Teledyne 460L User Manual
PRINT DATE: 19 February 2009
INSTRUCTION MANUAL
MODEL 460L
Nema Ozone Monitor
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
USA
Toll-free Phone:
Phone:
Fax:
Email:
Website:
800-324-5190
858-657-9800
858-657-9816
api-sales@teledyne.com
http://www.teledyne-api.com/
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© 2008 T-API 22 January 2009
TELEDYNE INSTRUMENTS
HIGHLIGHTS Model 460L – NEMA Ozone Monitor Instruction Manual
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460L Instruction Manual Safety Messages
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 may be found in the manual and
inside the monitor. The definition of these symbols is described below:
GENERAL SAFETY HAZARD: Refer to the instructions for details on the
specific hazard.
CAUTION: Hot Surface Warning
CAUTION: Electrical Shock Hazard
TECHNICIAN SYMBOL: All operations marked with this symbol are to
be performed by qualified maintenance personnel only.
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 was intended,
unpredictable behavior could ensue with possible hazardous consequences.
NOTE
Technical Assistance regarding the use and maintenance of the Model 460L Nema Ozone
Monitor 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/inquiries.asp
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460L Instruction Manual Table of Contents
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................................... 1
1.1. Preface ..................................................................................................................................1
1.2. 460L Documentation................................................................................................................1
1.3. Using This Manual ...................................................................................................................2
2. SPECIFICATIONS AND WARRANTY .............................................................................................. 5
2.1. Specifications .........................................................................................................................5
2.2. Warranty................................................................................................................................6
3. GETTING STARTED....................................................................................................................... 7
3.1. Unpacking ..............................................................................................................................7
3.2. Mechanical Installation .............................................................................................................9
3.3. Pneumatic Connections ..........................................................................................................10
3.4. Electrical Connections ............................................................................................................ 12
3.4.1. AC Power Connection.......................................................................................................12
3.5. Signal I/O Connections........................................................................................................... 13
3.5.1. Analog Output ................................................................................................................13
3.5.2. Digital Status Outputs......................................................................................................14
3.5.3. Control Inputs ................................................................................................................ 15
3.5.4. Relay Outputs.................................................................................................................15
3.6. Initial Startup .......................................................................................................................17
3.7. Setting up the Serial Communications Port................................................................................ 17
3.7.1. Physical Serial Port Configuration ......................................................................................18
3.7.2. Software Setup for Serial Port Communications ...................................................................19
4. FREQUENTLY ASKED QUESTIONS................................................................................................21
5. OPTIONAL HARDWARE AND SOFTWARE .....................................................................................23
5.1. Sample Conditioning System................................................................................................... 23
5.2. Current Loop Analog Output.................................................................................................... 23
5.3. Ozone Destruct Option ...........................................................................................................23
6. OPERATING INSTRUCTIONS .......................................................................................................25
6.1. Front Panel Display................................................................................................................ 25
6.1.1. O
6.1.2. Zero Point Calibration ...................................................................................................... 25
6.1.3. Status LED’s...................................................................................................................25
6.2. Concentration Alarms............................................................................................................. 26
6.2.1.1. Concentration Alarm Configuration.............................................................................. 26
6.2.1.2. Remotely Sensing the Status of the Alarm.................................................................... 26
6.2.1.3. Clearing Alarms........................................................................................................ 26
7. SERIAL COMMUNICATIONS.........................................................................................................27
7.1. Serial Port Command Syntax...................................................................................................27
7.2. Serial Port Command Summary............................................................................................... 28
7.3. Serial Port Command Reference .............................................................................................. 29
7.3.1. ALMACK.........................................................................................................................29
7.3.2. ALMSTAT .......................................................................................................................30
7.3.3. CZERO ..........................................................................................................................31
7.3.4. DACSTEP .......................................................................................................................32
7.3.5. O
7.3.6. SETADDR.......................................................................................................................34
7.3.7. TDUMP ..........................................................................................................................35
7.3.8. TLIST ............................................................................................................................ 36
