Teledyne 460H User Manual
INSTRUCTION MANUAL
MODEL 460H NEMA
OZONE MONITOR
© Teledyne Instruments
Advanced Pollution Instrumentation Division
(T-API)
6565 Nancy Ridge Drive
San Diego, CA 92121-2251
TOLL-FREE: 800-324-5190
TEL: 858-657-9800
FAX: 858-657-9816
EMAIL:
WEB SITE: www.teledyne-api.com
api-sales@teledyne.com
03662
Rev. D
1/8/04
SAFETY MESSAGES
Your safety and the safety of others is very important. We have provided many
important safety messages in this manual. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each
safety message is associated with a safety alert symbol. These symbols are found in the
manual and inside the instrument. The definition of these symbols is described below:
General Warning/Caution: Refer to the instructions for details on the specific
danger.
Caution: Hot Surface
Caution:
Technician Symbol
performed by qualified maintenance personnel only.
was intended, unpredictable behavior could ensue with possibly
Electrical Shock Hazard
: All operations marked with this symbol are to be
CAUTION
The monitor should only be used for the purpose and in the
manner described in this manual.
If you use the monitor in a manner other than that for which it
hazardous consequences.
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page ii
TABLE OF CONTENTS
SAFETY MESSAGES....................................................................................................................................II
TABLE
FIGURES........................................................................................................................................................
TABLES........................................................................................................................................................
I. 0 INTRODUCTION..................................................................................................................................7
1.
1.2
1.3
1.4
2.0 INSTALLATION.................................................................................................................................11
2.1
2.2
2.3
2.4 E
3.0 STARTUP..............................................................................................................................................18
4.0 OPERATION.........................................................................................................................................19
OF CONTENTS ...............................................................................................................................III
1 PREFACE....................................................................................................................................................7
WARRANTY POLICY............................................................................................................................8
PRINCIPLE OF OPERATION .........................................................................................................................9
SPECIFICATIONS ......................................................................................................................................10
MECHANICAL INSTALLATION...................................................................................................................11
PNEUMATIC CONNECTIONS ......................................................................................................................12
AC POWER CONNECTION .........................................................................................................................13
LECTRICAL I/O CONNECTIONS.......................................................................................................14
2.4.1 Analog Output.......................................................................................................................14
2.4.2 Digital Status Outputs ...........................................................................................................15
2.4.3 Control Inputs .......................................................................................................................16
2.4.4 RS232/RS485 Serial Communications Port ..........................................................................17
V
VI
FRONT PANEL DISPLAY............................................................................................................................19
4.1
4.1.1 O3 readout.......................................................................................................................................19
4.1.2 Pressure Display .............................................................................................................................19
4.1.3 Zero Calibration..............................................................................................................................19
4.1.4 Status LED’s....................................................................................................................................19
AUTO-ZERO OPERATION (OPTIONAL)......................................................................................................20
4.2
4.2.1 Auto-Zero Installation.....................................................................................................................20
4.2.2 Auto-Zero Function.........................................................................................................................20
4.2.3 Auto Zero Error...............................................................................................................................20
5.0 SERIAL COMMUNICATIONS..........................................................................................................21
SERIAL PORT CONFIGURATION.................................................................................................................21
5.1
COMMAND SYNTAX .................................................................................................................................21
5.2
COMMAND SUMMARY..............................................................................................................................22
5.3
COMMAND REFERENCE............................................................................................................................23
5.4
5.4.1 CAUTO............................................................................................................................................23
5.4.2 CZERO ............................................................................................................................................24
5.4.3 DACSTEP........................................................................................................................................25
5.4.4 O3....................................................................................................................................................26
5.4.5 SETADDR........................................................................................................................................27
5.4.6 TDUMP...........................................................................................................................................28
5.4.7 TLIST...............................................................................................................................................29
