ABLE 7-6: SPECIAL DIAGNOSTIC COMMANDS........................................................................................7-7

ABLE 7-7: DIAGNOSTIC REPORTS...........................................................................................................7-7

ABLE 7-8: TEST MEASUREMENT REQUEST COMMANDS.........................................................................7-8

ABLE 7-9: RS-232 VARIABLE NAMES..................................................................................................7-10

ABLE 8-1: THE CALIBRATOR HAS THE FOLLOWING STATUS CONDITIONS.............................................8-7

ABLE 9-1: WARNING MESSAGES............................................................................................................9-4

ABLE 9-2: TEST FUNCTION VALUES.......................................................................................................9-5

ABLE 9-2: TEST FUNCTION VALUES (CONTINUED) ................................................................................9-6

ABLE 9-3: V/F BOARD JUMPERS - FACTORY SETTINGS........................................................................9-12

ABLE 9-4: V/F BOARD DIP SWITCHES - RANGES FOR ANALOG OUTPUT..............................................9-12

ABLE 9-5: UV SOURCE LAMP AND DETECTOR DIAGNOSTICS..............................................................9-15

ABLE 10-1: MAINTENANCE SCHEDULE ................................................................................................10-1

ABLE 11-1: SPARE PARTS FOR CE MARK UNITS..................................................................................11-1

T T

ABLE 11-1: SPARE PARTS FOR CE MARK UNITS (CONTINUED)...........................................................11-2

ABLE 11-2: SPARE PARTS FOR NON-CE MARK UNITS.........................................................................11-3

ABLE 11-2: SPARE PARTS FOR NON-CE MARK UNITS (CONTINUED) ..................................................11-4

ABLE A-1: AVAILABLE MODEL 401 OPTIONS.......................................................................................A-1

T T

ABLE E-1: ELECTRICAL SCHEMATIC INDEX ...........................................................................................E-1

viii

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1 INTRODUCTION

1.1 Preface

Teledyne API is pleased that you have purchased the Model 401. We offer a full one year warranty (see Section 1.2) and we at Teledyne API will be pleased to provide you with any support required so that you may utilize our equipment to the fullest extent.

The Teledyne API Model 401 keyboard/operator interface with its "talking keys" makes the Teledyne API a very user-friendly system. We hope you will not experience any problems with the Teledyne API Model 401 but if you do, the built-in tests and diagnostics should allow you to quickly and easily find the problem. In addition, our full time customer service department is always available to answer your questions.

1.2 Warranty

WARRANTY POLICY (02024c)

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

COVERAGE

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

NON-TELEDYNE API MANUFACTURED EQUIPMENT

Equipment provided but not manufactured by Teledyne API is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty.

GENERAL

Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in material and workmanship under normal use and service for a period of one year from the date of delivery. All replacement parts and repairs are warranted for 90 days after the purchase.

If a Product fails to conform to its specifications within the warranty period, Teledyne API shall correct such defect by, in Teledyne API's discretion, repairing or replacing such defective Product or refunding the purchase price of such Product.

1-1

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

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 Teledyne API or (iii) not properly maintained.

THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED. THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN. TELEDYNE API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE.

TERMS AND CONDITIONS

All units or components returned to Teledyne API should be properly packed for handling and returned freight prepaid to the nearest designated Service Center. After the repair, the equipment will be returned, freight prepaid.

1.3 Principle Of Operation

M401 Ozone calibrator consist of two major parts; the ozone generating device and the photometer. Ozone generating device itself also consist of a pump, an air scrubber to selfgenerate zero air, a pressure regulator to control flow rate, an ozone generator using UV lamp, and a manifold. The pressure regulator provides very stable flow of zero air through the O generator, while the light intensity of the UV lamp is controlled to generate accurate and stable ozone output.

