Teledyne 465M User Manual
INSTRUCTION MANUAL
MODEL 465M
OZONE MONITOR
TELEDYNE ADVANCED POLLUTION INSTRUMENTATION (TELEDYNE API)
9480 Carroll Park Drive
San Diego, CA 92121-5201
TOLL-FREE: 800-324-5190
TEL: 858-657-9800
FAX: 858-657-9816
EMAIL: api-sales@teledyne.com
WEB SITE: http://www.teledyne-api.com/
Copyright 2007-2012 06160D DCN 6409
Teledyne Advanced Pollution Instrumentation 23 MARCH 2012
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SAFETY MESSAGES
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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WARRANTY
WARRANTY POLICY (02024F)
Teledyne Advanced Pollution Instrumentation (TAPI), a business unit of
Teledyne Instruments, Inc., provides that:
Prior to shipment, TAPI equipment is thoroughly inspected and tested.
Should equipment failure occur, TAPI assures its customers that prompt
service and support will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, TAPI
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-TAPI MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by TAPI is warranted and will be
repaired to the extent and according to the current terms and conditions of
the respective equipment manufacturer’s warranty.
Product Return
All units or components returned to Teledyne API should be properly
packed for handling and returned freight prepaid to the nearest designated
Service Center. After the repair, the equipment will be returned, freight
prepaid.
The complete Terms and Conditions of Sale can be reviewed at
http://www.teledyne-api.com/terms_and_conditions.asp
CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti-Electro-Static Discharge (ESD)
handling and packing instructions and Return Merchandise
Authorization (RMA) procedures when returning parts for repair or
calibration may void your warranty. For anti-ESD handling and
packing instructions please refer to “Packing Components for
Return to Teledyne API’s Customer Service” in the Primer on
Electro-Static Discharge section of this manual, and for RMA
procedures please refer to our Website at http://www.teledyne-
api.com under Customer Support > Return Authorization.
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TABLE OF CONTENTS
1. INTRODUCTION..........................................................................................................9
1.1. PREFACE..............................................................................................................................................9
2. SPECIFICATIONS AND AGENCY APPROVALS................................................11
2.1. SPECIFICATIONS.................................................................................................................................11
2.2. APPROVALS.......................................................................................................................................12
2.2.1. Safety .......................................................................................................................................12
2.2.2. EMC.........................................................................................................................................12
2.2.3. Other Type Certifications ........................................................................................................12
3. PRINCIPLE OF OPERATION..................................................................................13
4. GETTING STARTED.................................................................................................15
4.1. MECHANICAL INSTALLATION (FOR NEMA 4X ENCLOSURE).............................................................15
4.1.1. Ventilation Clearance..............................................................................................................15
4.2. MECHANICAL INSTALLATION (19” RACK VERSION)..........................................................................16
4.2.1. Ventilation Clearance..............................................................................................................16
4.3. AC POWER CONNECTION (FOR MONITORS IN NEMA 4X ENCLOSURES)...........................................17
4.4. PNEUMATIC CONNECTIONS................................................................................................................19
4.4.1. Ozone Inlet Connection ...........................................................................................................20
4.4.2. Exhaust Connection.................................................................................................................21
4.5. ELECTRICAL I/O CONNECTIONS.........................................................................................................23
4.5.1. Location of I/O Connectors in the NEMA Configuration........................................................23
4.5.2. Analog Output..........................................................................................................................23
4.5.3. Status Outputs..........................................................................................................................24
4.5.4. Hi-Current Relay Outputs........................................................................................................25
4.5.5. Digital Serial Interfaces ..........................................................................................................25
5. FREQUENTLY ASKED QUESTIONS.....................................................................27
6. OPTIONAL HARDWARE AND SOFTWARE........................................................29
6.1. RACK MOUNT SLIDES........................................................................................................................29
6.2. LOW FLOW ALARM ...........................................................................................................................29
7. OPERATION ...............................................................................................................31
7.1. FRONT PANEL OVERVIEW..................................................................................................................31
7.1.1. Ozone Concentration Display..................................................................................................31
7.1.2. Menu Navigation Keypad ........................................................................................................31
7.1.3. Concentration Alarm Status/Reset...........................................................................................32
7.1.4. Status LED’s............................................................................................................................32
7.2. FRONT PANEL MENUS .......................................................................................................................33
7.2.1. Menu Navigation Basics..........................................................................................................33
7.2.2. Editing Numeric Values...........................................................................................................33
7.2.3. DIAG Menu..............................................................................................................................36
