Teledyne 465L User Manual

OPERATION MANUAL
MODEL 465L
OZONE MONITOR
Teledyne Advanced Pollution Instrumentation (TAPI)
San Diego, CA 92121-5201
Phone: 800-324-5190 (toll free in North America)
858-657-9800 (direct)
FAX: 858-657-9816
EMAIL: api-sales@teledyne.com
WEB SITE: http://www.teledyne-api.com/
© 2007-2012 TAPI 05509F DCN6409 Teledyne Advanced Pollution Instrumentation 09 May 2012
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI)
Teledyne Advanced Pollution Instrumentation, Inc. (TAPI) is a worldwide market leader in the design and manufacture of precision analytical instrumentation used for air quality monitoring, continuous emissions monitoring, and specialty process monitoring applications. Founded in San Diego, California, in 1988, TAPI introduced a complete line of Air Quality Monitoring (AQM) instrumentation, which comply with the United States Environmental Protection Administration (EPA) and international requirements for the measurement of criteria pollutants, including CO, SO2, NOX and Ozone.
Since 1988 TAPI has combined state-of-the-art technology, proven measuring principles, stringent quality assurance systems and world class after-sales support to deliver the best products and customer satisfaction in the business.
For further information on our company, our complete range of products, and the applications that they serve , please visit www.teledyne-api.com or contact sales@teledyne-api.com.
Notice of Copyright
© 2007-2012 Teledyne Advanced Pollution Instrumentation. Inc. All rights reserved.
Trademarks
All trademarks, registered trademarks, brand names or product names appearing in this document are the property of their respective owners and are used herein for identification purposes only.
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IMPORTANT SAFETY INFORMATION
Important safety messages are provided throughout this manual for the purpose of avoiding personal injury or instrument damage. Please read these messages carefully. Each safety message is associated with a safety alert symbol and placed throughout this manual and inside the instrument. The symbols with messages are defined as follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message
for specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or the instrument.
Technician Symbol: All operations marked with this symbol are to be performed by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central safety grounding point for the instrument.
CAUTION
GENERAL SAFETY HAZARD
This instrument should only be used for the purpose and in the manner described in this manual. If you use it in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences.
NEVER use any gas analyzer to sample combustible gas(es).
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CONSIGNES DE SÉCURITÉ
Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes suivantes :
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne
complémentaire pour des renseignements spécifiques
MISE EN GARDE : Surface chaude Ne pas toucher : Toucher à certaines parties de l’instrument sans
protection ou sans les outils appropriés pourrait entraîner des dommages aux pièces ou à l’instrument.
Pictogramme « technicien » : Toutes les opérations portant ce symbole doivent être effectuées uniquement par du personnel de maintenance qualifié.
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le point central de la mise à la terre sécuritaire de l’instrument.
MISE EN GARDE
Cet instrument doit être utilisé aux fins décrites et de la manière décrite dans ce manuel. Si vous utilisez cet instrument d’une autre manière que celle pour laquelle il a été prévu, l’instrument pourrait se comporter de façon imprévisible et entraîner des conséquences dangereuses.
NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz combustibles!
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ABOUT THIS MANUAL
This manual is comprised of multiple documents as listed below.
Part
Number
05590 M465L Operation Manual (this manual) 05919 Rack Mount Spare Parts List (integrated into this manual as Section 12.1) 05910 NEMA Spare Parts List (integrated into this manual as Section 12.2)
Name/Description
NOTE
We recommend that this manual be read in its entirety before any attempt is made to operate the
instrument.