5.4.8 VGET...............................................................................................................................................30
5.4.9 VLIST...............................................................................................................................................31
5.4.10 VSET..............................................................................................................................................32
6.0 MAINTENANCE..................................................................................................................................33
REPLACING THE GAS FILTER ELEMENT (OPTIONAL)..................................................................................33
6.1
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page iii
6.2
CLEANING EXTERIOR SURFACES OF THE M460H .....................................................................................33
DEGREE OF PROTECTION ..........................................................................................................................33
6.3
7.0 SENSOR AND SYSTEM TROUBLESHOOTING............................................................................34
7.1
STATUS OUTPUT SUMMARY .....................................................................................................................34
SENSOR OK..............................................................................................................................................34
7.2
INVALID READING ....................................................................................................................................35
7.3
LAMP LOW ...............................................................................................................................................35
7.4
CELL DIRTY..............................................................................................................................................35
7.5
STATUS OUTPUT SUMMARY TABLE..........................................................................................................36
7.6
APPENDIX A – SERIAL PORT CONFIGURATION............................................................................37
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page iv
FIGURES
Figure 2-1 Mounting Hole Locations........................................................................................................11
Figure 2-2 Pneumatic Connections...........................................................................................................12
Figure 2-3 Electrical Connections.............................................................................................................14
Figure 2-4 Digital Output Connections....................................................................................................15
Figure 2-5 Typical RS232 and RS485 Connections.................................................................................17
Figure A-1 RS232/RS485 Jumpers (Controller PCA#03492) ................................................................37
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page v
TABLES
Table 2-1 Digital Status Output Pins........................................................................................................15
Table 2-2 Control Inputs.............................................................................................................................16
Table 2-3 Serial Port Pins...........................................................................................................................17
Table 4-1 Auto-Zero Function....................................................................................................................20
Table 5-1 Serial Port Configuration ..........................................................................................................21
Table 5-2 Serial Port Command Summary...............................................................................................22
Table 7-1 Digital Status Outputs...............................................................................................................34
Table 7-2 Status Output Truth Table.......................................................................................................36
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page vi
I.0 INTRODUCTION
1.1 Preface
Teledyne API is pleased that you have purchased the Model 460H NEMA. Included is 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 Model 460H is a microprocessor based high concentration ozone monitor for
monitoring process streams in water treatment, food processing, and research
applications. The Model 460H has been designed to give accurate and stable readings
over long time periods with little or no maintenance or calibration.
The flexibility of the software as well as the analog and digital I/O allow the Model 460H
to interface with a broad range of devices for process control and data logging.
We hope you will not experience any problems with the Teledyne API Model 460H but if
you do, our full time customer service department is always available to answer your
questions.
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 7
1.2 WARRANTY POLICY
ADVANCED POLLUTION INSTRUMENTATION DIVISION
02024c
Prior to shipment, Teled yne API equipment is thoroughly inspected and tested. Should equipment
failure occur, Teledyne API assures its customers that prompt service and support will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, Teledyne API stands ready to
provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the
industry. All maintenance and the first level of field troubleshooting are to be performed by the
customer.
NON- TELEDYNE API MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by Teled yn e 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 Tele d y n e 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 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.
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 API should be properly packed for handling and
returned freight prepaid to the nearest designated Service Center. After the repair, the
equipment will be return e d , frei g h t p r e p a i d .
TELEDYNE API
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 8
1.3 Principle of Operation
α
C
T
P
The detection of ozone molecules is based on absorption of 254 nm UV light due to an
internal electronic resonance of the O3 molecule. The Model 460H uses a mercury lamp
constructed so that a large majority of the light emitted is at the 254nm wavelength. Light
from the lamp shines through an absorption cell through which the sample gas being
measured is passed. The ratio of the intensity of light passing through the gas to a
reference measurement which does not pass through the gas forms the ratio I/Io. This
ratio forms the basis for the calculation of the ozone concentration.
The Beer-Lambert equation, shown below, calculates the concentration of ozone from the
ratio of light intensities.
6
C
O
3
=−
α
10
l
×
Where:
I = Intensity of light passed through the sample
I
= Intensity of light through sample free of ozone
o
= absorption coefficient
l = path length
= concentration of ozone in parts per million
O
3
= sample temperature in degrees Kelvin
= pressure in pounds per square inch (absolute)
As can be seen the concentration of ozone depends on more than the intensity ratio.