7.3.9. VGET ............................................................................................................................37
7.3.10. VLIST ..........................................................................................................................38
7.3.11. VSET ........................................................................................................................... 39
8. CALIBRATION .............................................................................................................................41
8.1. Zero Point calibration............................................................................................................. 41
8.2. Span Point Calibration............................................................................................................ 41
8.3. Adjusting the Optional Current Loop Output .............................................................................. 43
9. MAINTENANCE:...........................................................................................................................45
9.1. Replacing the Particulate Filter Element .................................................................................... 45
readout ....................................................................................................................25
3
.................................................................................................................................33
3
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9.1.1. Filter Replacement Procedure............................................................................................45
9.1.2. Mounting the Particulate Filter Externally............................................................................ 46
9.2. Maintaining the Optional H
9.2.1. Draining the Optional Coalescing Filter ...............................................................................47
9.2.2. Replacing the Coalescing Membrane ..................................................................................48
9.3. UV Lamp Replacement ........................................................................................................... 49
9.4. Cleaning Exterior Surfaces of the 460L ..................................................................................... 50
9.5. Degree of Protection ..............................................................................................................50
10. THEORY OF OPERATION............................................................................................................51
10.1. Basic O
Measurement Principle .............................................................................................51
3
10.1.1. (Beer’s Law)................................................................................................................. 51
10.1.2. The Absorption Path ...................................................................................................... 52
10.1.3. The Reference / Measurement Cycle ................................................................................53
10.1.4. Digital Noise Filter ......................................................................................................... 54
10.2. Pneumatic Theory of Operation.............................................................................................. 55
10.2.1. Basic Pneumatic Flow And Flow Control ............................................................................55
10.2.2. Internal Pump and Flow Control.......................................................................................55
10.2.3. Optional Sample Conditioning .........................................................................................56
10.2.3.1. H
10.2.3.2. H
O Coalescing Filter ............................................................................................... 56
2
O Vapor Dryer..................................................................................................... 56
2
10.2.3.3. Ozone Destruct Scrubber ......................................................................................... 57
10.3. Electronic Theory of Operation............................................................................................... 58
10.3.1. Main Board................................................................................................................... 58
10.3.2. O
10.3.2.1. O
Sensor Module.......................................................................................................... 59
3
Sensor Components ............................................................................................ 59
3
10.3.2.2. Sensor Module PCA .................................................................................................60
10.3.3. CPU Board....................................................................................................................61
10.3.3.1. I/O Functions ......................................................................................................... 61
10.3.3.2. Status and Alarm Functions...................................................................................... 61
10.3.4. Display Driver and Keyboard Assembly............................................................................. 62
10.3.4.1. Keyboard............................................................................................................... 62
10.3.4.2. Display.................................................................................................................. 62
10.3.4.3. Display Driver ........................................................................................................62
10.3.5. Power Distribution ......................................................................................................... 63
11. TROUBLESHOOTING..................................................................................................................65
11.1. Status Output Summary .......................................................................................................65
11.2. Troubleshooting Using Status Outputs .................................................................................... 65
11.2.1. Sensor OK.................................................................................................................... 65
11.2.2. Invalid Reading............................................................................................................. 66
11.2.3. Lamp Low .................................................................................................................... 66
11.2.4. Status LED / Status Output Troubleshooting Summary .......................................................66
11.3. Concentration Alarm Outputs.................................................................................................67
11.4. Technical Assistance ............................................................................................................68
12. A PRIMER ON ELECTRO-STATIC DISCHARGE.............................................................................69
12.1. How Static Charges are Created.............................................................................................69
12.2. How Electro-Static Charges Cause Damage .............................................................................70