The photometer is used as part of a feedback lamp control to assure stable O changing conditions. The photometer is compensated for both pressure and temperature variations. This true photometer operation along with self-generated zero air results in a completely self-contained O

The detection of ozone molecules of the photometer is based on absorption of 254 nm UV light due to an internal electronic resonance of the O mercury lamp constructed so that a large majority of the light emitted is at the 254nm wavelength. Light from the lamp shines down a hollow glass tube that is alternately filled with sample gas, then filled with zero air. The ratio of the intensity of light passing through the zero air to that of the sample forms a ratio I/I ozone concentration.

generating system.

output even during

molecule. The Model 401 Photometer uses a

. This ratio forms the basis for the calculation of the

1-2

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

NOTE

Model 401 Photometric Calibrator is designed to be a dedicated

calibrator. The M401 Photometer should not be used as a monitor.

The Beer-Lambert equation, shown below, calculates the concentration of ozone from the ratio of light intensities.

−=

K273

inHg92.29

ll×××

Where:

= Intensity of light passed through the sample

I = Intensity of light through sample free of ozone

= absorption coefficient

= path length

= concentration of ozone in ppm = sample temperature in Kelvin = pressure in inches of mercury

= natural logarithm

As you can see the concentration of ozone depends on more than the intensity ratio. Temperature and pressure influence the density of the sample. The density changes the number of ozone molecules in the absorption tube which impacts the amount of light removed from the light beam. These effects are addressed by directly measuring temperature and pressure and including their actual values in the calculation. The absorption coefficient is a number that reflects the inherent ability of ozone to absorb 254 nm light. Most current measurements place this value at 308 cm

-1

atm-1 at STP. The value of this number reflects the fact that ozone is a very efficient absorber of UV radiation which is why stratospheric ozone protects the life forms lower in the atmosphere from the harmful effects from solar UV radiation. Lastly, the absorption pathlength determines how many molecules are present in the column of gas in the absorption tube.

1-3

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

The intensity of light is converted into a voltage by the detector/preamp module. The voltage is converted into a number by a voltage-to-frequency (V/F) converter capable of 80,000 count resolution. The digitized intensities, along with the other variables, are used by the CPU to compute the concentration using the above formula.

Every 8 seconds the M401 Photometer completes a measurement cycle consisting of a 2 second wait period for the sample tube to flush, followed by 2 seconds of measuring the average light intensity to determine I. The sample valve is switched to admit scrubbed sample gas for 2 seconds followed by 2 seconds measuring the average light intensity to obtain I of the I

every 8 seconds minimizes instrument drift due to changing intensity of the lamp due to

. Measurement

aging and dirt. The 120 sec filter provides 32 averages.

1.3.1 Interferent Rejection

It should be noted that the UV absorption method for detecting ozone is subject to interference from a number of sources. The Model 401 has been successfully tested for its ability to reject interference from sulfur dioxide, nitrogen dioxide, nitric oxide, water, and meta-xylene.

While the instrument rejected interference from the aromatic hydrocarbon meta-xylene, it should be noted that there are a very large number of volatile aromatic hydrocarbons that could potentially interfere with ozone detection. If the Model 401 is installed in an environment where high aromatic hydrocarbon concentrations are suspected, specific tests should be conducted to reveal the amount of interference these compounds may be causing.

1-4

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.4 Specifications

Photometer

Ranges User selectable to any full scale range from 100 ppb to 20,000 ppb Zero Noise < 0.3 ppb (rms) Span Noise < 0.5% of reading (rms) Lower Detectable Limit < 0.6 ppb (rms) Zero Drift (24 hours) < 1.0 ppb* Zero Drift (7 days) < 1.0 ppb* Span Drift (24 hours) 1% of reading * Span Drift (7 days) 2% of reading * Linearity Better than 1% FS Precision 1.0 ppb Lag Time 10 sec Rise/Fall Time (95%) <20 sec Sample Flow Rate Temperature Range Humidity Range 0-95% RH, Non-Condensing Temp Coefficient Voltage Coefficient < 0.05 % per V Dimensions HxWxD 7" x 17" x 27" (178 mm x 432 mm x 686 mm) Weight, Analyzer 60 lb. (27 kg) Power, Analyzer 110v/60Hz, 220v/50Hz 250 watts Environmental Conditions Installation Category (Overvoltage Category) II

Recorder Instantaneous (Bi-Polar) Status 12 Status Outputs from Opto-Isolators

Calibration Ozone Generator

Flow rate 2 to 5 LPM adjustable

800 cc/min ± 10% 5-40° C

< 0.05 % per °C

Pollution Degree 2

± 100 mV, ± 1 v ± 5 v, ± 10 v

Maximum concentration 1.0 ppm @ 5 LPM Minimum concentration 0.050 ppm @ 2 LPM Stability

* at constant temperature and voltage

± 0.002 ppm (bench feedback)

1-5

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.4.1 Noise (PPB RMS)

The standard deviation of reported concentration calculated over 25 samples times 7 runs minimum, N-1 weighted.