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REVISION HISTORY
M465L Operation Manual, PN05509
2012 May 09, Rev F, DCN 6409: technical and administrative updates 2011 August 2, Rev E, DCN 6198: technical and administrative updates 2009 October, Rev D, DCN 5522: technical and administrative updates 2009 October, Rev D, DCN 5522: technical and administrative updates 2009 June, Rev C, DCN 5456: administrative udpates
2009 February, Rev B, DCN 5371: administrative updates 2007, Rev A, Initial Release
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TABLE OF CONTENTS
ABOUT THIS MANUAL.........................................................................................i
SAFETY MESSAGES...........................................................................................ii
ABOUT TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TAPI).....I
1. INTRODUCTION..........................................................................................13
1.1. PREFACE................................................................................................13
2. SPECIFICATIONS AND AGENCY APPROVALS.......................................15
2.1. S
2.2. A
2.2.1. Safety..............................................................................................................16
2.2.2. EMC...............................................................................................................16
2.2.3. Other Type Certifications..............................................................................17
3. PRINCIPLE OF OPERATION......................................................................19
4. GETTING STARTED ...................................................................................21
4.1. PNEUMATIC CONNECTIONS.......................................................................23
4.1.1. Sample Gas Connection.................................................................................24
4.1.2. Exhaust Connection.......................................................................................28
4.2. ELECTRICAL I/O CONNECTIONS................................................................29
4.2.1. Location of I/O Connectors in the NEMA Configuration..............................29
4.2.2. Analog Output................................................................................................29
4.2.3. Status Outputs................................................................................................29
4.2.4. Hi-Current Relay Outputs .............................................................................31
4.2.5. Multi-Stream Relay Outputs (Optional) ........................................................32
4.2.6. Digital Serial Interfaces ................................................................................33
PECIFICATIONS......................................................................................15
PPROVALS ............................................................................................16
5. FREQUENTLY ASKED QUESTIONS .........................................................35
6. OPTIONS.....................................................................................................37
6.1. S
TREAM SELECTOR (3 OR 6 STREAM).......................................................37
6.2. DISPOSABLE SAMPLE INLET FILTERS.........................................................37
6.3. RACK MOUNT SLIDES ..............................................................................37
6.4. ELECTRONIC FLOWMETER........................................................................37
6.5. S
AMPLE CONDITIONER.............................................................................37
6.6. PERMEATION GAS DRYER........................................................................37
7. OPERATION ................................................................................................39
7.1. F
RONT PANEL OVERVIEW.........................................................................39
7.1.1. Ozone Concentration Display .......................................................................39
7.1.2. Menu Navigation Keypad..............................................................................39
7.1.3. Stream Selector Status/Control (Optional)....................................................40
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7.1.4. Concentration Alarm Status/Reset.................................................................40
7.1.5. Status LEDs ...................................................................................................41
7.2. FRONT PANEL MENUS..............................................................................41
7.2.1. Menu Navigation Basics................................................................................41
7.2.2. Editing Numeric Values.................................................................................42
7.2.3. DIAG Menu....................................................................................................45
7.2.4. VIEW Menu....................................................................................................51
7.2.5. CONFIG Menu ..............................................................................................51
7.2.6. SETUP-VARS Menu.......................................................................................52
7.2.7. SETUP-STREAM Menu.................................................................................53
7.3. MULTI-STREAM OPERATION .....................................................................54
8. DIGITAL COMMUNICATIONS....................................................................55
8.1. D
8.2. C
IGITAL COMMUNICATIONS OVERVIEW......................................................55
HANGING COM PORT HARDWARE CONFIGURATION ..................................55
8.3. RS-232 CONFIGURATION.........................................................................57
8.4. RS-485 CONFIGURATION.........................................................................58
8.5. ETHERNET CONFIGURATION.....................................................................59
8.5.1. Hardware Setup for Configuring the Ethernet Module.................................59
8.5.2. Verifying Network Hardware Connection.....................................................59
8.5.3. Determining a Dynamically Assigned IP Address (DHCP Mode)................60
8.5.4. Manually Assigning a Static IP Address .......................................................60
8.6. MODBUS REGISTER MAPS.....................................................................61
8.6.1. MODBUS Commands Supported ..................................................................61
8.6.2. Notes on MODBUS registers.........................................................................61
8.6.3. Real-Time Concentration and Status Registers (Read Only)........................62
8.6.4. Instrument Setup and Configuration Registers (Read / Write)......................63
9. MAINTENANCE AND ADJUSTMENTS......................................................66
9.1. MAINTENANCE SCHEDULE........................................................................66
9.2. I
NSTRUMENT LAYOUT...............................................................................67
9.3. REPLACING INTERNAL PARTICULATE FILTER ..............................................68
9.4. UV LAMP ADJUSTMENT............................................................................69