12.3. Common Myths About ESD Damage ....................................................................................... 71
12.4. Basic Principles of Static Control ............................................................................................ 72
12.4.1. General Rules ...............................................................................................................72
12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..........................................73
12.4.2.1. Working at the Instrument Rack................................................................................73
12.4.2.2. Working at an Anti-ESD Work Bench.......................................................................... 73
12.4.2.3. Transferring Components from Rack to Bench and Back................................................74
12.4.2.4. Opening Shipments from Teledyne Instruments’ Customer Service.................................75
12.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service ...................76
O Coalescing Filter ........................................................................... 47
2
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460L Instruction Manual Table of Contents
List of Figures
Figure 3-1 M460L Front Cover Layout .............................................................................7
Figure 3-2 460L Layout ................................................................................................8
Figure 3-3 460L Sensor Module Layout ........................................................................... 9
Figure 3-4 460L Mounting Hole Locations and Dimensions ............................................... 10
Figure 3-5 460L Pneumatic Connections........................................................................ 11
Figure 3-6 Location of Electrical Connectors................................................................... 12
Figure 3-7 Signal I/O Connector Pin Assignments........................................................... 13
Figure 3-8 Digital Status Output Connections................................................................. 14
Figure 3-9 Control Input Connections ........................................................................... 15
Figure 3-10 Alarm Output Relays................................................................................... 16
Figure 3-11 RS-232/RS-485 Jumper Location and Settings................................................ 18
Figure 3-12 Typical RS-232 and RS-485 Connections........................................................ 19
Figure 8-1 Setup for Measuring Current Output Signal Level ............................................ 43
Figure 8-2 Location Current Output Adjustment Potentiometers ....................................... 44
Figure 9-1 Changing the Particulate Filter...................................................................... 45
Figure 9-2 Changing the Particulate Filter...................................................................... 46
Figure 9-3 Draining the Optional H2O Coalescing filter..................................................... 47
Figure 9-4 Replacing the Membrane of the Optional H2O Coalescing filter........................... 48
Figure 9-5 UV Lamp Set Screws and Calibration Test Points............................................. 49
Figure 10-1 O3 Absorption Path ..................................................................................... 53
Figure 10-2 Reference / Measurement Gas Cycle ............................................................. 53
Figure 10-3 460L Internal Pneumatic Diagram – Basic Configuration................................... 55
Figure 10-4 460L Internal Pneumatic Diagram with Optional Sample Conditioning ................ 56
Figure 10-5 460L Electronic Block Diagram ..................................................................... 58
Figure 10-6 460L Power Distribution Block Diagram ......................................................... 63
Figure 12-1 Triboelectric Charging ................................................................................. 69
Figure 12-2 Basic anti-ESD Workbench........................................................................... 72
LIST OF TABLES
Table 2-1 460L Specifications....................................................................................... 5
Table 3-1 460L Ventilation Clearances ......................................................................... 10
Table 3-2 Digital Status Output Descriptions................................................................. 14
Table 3-3 Control Inputs............................................................................................ 15
Table 3-4 Relay Output Operation............................................................................... 16
Table 3-5 Serial I/O Port Connection ........................................................................... 17
Table 3-6 Serial Port Configuration.............................................................................. 20
Table 6-1 Status LED’s .............................................................................................. 25
Table 6-2 Concentration Alarm Default Settings ............................................................ 26
Table 7-1 Serial Port Command Summary.................................................................... 28
Table 7-2 VAR_INDEX List for VGET Command ............................................................. 37
Table 7-3 VAR_INDEX List for VSET Command.............................................................. 39
Table 10-1 Measurement / Reference Cycle.................................................................... 54
Table 11-1 Digital Status Outputs Definitions ................................................................. 65
Table 11-2 Status LED / Output Trouble shooting Truth Table........................................... 67
Table 11-3 Alarm Output Troubleshooting...................................................................... 67
Table 12-1 Static Generation Voltages for Typical Activities .............................................. 70
Table 12-2 Sensitivity of Electronic Devices to Damage by ESD......................................... 70
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LIST OF APPENDICES
Appendix A – Spare Parts List
Appendix B – List of Schematics
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460L Instruction Manual Introduction
1. INTRODUCTION
1.1. Preface
Teledyne Instruments is pleased that you have purchased the Model 460L NEMA Ozone Monitor.
Included is a full one-year warranty (see Section 2.2) and we at Teledyne Instruments will be
pleased to provide you with any support required so that you may utilize our equipment to the
fullest extent.
The Model 460L is a microprocessor based low range ozone monitor for safety monitoring of ozone
levels in a variety of applications such as water treatment, food processing, and research. The
design has been specifically optimized for applications requiring the measurement of ozone at the
typically low concentration levels encountered when tracking ambient conditions. The Model 460L
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 460L 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 Instruments Model 460L but if
you do, our full time customer service department is always available to answer your questions.