1.4.2 Lower Detectable Limit (LDL) PPB

LDL is defined as twice the (RMS) noise at the lower end of the most sensitive operating range.

1.4.3 Zero Drift (PPB)

Zero drift is defined as unadjusted (automatic) operation maximum shift over the given period at constant temperature and pressure.

1.4.4 Span Drift

Span drift is defined similarly to zero drift, requiring unadjusted operation at constant temperature and pressure.

1.4.5 Linearity

< 1.0% of URL, best-straight-line deviation over range of LDL to URL.

1.4.6 Lag Time

Lag time is defined as the time interval between a step change, at the sample inlet port, of input concentration and the first observable corresponding change in analyzer output.

1.4.7 Rise And Fall Times

Rise/fall times are defined as the time interval between a step change in input concentration and 95% of final response unless otherwise noted.

1.4.8 Temperature Range

5-40° C.

1.4.9 Humidity Range

0 to 95% relative humidity, non-condensing.

1-6

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.4.10 Flow Rates

800 scc/min ± 10% (standard cubic centimeters/minute) sample flow rate.

2-5 l/min ± 10% (standard cubic liter/minute) O

1.4.11 Power

Standard input power: 120VAC rms, 60 Hz, 250 watts maximum and 220, 240 V, 50 Hz. 5A resettable circuit breaker.

1.4.12 Weight

27 Kg (60 lb.) maximum.

1.5 Installation And Overview

The Model 401 is shipped with the following standard equipment:

1. Power cord.

2. Instruction manual.

CAUTION

generator flow rate.

To avoid personal injury, always use two persons to lift and carry

the Model 401.

Upon receiving the Model 401 please do the following:

1. Verify no apparent shipping damage. (If damage has occurred please advise shipper first,

then Teledyne API.)

2. Remove all red colored shipping screws from the underside of the instrument. Note: Save

these shipping screws and re-install them whenever the unit is shipped to another location.

3. When installing the Model 401, allow a minimum of 4 inches (100mm) of clearance at the

back of the instrument and 1 inch (25mm) of clearance on each side for proper ventilation.

4. Check that all options ordered are enclosed.

5. Connect analyzer' sample inlet line to the M401 sample port of manifold on rear panel.

1-7

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

NOTE

See Figure 1-4 for rear panel pneumatic connections. Span gas

should only come into contact with PTFE or glass. Leak check

all fittings with soap solution.

Maximum pressure for leak check is 15 PSIG.

6. Connect the pump exhaust to a suitable vent outside the analyzer area.

CAUTION

Connect the exhaust fitting on the rear panel (see Figure 1-5) to a

suitable vent outside the analyzer area.

7. For internal pressurized zero air using an external dry air supply connect AIR IN port to a

clean, dry air supply (see Figure 1-6).

NOTE

For best O3 generator stability and to avoid moisture condensation,

it is recommended that zero air be dried to approximately -20°C dew

point.

For external pressurized dry zero air using an external dry pressurized source (see Figure 1-

6) proceed as follows: a. Remove cap plug from the tee of zero air scrubber assembly and connect external dry

zero air line instead (air pressure should be about 30-40 psi).

b. Install the cap plug to dry air inlet port. c. Verify the power is off and unplug O

GENERATOR pump's power cable connector.

8. Connect a recording device to the terminal strip connections on the rear panel (see

Figure 1-2). See Table 9-4 for setting proper analog output voltage jumpers.

9. Connect the power cord to an appropriate power outlet (see the serial number tag for correct

voltage and frequency).