7.2.4. VIEW Menu..............................................................................................................................39
7.2.5. SETUP-VARS Menu................................................................................................................. 40
7.2.6. SETUP-ALARM Menu.............................................................................................................41
7.2.7. CONFIG Menu ........................................................................................................................41
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8. DIGITAL COMMUNICATIONS..............................................................................43
8.1. DIGITAL COMMUNICATIONS OVERVIEW ............................................................................................43
8.2. CHANGING COM PORT HARDWARE CONFIGURATION .......................................................................43
8.3. RS-232 CONFIGURATION...................................................................................................................45
8.4. RS-485 CONFIGURATION...................................................................................................................46
8.5. ETHERNET CONFIGURATION ..............................................................................................................47
8.5.1. Hardware Setup for Configuring the Ethernet Module ...........................................................47
8.5.2. Verifying Network Hardware Connection ...............................................................................47
8.5.3. Determining a Dynamically Assigned IP Address (DHCP Mode)...........................................48
8.5.4. Manually Assigning a Static IP Address ..................................................................................48
8.6. MODBUS REGISTER MAPS...............................................................................................................50
8.6.1. Notes on MODBUS registers...................................................................................................50
8.6.2. Real-Time Concentration and Status Registers (Read Only)...................................................50
8.6.3. Instrument Setup and Configuration Registers (Read / Write)................................................50
9. MAINTENANCE.........................................................................................................51
9.1. MAINTENANCE SCHEDULE.................................................................................................................51
9.2. INSTRUMENT LAYOUT .......................................................................................................................52
9.3. REPLACING INTERNAL PARTICULATE FILTER ....................................................................................54
9.4. UV LAMP ADJUSTMENT ....................................................................................................................56
9.5. UV LAMP REPLACEMENT ..................................................................................................................56
9.6. SAMPLE PUMP REPLACEMENT ...........................................................................................................57
9.7. AUTO-ZERO VALVE REPLACEMENT...................................................................................................57
9.8. CONFIGURING THE ANALOG OUTPUT.................................................................................................58
9.9. CLEANING EXTERIOR SURFACES OF THE M465M..............................................................................59
9.10. BOOT LOADER OPERATION..............................................................................................................60
9.10.1. Boot Loader – Hardware Setup.............................................................................................60
9.10.2. Boot Loader – Software Setup...............................................................................................60
10. TROUBLESHOOTING............................................................................................63
10.1. REFERENCE DRAWINGS ...................................................................................................................63
10.1.1. Pneumatic Diagram ..............................................................................................................63
10.1.2. Interconnect Diagram ...........................................................................................................64
10.2. TROUBLESHOOTING USING FRONT PANEL STATUS LED’S OR STATUS OUTPUTS ............................66
10.2.1. Sensor OK..............................................................................................................................67
10.2.2. Invalid Reading .....................................................................................................................67
10.2.3. Check Lamp...........................................................................................................................67
10.2.4. Pneumatic Error....................................................................................................................67
11. CALIBRATION.........................................................................................................69
11.1. FACTORY CALIBRATION ..................................................................................................................69
12. TECHNICAL ASSISTANCE...................................................................................71
13. M465M SPARE PARTS
13.1. SPARE PARTS LIST FOR RACK MOUNT VERSION..............................................................................73
13.2. SPARE PARTS LIST FOR NEMA VERSION.........................................................................................74
............................................................................................73
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FIGURES
Figure 4-1: M465M Mounting Hole Locations and Dimensions .................................................................16
Figure 4-2. NEMA AC Power Connection to Monitor................................................................................18
Figure 4-3: Pneumatic Connections, Rack Mount Configuration................................................................19
Figure 4-4: Pneumatic Connections, NEMA Configuration........................................................................20
Figure 4-5: Rear Panel Electrical I/O Connections......................................................................................21
Figure 4-6: NEMA Electrical I/O Connections............................................................................................22
Figure 4-7: NEMA I/O Label.......................................................................................................................23
Figure 4-8: Status Output Schematic............................................................................................................24
Figure 7-1: Front Panel Display...................................................................................................................31