1.2. 460L Documentation
The documentation for this monitor is available in several different formats:
Printed format, part number 050120100
Electronic format on a CD-ROM, part number 050120200
The electronic manual is in Adobe
Acrobat Reader
the Internet at http://www.adobe.com/.
The electronic version of the manual has many
Keyword and phrase search feature
Figures, tables and internet addresses are linked so that clicking on the item will display
the associated feature or open the website.
®
software, which is necessary to view these files, can be downloaded for free from
®
Systems Inc. “Portable Document Format”. The Adobe®
advantages:
A list of chapters and sections as well as thumbnails of each page are displayed to the left
of the text.
Entries in the table of contents are linked to the corresponding locations in the manual.
Ability to print sections (or all) of the manual
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1.3. Using This Manual
This manual has the following data structures:
1.0 Table of Contents:
Outlines the contents of the manual in the order the information is presented. This is a good
overview of the topics covered in the manual. There is also a list of tables, a list of figures and a
list of appendices. In the electronic version of the manual, clicking on any of these table entries
automatically views that section.
2.0 Specifications and Warranty
This section contains a list of the monitor’s performance specifications, a description of the
conditions and configuration under which Teledyne Instruments Incorporated warranty statement
applies.
3.0 Getting Started:
A concise set of instructions for setting up, installing and starting your monitor for the first time.
This includes unpacking; mechanical installation; attaching all pneumatic lines; attaching all
electrical and electronic connections and the physical configuration the RS-232/RS-485 port.
4.0 FAQ:
Answers to the most frequently asked questions about operating the monitor.
5.0 Optional Hardware & Software
A description of optional equipment to add functionality to your monitor.
6.0 Operation Instructions
Instructions for operating the monitor and using its basic features and functions.
7.0 Serial Communications
Information regarding the syntax and command definitions for the monitor’s serial I/O interface.
8.0 Calibration Procedures
General information and step-by-step instructions for manually calibrating your monitor.
9.0 Monitor Maintenance
Description of certain preventative maintenance procedures that should be regularly performed on
your monitor to keep it in good operating condition.
10.0 Theory of Operation
An in-depth look at the various principals by which your monitor operates as well as a description
of how the various electronic, mechanical and pneumatic components of the monitor work and
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460L Instruction Manual Introduction
interact with each other. A close reading of this section is invaluable for understanding the
monitor’s operation.
11.0 Troubleshooting Section:
This section includes pointers and instructions for diagnosing problems with the monitor, such as
excessive noise or drift, as well as instructions on performing repairs of the monitor’s major
subsystems.
12.0 Electro-Static Discharge (ESD) Primer:
This section describes how static electricity occurs; why it is a significant concern and how to
avoid it and; how to avoid allowing ESD to affect the reliable and accurate operation of your
monitor.
USER NOTES:
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Introduction 460L Instruction Manual
USER NOTES:
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460L Instruction Manual Specifications and Warranty
2. SPECIFICATIONS AND WARRANTY
2.1. Specifications
Table 2-1 460L Specifications
Measurement Principle UV Absorption (Beer Lambert Law)
Ranges 1ppm to 500 ppm: User selectable
Measurement Units ppm; ppb
Accuracy 1% of Full Scale
Zero Noise < 0.0015 ppm (rms)
Span Noise < 0.5% of reading (rms) (above 0.1 ppm)
Lower Detectable Limit < 0.003 ppm (rms)
Linearity Better than 1% of selected range
Response Time (95%) <30 sec
Repeatability 0.5% of selected range
Display Resolution 0001 ppm, 1 ppb
Gas Flow Rate 1.0-2.0 LPM
Compensation Pressure, Temperature (NTP = 273.15K, 760mmHg)
Gas Inlet Pressure Range 11.0 – 16.0 psia
Temperature Range 5-45 ˚C
Humidity Range 10-90% RH, Non-Condensing
Dimensions (H x W x D) 12.64" x 11.19" x 6.08"
(321mm x 284mm x 154mm)
Weight 9.40lb (4.27kg)
Power 110-240V~, 50/60Hz, 200 VA
Environmental Conditions Installation Category (Over Voltage Category) II
Pollution Degree 2
Maximum Operating Altitude 2000 meters
Analog Voltage Output Single output: 0-5V,
Option available converting voltage output to 4-20mA output
with maximum voltage between outputs and ground 60V peak
Relay Outputs 3 relay outputs: Sensor OK and two concentration alarms (HI &
Hi-Hi)
Relay type & Output Rating SPDT: 250V AC, 3A
Degree of Protection (IP Code) IP65 (NEMA 4X)
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Specifications and Warranty 460L Instruction Manual
2.2. 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
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460L Instruction Manual Getting Started
3. GETTING STARTED
3.1. Unpacking
1. Inspect the received packages for external shipping damage. If damaged, please advise
the shipper first, then Teledyne Instruments.