NOTE

Power plug must have ground lug.

1-8

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

10. Turn on the M401 by switching the switch on the lower right corner of the front panel (See

Figure 2-1). The front panel display should light with a sequence of messages,-API - M401 software version number, then a normal display as shown in Figure 2-2.

11. Allow about 60 minutes for the temperatures to come up to their respective setpoints then

press the leftmost button on the front keyboard to scroll through the TEST values. Compare these values to those noted during the final factory checkout listed in Table 1-1. The values observed should closely match the Table 1-1 values.

NOTE

Words in all caps are messages on the analyzer front panel.

12. Select the range the analyzer will be calibrated on.

a. From the MAIN menu press SETUP to enter the SETUP menu. (See Figure 2-2 for

appearance of front panel.)

b. Press MISC. c. Press D/A. d. Enter the PASSWORD (818). e. Press RNGE (RANGE). f. Enter the derived full scale range for analog outputs and press ENTR. (Example: if full

scale range is 500 ppb, then press corresponding digit's button until desired range is selected and press ENTR.)

g. Press EXIT 3 times to return to the MAIN menu.

13. O

generator flow adjustment. The O3 generator flow is controlled by a precision pressure

regulator and flow restrictor. Increasing upstream pressure of flow restrictor will increase flowrate and vice versa. In order to increase pressure, adjust knob clockwise as needed while monitoring the O

flow test measurement display. In general, the O3 generator flow should be

at least 1 L/MIN in addition of total flow demands for the Model 401 (800 cc/min) and remote analyzers.

NOTE

Adjustment of the O3 generator flow is to be performed by qualified

maintenance personnel only.

1-9

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

14. Generate the Zero Air.

a. Press ZERO from the main menu and enter the password (512). b. Press STBY to terminate or press O

15. Generate the O

a. Press O b. Enter the O

Span Gas.

GN from the main menu and enter the password (512).

concentration value desired (0.05 - 1 ppm range).

c. Press CONC in order to change O d. Press STBY to terminate O

GN to continue to generate O3 span gas.

gas concentration while generating specified O3 gas.

gas generation or press zero to continue to generate zero air.

1-10

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-1: Model 401 Ozone Calibrator Block Diagram

1-11

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

8.7

Figure 1-2: M401 Rear Panel Electrical Connections

1-12

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-3: Rear Panel Electrical and Pneumatic Connections (CE Version)

1-13

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.6 Electrical And Pneumatic Connections

1.6.1 Electrical Connections

Output #1 Ozone concentration - chart recorder Output #2 Ozone concentration - DAS Output #3 Test function analog output Input #4 Zero valve request Input #5 Span valve request Input #6 N/C There are 2 six-pin connector strips on the rear panel shown in Figure 1-2. The pins are divided

into 3-plus/minus pairs and have the functions shown above. Outputs 1 and 2 have identical signals and electrical characteristics. Output 3 is the same as 1

and 2 electrically, but has analog TEST function signals routed to it. See Diagnostics in Section 5 for details.

1.6.2 RS-232

See Figure 1-4. The RS-232 connection is a male 9-pin D-sub connector.

1-14

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-4: RS-232 Pin Assignments

1-15

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.6.3 Pneumatic System

The Model 401 Photometric Calibrator is equipped with a compression pump to deliver up to 5 L/MIN for ozone generator system. It is also equipped with a second pump capable of pulling 800 cc/min across a critical flow orifice. This allows a smooth, stable flow of sample through the Photometer.

Compressed air is delivered through a charcoal scrubber. While one path is used as zero air reference, the other path of same zero air is used to generate the stable ozone output. This will ensure reliable ozone output as well as proper Photometer operation. Please see Figure 1-1 for flow diagram and Figure 1-5 for pneumatic connections.

NOTE

The photometer output varies linearly with pressure and

temperature. Temperature and pressure compensation is

done automatically.

A critical flow orifice is used to control the sample flow. The orifice is a precision-drilled sapphire jewel protected by a 20 micron sintered filter. The critical flow orifice never needs adjustment and maintains precise flow control as long as the ratio of the up-stream to downstream pressures is greater than 0.53 (sonic flow conditions).