9.5. UV
9.6. S
LAMP REPLACEMENT..........................................................................70
AMPLE PUMP REPLACEMENT..................................................................70
9.7. SENSOR VALVE REPLACEMENT.................................................................72
9.8. WATER DROP-OUT FILTER (OPTION) MAINTENANCE .................................73
9.9. CONFIGURING THE ANALOG OUTPUT.........................................................73
9.10. C
LEANING EXTERIOR SURFACES OF THE M465L....................................74
9.11. BOOT LOADER OPERATION...................................................................74
9.11.1. Boot Loader – Hardware Setup ..................................................................75
9.11.2. Boot Loader – Software Setup.....................................................................75
10. TROUBLESHOOTING.............................................................................78
10.1. R
EFERENCE DRAWINGS .......................................................................78
10.1.1. Pneumatic Diagram....................................................................................78
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10.1.2. Interconnect Diagram.................................................................................79
10.2. TROUBLESHOOTING USING FRONT PANEL STATUS LED’S OR STATUS OUTPUTS 80
10.2.1. Sensor OK ...................................................................................................81
10.2.2. Invalid Reading...........................................................................................81
10.2.3. Check Lamp.................................................................................................81
10.2.4. Pneumatic Error..........................................................................................81
11. CALIBRATION.........................................................................................84
11.1. FACTORY CALIBRATION ........................................................................ 84
11.2. ZERO CALIBRATION..............................................................................84
12. SPARE PARTS........................................................................................86
12.1. M465L
RACK MOUNT SPARE PARTS LIST..............................................86
12.2. M465L NEMA SPARE PARTS LIST........................................................87
FIGURES
Figure 4-1: NEMA AC Power Connection to Monitor ....................................22
Figure 4-2: Pneumatic Connections, Rack Mount Configuration.................23
Figure 4-3: Pneumatic Connections, NEMA Configuration, Single Stream 23 Figure 4-4: Pneumatic Connections, NEMA Configuration, Multi-Stream...24 Figure 4-5. M465L Pneumatic Diagram with Sample Conditioner and Permeation
Gas Dryer Options (in single-stream configuration).......................26
Figure 4-6: Rear Panel Electrical I/O Connections........................................28
Figure 4-7: NEMA Electrical I/O Connections................................................28
Figure 4-8: Status Output Schematic .............................................................30
Figure 7-1: Front Panel Display.......................................................................39
Figure 7-2: Front Panel Menu Diagram (Page 1)............................................43
Figure 7-3: Front Panel Menu Diagram (Page 2)............................................44
Figure 7-4: Span Cal Menu.............................................................................. 49
Figure 7-5: Flow Cal Menu...............................................................................50
Figure 8-1: Com Configuration Jumper Settings (SW2) ...............................56
Figure 9-1: Instrument Layout, Rack Mount Configuration.......................... 67
Figure 9-2: Instrument Layout, NEMA Configuration....................................68
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Figure 9-3: Sensor Detail................................................................................. 72
Figure 9-4: Mainboard – Analog Output Configuration.................................74
Figure 10-1: Pneumatic Diagram, 3 Stream Configuration...........................78
Figure 10-2: Interconnect Diagram.................................................................79
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TABLES
Table 4-1: Status Output Definitions ..............................................................30
Table 4-2: Relay Functions for Single Stream Config...................................31
Table 4-3: Relay Functions for Multi-Stream Configs...................................31
Table 4-4: Multi-Stream Relays.......................................................................32
Table 7-1: Alarm LED’s.....................................................................................40
Table 7-2: Status LED’s ...................................................................................41
Table 7-3: Analog Step Test Values................................................................45
Table 7-4: Signal I/O List..................................................................................46
Table 7-5: VIEW Menu Parameters..................................................................51
Table 7-6: CONFIG Menu Parameters .............................................................51
Table 7-7: VARS List........................................................................................52
Table 7-8: STREAM Properties........................................................................53
Table 8-1: RS-232 Connector Details..............................................................57
Table 8-2: RS-232 Port Setup ..........................................................................57
Table 8-3: RS-485 Connector Details..............................................................58
Table 8-4: RS-485 Port Setup ..........................................................................58
Table 8-5: Ethernet LED Definitions ...............................................................59
Table 8-6: Supported MODBUS Commands ..................................................61
Table 9-1: Maintenance Schedule...................................................................66
Table 10-1: Status LED/Output Definitions....................................................80
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1. INTRODUCTION
1.1. Preface
The Teledyne API Model 465L is a UV photometric ozone monitor designed and manufactured for single/multi-channel industrial hygiene ozone analysis. It is a very stable analyzer, ideal for critical low-level PPM safety and process applications. Whether you have selected the rack mount or wall mount unit in NEMA 4X enclosure, the M465L is designed to be highly reliable and simple to operate with easy setup and user-friendly menu driven software that can also be set and monitored remotely.
As the M465L was designed for stability, reliability and simplicity, it includes built-in tests and diagnostics to facilitate maximum uptime. In addition to a full one year warranty (see Section
1.2), Teledyne API is pleased to provide you with any support required so that you may utilize our equipment to the fullest extent. Our full time customer service department is available to answer your questions.