Figure 7-2: Front Panel Menu Diagram.......................................................................................................34
Figure 7-3: Front Panel Menu Diagram.......................................................................................................35
Figure 7-4: Span Cal Menu..........................................................................................................................39
Figure 8-1: Com Configuration Jumper Settings (SW2)..............................................................................44
Figure 9-1: Instrument Layout, Rack Mount Configuration........................................................................52
Figure 9-2: Instrument Layout, NEMA Configuration................................................................................53
Figure 9-3: Internal Particulate Filter Replacement.....................................................................................55
Figure 9-4: Mainboard – Analog Output Configuration..............................................................................59
Figure 10-1: Pneumatic Diagram (Rack Mount Version)............................................................................63
Figure 10-2: Pneumatic Diagram (NEMA Version with Sample Conditioner)...........................................64
Figure 10-3: Interconnect Diagram..............................................................................................................65
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TABLES
Table 4-1: M465M Ventilation Clearances, NEMA Version ........................................................................15
Table 4-2: M465M Ventilation Clearances, Rack Mount Version................................................................16
Table 4-3: Status Output Definitions............................................................................................................24
Table 4-4: Relay Functions...........................................................................................................................25
Table 7-1: Alarm LED’s...............................................................................................................................32
Table 7-2: Status LED’s...............................................................................................................................32
Table 7-3: Analog Step Test Values.............................................................................................................36
Table 7-4: Signal I/O List.............................................................................................................................37
Table 7-5: VIEW Menu Parameters.............................................................................................................39
Table 7-6: VARS List...................................................................................................................................40
Table 7-7: Alarm Configuration Settings.....................................................................................................41
Table 8-1: RS-232 Connector Details ..........................................................................................................45
Table 8-2: RS-232 Port Setup.......................................................................................................................45
Table 8-3: RS-485 Connector Details ..........................................................................................................46
Table 8-4: RS-485 Port Setup.......................................................................................................................46
Table 8-5: Ethernet LED Definitions ...........................................................................................................47
Table 9-1: Maintenance Schedule ................................................................................................................51
Table 9-2: Required Software ......................................................................................................................60
Table 10-1: Status LED/Output Definitions.................................................................................................66
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1. INTRODUCTION
1.1. Preface
Teledyne API is pleased that you have purchased the M465M. We offer a full one year
warranty (see Section 2.2) 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.
We hope you will not experience any problems with the Teledyne API Model 465M
(M465M) but if you do, the built-in tests and diagnostics should allow you to quickly and
easily find the problem. In addition, our full time customer service department is always
available to answer your questions.
Teledyne API, Customer Service,
9480 Carroll Park Drive
San Diego, California 92121-5201USA
Toll-free Phone: 800-324-5190
Phone:
Fax:
Email:
Website:
858-657-9800
858-657-9816
api-sales@teledyne.com
http://www.Teledyne-API.com
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2. SPECIFICATIONS AND AGENCY
APPROVALS
2.1. Specifications
Measuring principle UV absorption (Beer Lambert Law)
Ranges
Measurement Units PPM, wt%, g/Nm3
Accuracy
Precision/Repeatability
Display Resolution 1 PPM, 0.001 wt%, 0.01 g/Nm3
Response Time (95%) <45 seconds to 95%
Compensation
Gas Inlet Pressure Range 11.0 – 16.0 psia
Sample Flow Rate 0.8 LPM
Temperature Range 5-45o C
Dimensions (H x W x D)
Weight
Power 100-240 VAC, 47-63 Hz, 74 W Max
Maximum Operating Altitude 2000 meters
Analog Output 0 – 5 V or 4-20 mA isolated output
Status Outputs
RS-232 (optional RS-485) 57.6 Kbaud, DB-9 connector
User selectable to any full scale range from:
0-1000 PPM to 0-10,000 PPM
0-5 g/Nm3 to 0-50 g/Nm
0-1 wt% to 0-5 wt%
1% of Full Scale
0.5% of Full Scale
Pressure, Temperature (NTP = 273.15K, 760
mmHg)
Rack Mount (3U Panel) - 5.22” (133 mm) x 19.0"
(483 mm) x 15.3" (388 mm)
With NEMA 4X enclosure – 16.01” (407 mm) x
15.77” (401 mm) x 8.02” (204 mm)
Rack Mount – 13.6 lbs (6.17 kg)
With NEMA 4X enclosure– 16.5 lbs (7.5 kg)
System OK, Invalid Reading, UV Lamp Fault,
Pneumatic Error
3
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2.2. Approvals
This section presents Safety and Electromagnetic Compatibility (EMC) compliance
approvals for the Model 465M 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
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 M465M 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 is passed.
The ratio of the intensity of light passing through the absorption cell and the intensity of
light measured by a reference detector 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
6
10
O
3
L
273
psi
695.14
n
o
I = Intensity of light passed through the sample
Io = Intensity of light through sample free of ozone
= absorption coefficient
L = path length
C = concentration of ozone in parts per million
O
3
= sample temperature in 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 changes the
number of ozone molecules in the absorption path 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
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length determines how many molecules are present in the column of gas in the absorption
tube.