2. Loosen the 2 setscrews located in the top and bottom left corners of the front and swing
open the cover.
O3 Concentration
Display
SYSTEM OK
INVALID READING
LAMP LOW
ALARM ACTIVE
Set Screw
Status
LED’s
ZERO
Buttons
Gas
Ozone Monitor – Model 460L
Alarm
Acknowledge
Key
Flowmeter
&
Control
Set Screw
Figure 3-1 M460L Front Cover Layout
3. Inspect the interior of the monitor to make sure all circuit boards and other components
are in good shape and properly seated.
NOTE
Printed circuit assemblies (PCAs) are static sensitive. Electro-static discharges (ESD),
too small to be felt by the human nervous system, are large enough to destroy sensitive
circuits.
Before touching PCAs, read Chapter 12 of this manual and follow the procedure
described there for avoiding damage to your monitor due to ESD.
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CAUTION
Never disconnect electronic circuit boards, wiring harnesses or
4. Check the connectors of the various internal wiring harnesses and pneumatic hoses to
make sure they are firmly and properly seated (see Figure 3-2).
5. Verify that all of the optional hardware ordered with the unit has been installed. These are
listed on the paperwork accompanying the monitor.
electronic subassemblies while the unit is under power.
Analog Relay
CPU
Board
Outputs
O Vapor Dryer
H
2
(optional)
Scrubber
Not Shown
Optional
Ozone
Display
Board
Flow Meter
Sensor Module
Main
Board
Main
Power
Supply
Pump
Exhaust
Outlet
Figure 3-2 460L Layout
Particulate
Filter
Ozone
Inlet
Signal I/O
Connector
AC Power
Input
Connector
H2O
Coalescing
Filter
(optional)
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A
460L Instruction Manual Getting Started
UV
Lamp
UV Lamp
Power Connector
UV Lamp
Power Supply
Sensor
Module PCA
UV Lamp
Housing
Ozone Outlet
Manifold
Reference
Scrubber
bsorption
Tube
Ozone Intlet
Manifold
UV
Detector
Measure / Reference
Valve
Figure 3-3 460L Sensor Module Layout
3.2. Mechanical Installation
Mount the enclosure securely to a vertical surface.
Figure 3-4 below shows the locations of the four mounting holes.
All four mounting holes should be used to secure the monitor.
Use stainless steel, 5/16” diameter bolts.
VENTILATION CLEARANCE:
When installing the monitor be sure to leave sufficient ventilation clearance.
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Table 3-1 460L Ventilation Clearances
AREA MINIMUM REQUIRED CLEARANCE
Sides of the monitor 1 inch
Above and below the monitor. 1 inch
Figure 3-4 460L Mounting Hole Locations and Dimensions
3.3. Pneumatic Connections
1. Connect a ¼” exhaust line to the fitting labeled ‘Exhaust.’
CAUTION
If using the 460L to measure O3 levels that are ≥100 ppb exhaust gas
from the MODEL 460L may contain dangerous levels of ozone!
2. Connect the ozone delivery line to the ¼” inlet fitting labeled “Ozone Inlet” on the bottom
face of the enclosure (See Figure 3-5.)