Temperature and pressure influence the density of the sample. The density of the gas
changes the number of ozone molecules in the absorption cell which impacts the amount
of light removed from the light beam. These effects are addressed by directly measuring
temperature and pressure and including their actual values in the calculation. The
absorption coefficient is a number that reflects the inherent ability of ozone to absorb 254
nm light. Most current measurements place this value at 308 cm-1 atm-1 at STP. The
value of this number reflects the fact that ozone is a very efficient absorber of UV
radiation which is why stratospheric ozone protects the life forms lower in the
atmosphere from the harmful effects from solar UV radiation. Lastly, the absorption path
length determines how many molecules are present in the column of gas in the absorption
cell.
The intensity of light is converted into a voltage by the detector/preamp module. The
voltage is converted into a number by a voltage-to-frequency (V/F) converter capable of
80,000 count resolution. The digitized signal, along with the other variables, are used by
the CPU to compute the concentration using the above formula.
Τ
×× ×
o
Κ
273
.
14 695
Ρ
psi
Ι
l
n
Ι
o
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 9
1.4 Specifications
Measurement Principle UV Absorption (Beer Lambert Law)
Ranges 0-5%, 0-10%, 0-15% w/w, 0-20% w/w
Measurement Units wt%, g/Nm
Accuracy
Precision/Repeatability
Resolution 0.1 % w/w or .01 g/Nm
Response Time (95%) <5 sec to 95%
Compensation Pressure, Temperature (NTP = 273.15K,
Gas Inlet Pressure Range 3.0 – 30.0 psig
Gas Flow Rate 0.2 – 2.0 LPM
Temperature Range 5-45oC
Dimensions (H x W x D) 12.64" x 11.19" x 6.08"
Weight 9.40lb (4.27kg)
Power 110-240V~, 50/60Hz, 2.5A
Environmental Conditions Installation Category (Overvoltage Category) II
Maximum Operating Altitude 2000 meters
Analog Output Voltage 0-5V, 4-20mA (Optional)
Isolated Analog Output 4-20mA
Mode*
Degree of Protection (IP Code) IPX65
*Optional
0-100 g/Nm
400g/ Nm
3
, 0-200 g/Nm3, 0-300 g/Nm3, 0-
3
3
± 1% of Full Scale
±0.5% of Full Scale Range
3
760mmHg)
(321mm x 284mm x 154mm)
Pollution Degree 2
Maximum voltage between outputs and ground
60V peak
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 10
2.0 Installation
Upon receiving the Model 460H please verify that there is no apparent shipping damage.
(If damage has occurred please advise shipper first, then Teledyne API.)
2.1 Mechanical Installation
1. Mount the enclosure securely to a vertical surface. Figure 2-1 below shows the
locations of the four mounting holes. All four mounting holes should be used to
secure the monitor.
6.050 [153.67]
10.700 [271.78]
Figure 2-1 Mounting Hole Locations
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 11
2.2 Pneumatic Connections
1. Connect a ¼” exhaust line to the fitting labeled ‘Exhaust.’ This line should be vented
to an outside area, since the exhaust gas may still contain trace levels of ozone that may
not be completely removed by the built-in the ozone scrubber.
CAUTION
Exhaust gas from the M460H may contain dangerous levels of
2. Connect the ozone delivery line to the ¼” inlet fitting labeled “Ozone Inlet” on the
bottom face of the enclosure (See Figure 2-2.) The ozone delivery should be
regulated to no more than 30psig. All tubing used should be made of ozone resistant
material such as PTFE(Teflon™) or FEP. API can supply appropriate tubing for
connecting the ozone supply line.
3. Connect the oxygen or other zero gas source to the ¼” tube fitting labeled ‘Zero Gas
Inlet.’ Zero Gas supply pressure should be regulated between 5 and 30 psig.
4. The gas flow rate through the monitor should be established between 0.5 and 2.0
L/min.
ozone!
OZONE INLET
WARNING - DO NOT EXCEED
30 PSIG GAS DELIVERY
PRESSURE
ZERO GAS INLET
WARNING - DO NOT EXCEED
30 PSIG GAS DELIVERY
PRESSURE
OF OZONE
EXHAUST
WARNING - THIS GAS MAY
CONTAIN HARMFUL LEVELS
Figure 2-2 Pneumatic Connections
P/N 03662D Teledyne API Model 460H O3 Monitor Operator Manual - Page 12
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