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2. SPECIFICATIONS AND AGENCY
APPROVALS
2.1. Specifications
User selectable to any full scale range from: 1 PPM to 500 PPM
Ranges
Measurement Units Zero Noise < .0015 PPM (rms) Span Noise < .5% of reading (rms) (above 0.1 PPM)
1000 PPB to 10,000 PPB 2000 µg/m3 to 10,000 µg/m 100 PPHM to 10,000 PPHM (optional
configuration) PPM, PPB, µg/m3, PPHM (optional
configuration)
3
Lower Detectable Limit < .003 PPM (rms) Accuracy +/- 1% of full scale range
<30 sec
Response Time (95%) Sample Flow Rate 0.8 L/min Temperature Range 5-45o C Humidity Range 10-90% RH, Non-Condensing
Dimensions (H x W x D)
Weight
Power 100-240 VAC, 47-63 Hz, 74W max Environmental Conditions
(<60 sec with the Sample Conditioner option)
5.22” x 19.0" x 15.3" (133 mm x 483 mm x 388 mm) – Rack Mount Version
16.01” x 15.6” x 6.90” (407mm x 396mm x 175mm) – with NEMA 4X enclosure
12.6 lb. (5.73 kg) - Rack Mount Version
15.2 lb. (6.91 kg) – with NEMA 4X enclosure
Installation Category (Overvoltage Category) II Pollution Degree 2
Maximum Operating Altitude 2000 meters
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Analog Output, Voltage Mode 0 - 5V Isolated Analog Output, 4-
20mA Mode System OK Status Relay SPDT (Form C) Dry Contact, 250 VAC, 5A
Global Alarm Relays
Instrument Status Outputs
Multi-Stream Specifications:
Minimum Stream Duration (Cycle Time) 1.0 min
Stream Alarm Relays (HI and HI-HI)
Stream ID Relays
Maximum voltage between outputs and ground 60V peak
SPDT (Form C) Dry Contact, 250 VAC, 5A (x2, HI and HI-HI)
6 - SPST Dry Contact, 50VDC, 250mA Resistive Load
SPST Dry Contact, 50VDC, 250mA Resistive Load (2 per stream)
SPST Dry Contact, 50VDC, 250mA Resistive Load (1 per stream)
2.2. Approvals
This section presents Safety and Electromagnetic Compatibility (EMC) compliance approvals for the Model 465L monitor.
2.2.1. Safety
IEC 61010-1:2001, Safety requirements for electrical equipment for measurement, control, and laboratory use.
CE: 2006/95/EC, Low-Voltage Directive North American:
cNEMKO (Canada): CAN/CSA-C22.2 No. 61010-1-04 NEMKO-CCL (US): UL No. 61010-1 (2nd Edition)
2.2.2. EMC
EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial Immunity EN 55011 (CISPR 11), Group 1, Class A Emissions FCC 47 CFR Part 15B, Class A Emissions CE: 2004/108/EC, Electromagnetic Compatibility Directive
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2.2.3. Other Type Certifications
For additional certifications, please contact Customer Service:
Toll-free
Phone: Phone:
Fax:
Email:
800-324-5190
858-657-9800 858-657-9816
api-customerservice@teledyne.com
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3. PRINCIPLE OF OPERATION
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 465 uses a 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 quartz tube that is alternately filled with sample gas, then filled with gas scrubbed to remove ozone. The ratio of the intensity of light passing through the scrubbed gas to that of the sample forms a 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.
Where:
C
9
10
ln
O
3
273
o
92.29
inHg
o
I = Intensity of light passed through the sample Io = Intensity of light through sample free of ozone
= absorption coefficient
= path length
C = concentration of ozone in ppb
O
3
T = sample temperature in degrees Kelvin P = pressure in inches of mercury
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 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 path length determines how many molecules are present in the column of gas in the absorption tube.
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The intensity of light is converted into a voltage by a high resolution A/D (analog-to-digital) converter. The digitized signal and other variables are used by the CPU to compute the concentration using the above formula.
About every 2.5 seconds the M465 completes a measurement cycle consisting of a 1 second wait period for the sample tube to flush, followed by a 150 ms measurement of the UV light intensity to obtain I. The sample valve is switched to admit scrubbed sample gas for 1 second, followed by a 150 ms measurement of the UV light intensity to obtain Io. Measurement of the Io every 2.5 seconds eliminates instrument drift due to changing intensity of the lamp caused by aging and dirt.
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4. GETTING STARTED
The Model 465 is shipped with the following standard equipment:
Power cord (Rack mount version only) Instruction manual.
Upon receiving the Model 465 please do the following:
1. Verify that there is no apparent shipping damage. (If damage has occurred please advise
shipper first, then Teledyne API.)
2. When installing the Model 465, allow a minimum of 4 inches for clearance at the back of
the instrument (rack mount only) and 1 inch of clearance on each side for proper ventilation.