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The optional ozone destruct (see Section 5.3) should be installed
and
Make sure that the exhaust line is vented to an outside area.
TELEDYNE INSTRUMENTS
460L Instruction Manual Getting Started
NOTE
The ozone delivery pressure should be at ambient pressure +/- 5 PSIG.
All tubing used should be made of ozone resistant material such as Stainless Steel, PTFE
(Teflon) or FEP. API can supply appropriate tubing for connecting the ozone supply
line.
Display
Ozone
Scrubber
(optional)
Gas
Flowmeter
&
Control
Coalescence
Filter
(optional)
OZONE INLET
Install AC
Power Cord
Through Here
EXHAUST
OUTLET
Figure 3-5 460L Pneumatic Connections
The gas flow rate through the monitor should be established between 1.0 and 2.0 L/min.
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3.4. Electrical Connections
NOTE
It is recommended that if multi-strand wires are used for the following electrical
connections. To ensure a reliable connection the wires should be:
“Tinned” with solder or;
Terminated with insulated crimped ferrules, such as Entrelec
(18 gauge) or 304.558.10 (22 gauge)
3.4.1. AC Power Connection
CAUTION
Disconnect power to the AC mains before making or removing any
electrical connections to the 460L.
®
P/N 304.456.02
CAUTION
A proper earth ground connection must be made to the receptacle
labeled “Earth Ground” on the 3-pin AC connector. Failure to do so may
result in a shock hazard and malfunction of the monitor
Connect AC power to the monitor.
3. Install a ½” conduit fitting for routing the electrical wiring into the monitor through the
hole provided (see Figure 3-5). In order to maintain the IP (NEMA4X) rating of the
enclosure, an appropriate sealed conduit connector should be used.
4. Attach the leads of the power line to the AC power connector (see Figure 3-6)
Analog and
Digital I/O
Connector
Relay
Outputs &
Connectors
Ground
AC Line
AC Neutral
AC POWER
Connector
Figure 3-6 Location of Electrical Connectors
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3.5. Signal I/O Connections
All digital and analog signal I/O connections are made via a 16-pin connector on the main board
(See Figure 3-6 for the location of the connector.)
This connector can be unplugged from the header on the main board for easier access when
wiring. To disconnect from main board, loosen the two retaining screws at either end of the
connector.
Retaining Screw
Analog Out +
Analog Out -
Zero Input
Aux Input
Gnd
Status Out 1
Status Out 2
Status Out 3
Status Out 4
Status Com
Serial TX
Serial RX
Serial GND
Status Out 5
Status Out 6
Retaining Screw
Figure 3-7 Signal I/O Connector Pin Assignments
3.5.1. Analog Output
The 460L is equipped with one analog output that is factory configurable as either a 0-5 VDC
signal or a 4-20 mA signal. You may verify how your 460L is set up by checking the information
on the
The analog output requires two connections: ANALOG +, the signal line, and ANALOG–, the
ground connection. See Figure 3-7 for the locations of the ANALOG OUT + and ANALOG OUT–
pins.
monitor’s serial number tag.
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Getting Started 460L Instruction Manual
3.5.2. Digital Status Outputs
The 460L has six assigned digital status outputs for indicating error and operational status
conditions of the monitor as well as the status of its O
These outputs are in the form of opto-isolated open-collector transistors. They can be used to
drive status LED’s on a display panel or interface to a digital device such as a Programmable Logic
Controller (PLC). Several of the status outputs are useful tools for diagnosing sensor and system
level malfunctions (see Section 11.2 for more information).
Table 3-2 Digital Status Output Descriptions
concentration alarms (see Table 3-2).
3
LABEL
STATUS OUT 1
STATUS OUT 2
STATUS OUT 3
1
2
2
2
NAME OPERATION
Sensor O.K. Normally On
Invalid Reading Normally Off
Lamp Low Normally Off
STATUS OUT 4 Alarm Active Normally Off
STATUS OUT 5 HI Alarm Status Normally Off
STATUS OUT 6 HI-HI Alarm Status Normally Off
STATUS COM Common Pin for all Status Outputs N/A
1
See Figure 3-7 for pin locations of the these output lines on the monitor’s 16-pin I/O
connector
2
See Section 11-2 for definitions and interpretations of these output.