1.6.4 Exhaust Connections (See Figure 1-5)

A single 1/4" O.D. tube should be connected from the Analyzer sample exhaust to an area outside of the room the analyzer occupies. The maximum length of the exhaust line should not exceed 30 feet.

1.6.5 Output Flow Adjustment

The flow rate of gas supplied to the output manifold can be changed by adjusting the internal pressure regulator located on the top of the optical bench (see Figure 1-7). The output flow, O FLOW, can be read on the front panel test functions. Adjust this flow rate to provide a minimum of 1 LPM for each analyzer being calibrated plus 1 LPM for the internal photometer in the M401. For example, when calibrating one analyzer the O LPM.

flow rate should be set to at least 2

1-16

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-5: M401 Calibrator Pneumatic Connections

1-17

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-6: M401 Rear Panel (External Dry Zero Air)

1-18

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

Figure 1-7: M401 Calibrator Chassis Layout

1-19

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.7 Operation Verification

The Model 401 Calibrator is now ready for operation.

1. Read Section 1.3 and all of Section 4 of the manual to understand the Calibrator operation.

2. Turn on the power by pressing the on/off switch on the front panel (see Figure 2-1). The

display should turn on and green (sample) status LED should be energized. The green LED should blink indicating the instrument has entered the HOLD-OFF mode. The standby mode can be entered immediately by pressing the EXIT button on the front panel. The red "fault" light will also be on until the flows, temperatures and voltages are within operating limits. Clear the fault messages.

3. After a 60 minute warm-up, review the TEST function values in the front panel display by

pushing the leftmost keyboard button labeled TEST. Not every TEST function is a diagnostic of correct analyzer operation, therefore TEST functions not covered below can be ignored for now.

4. O3 REF, O3 MEAS: TEST function values should be between 4200 mv and 4700 mv.

5. Pressure: 29 to 30 Inches-Mercury-Absolute at sea level. Other values will be displayed

depending on altitude of analyzer.

6. Sample Flow: 800 cc/min ± 10 %.

7. Sample Temp: Ambient temperature +10°

8. Analytical Lamp Temp: 52° C ± 0.1 The computer drives the temp to this setpoint -it should

be this value and not vary.

9. O

GEN Lamp Temp: 48° C ± 1° C.

10. Box Temp: Ambient ± 10° C.

11. DC Power Supply: 2500 mV ± 100 mv. This is a composite of all of the DC voltages in the

instrument. The value is not important but it should be within the range indicated, and should be constant.

12. If the TEST functions are within the limits given above the instrument should function

correctly. If there is a problem please read the manual and check your set-up. The Model 401 is now ready for calibration, see Section 3.

1-20

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.7.1 Final Test And Calibration Values

Table 1-1: Test Values

Test Parameter Displayed Value Units

TIME HH:MM:SS DCPS MV BOX TEMP DEG C O3 OFFSET PPB O3 SLOPE REG PRESSURE IN-HG-A O3 GEN TMP DEG C O3 GEN FLOW L/MIN ANA LAMP TMP DEG C SAMPLE TEMP DEG C SAMPLE FLOW SCC/MIN SAMPLE PRESS IN-HG-A O3 DRIVE MV O3 GEN REF MV O3 REF MV O3 MEAS MV O3 SET PPB/PPM

Options

RACK MOUNTS/SLIDES POWER VOLTS/Hz STATUS OUTPUT RS-232 OUTPUT

Calibration Settings

O3 SPAN SETTING PPB O3 ZERO SETTING PPB O3 SLOPE O3 OFFSET

PROM # Serial # Date Technician

1-21

Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2

1.8 Options

1.8.1 Rack Mount With Slides

This option, including slides and rack mounting ears, permits the Analyzer to be mounted in a standard 19" wide x 30" deep RETMA rack.

1.8.2 Status Outputs

The status output is an option that reports Analyzer conditions to a 50 pin connector from the mother board. The contacts are NPN transistors which can pass 50 ma of direct current. See Section 8.6 for status output pin assignments.

1-22

+ 84 hidden pages