The intensity of light is converted into a voltage by the detector/preamp module. The
voltage is converted into a number by a high resolution A/D (analog-to-digital) converter.
The digitized signal, along with the other variables, is used by the CPU to compute the
concentration using the above formula.
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4. GETTING STARTED
The M465M is shipped with the following standard equipment:
1. Power cord (Rack mount version only)
2. Instruction manual.
Upon receiving the M465M please do the following:
1. Verify that there is no apparent shipping damage. (If damage has occurred
please advise shipper first, then Teledyne API.)
4.1. Mechanical Installation (for NEMA 4X
Enclosure)
Mount the enclosure securely to a vertical surface.
Figure 4-1 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.
4.1.1. Ventilation Clearance
When installing the M465M be sure to leave sufficient ventilation clearance.
Table 4-1: M465M Ventilation Clearances, NEMA Version
Area Minimum required clearance
Back of the monitor None
Sides of the monitor 1 inch
Above and below the monitor 1 inch
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Figure 4-1: M465M Mounting Hole Locations and Dimensions
4.2. Mechanical Installation (19” Rack Version)
The Rack Mount version of the M465M was designed to be operated as a bench-top
monitor or to be mounted in a standard 19” RETMA instrumentation rack. For rack
installations, the four mounting feet should be removed from the bottom of the monitor.
4.2.1. Ventilation Clearance
When installing the M465M be sure to leave sufficient ventilation clearance.
Table 4-2: M465M Ventilation Clearances, Rack Mount Version
Area Minimum required clearance
Back of the monitor 3 inches
Sides of the monitor 1 inch
Above and below the monitor 1/2 inch
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4.3. AC Power Connection (for Monitors in
NEMA 4X Enclosures)
CAUTION
Disconnect power to the AC mains before making or removing
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
1. Install a ½” conduit fitting for routing the electrical wiring into the monitor through
the hole provided in the bottom face of the NEMA enclosure; an appropriate sealed
conduit connector should be used.
2. Attach the leads of the power line to the AC power connector (see Figure 4-6).
any electrical connections to the M465M.
CAUTION
of the monitor
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3. 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:
a. 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.
b. Line (Black): Connect the Line wire to the connector on the mainboard
PCB labeled “Line”.
c. Neutral (White): Connect the Neutral wire to the connector on the
mainboard PCB labeled “Neutral”.
Figure 4-2. NEMA AC Power Connection to Monitor
4. 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.
5. Turn on the M465 H by switching the switch on the left side of the rear panel, or
applying power to the monitor (NEMA configuration.) The front panel display
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should light with a sequence of messages, including the instrument serial number
and software revision. (When the instrument first pow ers up, the display will
show ‘xxxx’, indicating that the instrument is in start-up mode, waiting for the
UV detector readings to stabilize).
After the start-up period, the instrument will begin displaying the ozone concentration
and the optional stream selector will begin operating, if installed.
4.4. Pneumatic Connections
Figure 4-3: Pneumatic Connections, Rack Mount Configuration
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Figure 4-4: Pneumatic Connections, NEMA Configuration
4.4.1. Ozone Inlet Connection
Sample gas connections are made to the ¼” stainless steel compression fitting on the rear
panel. (See Figure 4-3 and Figure 4-4)
1/4" O.D. FEP (Teflon) or Stainless Steel tubing is recom
source to the monitor. Any fittings used in the sample lines should be constructed of
Stainless Steel or Teflon.
The M465M has an internal sample pump and is designed to sample gas that is close to
ambient pressure. Ensure that the sample gas pressure is in the range of 11 – 16 psia
(pounds per square inch absolute.)
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mended to connect the sample
4.4.2. Exhaust Connection
Connect a ¼” OD vent line to the “Exhaust” fitting on the rear panel. This line must be
vented outdoors or to an appropriate discharge system capable of handling ozone. Local
regulations regarding the discharge of ozone to the atmosphere must be observed. Note
that the monitor may be equipped with an internal ozone scrubber for removal of ozone
from the exhaust stream. For safety reasons, the exhaust port must still be vented
appropriately as described above.
CAUTION
Exhaust gas from the M465M may contain dangerous
levels of ozone! Do not vent this gas into enclosed or
occupied areas.
Figure 4-5: Rear Panel Electrical I/O Connections
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