Figure 3-8 shows the most common way of connecting the digital outputs to an external device
such as PLC.
460M
Status Outputs 1-6 (C ollector)
STATUS COM (Emitter)
PLC OR OTHER DEVICE
+5V
Digital Input
Opto-Isolator
Ground
Connection
Provided by PLC
Figure 3-8 Digital Status Output Connections
Note
Most devices, such as PLC’s, have internal provision for limiting the current that the
input will draw from an external device.
When connecting to a unit that does not have this feature, external dropping-resistors
must be used to limit the current through the transistor output to 50mA or less.
At 50 mA, the transistor will drop approximately 0.2V from its collector to emitter.
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460L Instruction Manual Getting Started
3.5.3. Control Inputs
Two digital control inputs are also available for use on the 460L. The control inputs are used for
remote control of the 460L by a device such as a PLC. They are labeled ZERO INPUT and AUX
INPUT (see Figure 3-9).
Table 3-
INPUT DESCRIPTION
ZERO INPUT This input performs exactly the same function as the ‘Zero’ buttons on the front panel.
AUX INPUT This input can be used to clear active concentration alarms in similar fashion as the serial
communications ALMACK.
3 Contro
l Inputs
Signal I/O
Connector
Analog Out +
Analo
Out -
Zero Input
Aux Input (AlmAck)
Gnd
Figure 3-9 Control Input Connections
NOTE:
Never connect a voltage level output from another device to these contacts.
3.5.4. Relay Outputs
The 460L is equipped with three SPDT relays. They are located at the top right hand side of the
main board and are labeled RELAY 1, RELAY 2 & RELAY 3.
RELAY 1 corresponds to the Sensor OK status output and LED;
RELAY 2 corresponds to the HI concentration alarm, and;
RELAY 3 corresponds to the HI-HI concentration alarm
See Section 11.2.1 for more information on the Sensor OK status output.
See Section 6.2 for more information on these alarms.
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Below each relay is a 3-pin connector that allows the relay to be connected for either
normally open or normally closed operation.
Table 3-4 describes how to connect the alarm relays.
NOTE
The relay contacts are rated to 3A at 240VAC. Do not exceed these ratings when
connecting equipment to the instrument.
RELAY FUNCTION
STATUS LEDS
RELAY 1
N.O.
COM
D6
RELAY 2
N.C.
N.O.
D7
RELAY 3
N.C.
COM
N.O.
Figure 3-10 Alarm Output Relays
Table 3-4 Relay Output Operation
RELAY PIN
N.
O.
STATE
C
O
M
2
N.
C.
STATUS
1
LED
N.C.
COM
D8
COMMENTS
SENSOR OK ON
D6 ON 460L is operating normally
1
SENSOR OK OFF
HI Alarm ON
D6 OFF
D7 ON O3 concentration > HI alarm limit
Problem with the O
See Section 11.2.
sensor module.
3
2
HI Alarm OFF
HI-HI Alarm ON
D7 OFF O3 concentration < HI alarm limit
D8 ON O3 concentration > HI-HI alarm limit
3
HI-HI Alarm OFF
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1
Located just below each relay connector (see Figure 3-10)
2
N.O. = Normally Open operation.
N.C. = Normally Closed operation.
3.6. Initial Startup
Perform the following steps when initially starting up the 460L or when bringing the monitor back
into service it has been shut down for repair or maintenance.
1. Turn on power to the monitor.
The display will briefly display the “API” logo followed by the software version.
The display will then begin showing ozone concentration.
2. Establish a flow of ozone to the monitor.
Flow rate through the monitor should be between 0.5 – 2.0 LPM (Liters per minute.)
Adjust as needed using the needle valve of the flow meter on the front panel
(see Figure 3-1).
3. Let the monitor warm up for a minimum of 5 minutes.
4. Check Status LED’s on front panel;
Sensor OK LED should be ON.
All other LED’s should be OFF.
If the Status LED’s are not in this state, refer to Chapter 11 for troubleshooting
information.