3. Connect sample inlet line(s) to the sample port on rear panel or bottom panel of
instrument. See Figure 4-2 or Figure 4-3 for rear panel pneumatic connections.
CAUTION
Connect the exhaust fitting on the rear panel (See Figure 4-2) to a suitable vent outside the monitor area.
4. Ensure that there are no communication devices connected until after start-up is
complete.
5. For the NEMA configuration, the electrical connection must be hard-wired to the 3-pin
connector on the mainboard labeled J23. AC power connection to the monitor should be made with 12-14 AWG stranded copper wire, connected to the monitor as follows:
NOTE
Sample tubing made from an inert material such as Teflon should
be used to minimize sample degradation.
Earth Ground (green): Connect the earth ground wire to the screw terminal lug on the
chassis as shown in the Figure below. Do not connect the earth ground wire directly to the PCB connector on the mainboard PCB.
Line (Black): Connect the Line wire to the connector on the mainboard PCB
labeled “Line”.
Neutral (White): Connect the Neutral wire to the connector on the mainboard PCB
labeled “Neutral”.
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Figure 4-1: NEMA AC Power Connection to Monitor
6. Connect the power cord to an appropriate power outlet (see the serial number tag for
correct voltage and frequency).
CAUTION
Verify that the instrument is set up for proper line voltage and frequency. Observe local electrical codes when connecting power to the monitor.
7. Turn on the M465L by switching the switch on the left side of the rear panel, or applying
power to the monitor (NEMA configuration.) The front panel display should light with a sequence of messages, including the instrument serial number and software revision. (When the instrument first powers up, the display will show ‘xxxx’, indicating that the instrument is in start-up mode, waiting for the UV detector readings to stabilize)..
8. After the start-up period, the instrument will begin displaying the ozone concentration
and the optional stream selector will begin operating, if installed.
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4.1. Pneumatic Connections
Figure 4-2: Pneumatic Connections, Rack Mount Configuration
Figure 4-3: Pneumatic Connections, NEMA Configuration, Single Stream
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Figure 4-4: Pneumatic Connections, NEMA Configuration, Multi-Stream
4.1.1. Sample Gas Connection
Sample gas connections are made to the ¼” tube fittings on the rear panel. For single stream monitors, use the fitting labeled “Sample Inlet.” For multi-stream monitors, the sample tubing is connected to the fittings labeled Stream 1, Stream 2, etc (See Figure 4-2, Figure 4-3, Figure 4-4)
1/4" O.D. FEP (Teflon) tubing is recommended to connect the sample source to the monitor. Any fittings used in the sample lines should be constructed of stainless steel or Teflon.
Teledyne API recommends that the length of tubing connecting the sample points to the monitor should be kept to 50 feet or less.
NOTE
For the sampling lines, use only ¼” O.D. FEP tubing. For best analytical performance, the
tubing should be pre-conditioned to ozone prior to installation to minimize ozone loss in the
sampling lines. Pre-conditioned ¼” FEP tubing is available from Teledyne API (Part number
02639)
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4.1.1.1. Sample Filtration
The most important factor in maintaining an accurate and stable monitoring system for ozone is the cleanliness of entire pneumatic system leading up to (and including) the sensor assembly inside the instrument. Provision must be made for keeping dust and other particulate matter out of the monitor and upstream sample delivery tubing. The monitor is equipped with an internal particulate filter down-stream of the selector manifold.
In addition, it is recommended that inlet filters be installed at the inlet of each sample line. These filters should be constructed of PTFE or other inert material to avoid degradation of the ozone concentration. Appropriate disposable inlet filters can be purchased from TAPI. See the Spare Parts list in Appendix A of this manual for ordering information.
4.1.1.2. Sample System Design in Humid Environments
Care must be taken in the design of the sampling system to ensure that water vapor does not condense in the sampling lines or in the instrument itself. The sample lines should be routed to avoid large temperature gradients along the lines. If sample is brought in from a hot, humid area into a much cooler area, then low power heating tape should be wrapped around the lines to keep the temperature of the sample lines up and avoid condensation. The lines should also not have loops or low points where water could collect.
For applications that require sampling of very humid gas, a Sample Conditioner and/or a Permeation Gas Dryer may be required to lower sample gas humidity. A pneumatic block diagram with the locations of these M465L options is shown in Figure 4-5, followed by a description of each. Please contact the Teledyne API Sales Department for additional information.
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Figure 4-5. M465L Pneumatic Diagram with Sample Conditioner and Permeation Gas Dryer Options (in single-
stream configuration)
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