5. Observe the monitor for several more minutes at zero to ensure that it is stable.
THE MONITOR IS NOW READY TO MEASURE OZONE.
3.7. Setting up the Serial Communications Port
The 460L’s bi-directional RS-232/485 Serial Port Interface allows the user to communicate with
the monitor via a computer over that computer’s serial communications port (COM port). A
terminal emulation program such as HyperTerminal is required to be installed and running on the
host computer.
The following three pins are provided on the I/O connector for serial communications (see Figure
3-12).
Table 3-
LABEL DESCRIPTION
SERIAL TX Serial Transmit (RS-485 – A)
SERIAL RX Serial Receive (RS-485 – B)
SERIAL GND Serial Ground (RS-232 Only)
5 Serial I/O Port C
onnection
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While the standard factory configuration is for RS-232, the monitor’s serial port can be configured
for either RS-232 or RS-485 (see Section 3.7.1 for the procedure).
Use RS-232 for direct connection to a nearby (no more than 6-8 feet cable length) PC or
Laptop, RS-232 should be used.
Use RS-485 for permanent connection to continuously operating data acquisition systems
or connections over greater distances.
3.7.1. Physical Serial Port Configuration
6. To configure the com port for RS-232 or RS-485, move the 4 shunts on JP3 of the CPU PCA
(P/N #03492) to the proper position as shown in below.
The jumpers may already be in this position but this still needs to be verified.
Also make sure that JP1 is jumpered. It may be hanging off of one pin, make sure it is
jumpered together as in Figure 3-11.
JP2 can either be jumpered or not as it is already shorted on the board.
Reset Button
Micro-Controller
Connector for
Optional 4-20 mA
output
JP2
JP1
JP3
JP3 set for RS-232 JP3 set for RS-485
Figure 3-11 RS-232/RS-485 Jumper Location and Settings
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7. Connect the appropriate type of cable to the 16 pin Signal I/O connector inside the
analyzer.
8. A cable may be included with you instrument. If not, Figure 3-12 below illustrates how to
construct wiring for both RS-232 and RS-485
RS-232
Serial TXD
Serial RXD
Serial GND
connections.
DB9 Female
1
6
2
7
3
8
4
9
5
RS-485
Serial TXD
Serial RXD
Twisted Pair
RS-485-
RS-485-B
Figure 3-12 Typical RS-232 and RS-485 Connections
3.7.2. Software Setup for Serial Port Communications
NOTE
This section refers to various serial communication commands for the M460M. For
detailed information regarding these commands see Chapter 7.
1. Connect the other end of the cable to your serial Com port on your computer
2. Open up Hyper-terminal or another terminal program and set up a connection with the
settings below. Your com port is most likely COM1.
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The Serial Port of the device being used to communicate with the 460L should be
configured as follows:
Table 3-6 Serial Port Configuration
PARAMETER VALUE
Baud Rate 9600 bps
Data Bits 8
Stop Bits 1
Parity None
3. Find the address of the 460L.
This can be accomplished by repeating the O3 command (see Section 7.3.5) for each
possible ad
EXAMPLE: 0O3<CR>
dress (0-9) until the M4
1O3<CR>
2O3<CR>
…
9O3<<CR>
60M responds:
When the instrument responds record the first number in the response line
This is the address of the analyzer.
4. To determine if the M460L is operating correctly type:
1TLIST<CR>
This analyzer will respond with a list of the current values of its test functions. See Section
7.3.8 for a list of the nominal values for these functions
5. C
heck the analyzer’s operation variables (VARS). These describe certain application
ic conditions such as units of measure, measurement ranges, etc.
specif
To check the current state of the VARS, type:
1VLIST<CR>
This analyzer will respond with a list of the current values of its VARS. See Section 7.3.10
for a l
ist of the nomi
6. If you need to change one of the VARS settings, see the VSET command (see Table 7-3 of
Section 7.3.11)
7. After viewing the data
After changing the value of any of the VARS return the analyzer to normal operation.
The simplest way to do this is to turn the analyzer off and back on. User Notes:
nal values for these functions
you can return the analyzer to normal operation.
USER NOTES:
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