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Teledyne 460L User's Manual

1. 65 11 1 Status Output S rmimarys Meus 65 11 2 Troubleshooting Using Status lt ee 65 iE ELMO 65 11 252 Invalid Reading riter 66 11 2 3 Lamp LOW iE 66 11 2 4 Status LED Status Output Troubleshooting Summary sse 66 11 3 Concentration Alarm QutpUts deer ipee neue see tans dna Re EU e dubbed PAREN DR cee RUM bn T 67 11 4 Technical Assistance zie eere roc treo y dere RR ARI dats AME ed epee dh tens SIR RR 68 12 A PRIMER ELECTRO STATIC 69 12 1 How Static Charges are Created ed der pa etna das s Ra R EXER dae CREAR 69 12 2 Electro Static Charges Cause 70 12 3 Common Myths About ESD 71
2. 5 2 21 amp 5 PAAR 6 GETTING 7 3 1 0 cL 7 3 2 Mechanical Installation Daw ea a OM E RUE RE 9 3 3 Pheurmnatic Connectioris A E E O 10 3 4 Electrical ded ee alee ued 12 3 451 AC POWER COMMECHOMN Ss bee du de dupes oe cee en tele hate 12 3 5 Signal I O Connections eese serere rk ka a 13 32550 Analog OUtpUt sonic ae a 13 3 5 2 Digital Status OUEDpUts iiie en dee EE EST SU re 14 3 5 3 Control Inputs wc desi oo e tene i 15 3 54 Relay Q tp lts fice ei ec pe en prete me se cede ERA Erba MINI
3. 45 9 1 Replacing the Particulate Filter Element nika iisa Eo 45 05228 Rev B iii DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Table of Contents 460L Instruction Manual 9 1 1 Filter Replacement Procedure eene tex e test Lax au nan Rara ere aa pira br REX Rad 45 9 1 2 Mounting the Particulate Filter 1 46 9 2 Maintaining the Optional H O Coalescing Filter sess memes ene 47 9 2 1 Draining the Optional Coalescing Filter esses mmm emen nene 47 9 2 2 Replacing the Coalescing 48 9 3 UV Eamp Repla erment ia 49 9 4 Cleaning Exterior Surfaces of the 460 50 9 5 Degree of Protection coii esent pem eaa tye aise oA ers len Eae RAE 50 10 THEORY OF
4. 51 10 1 Basic Measurement Principle seems eese nennen 51 10 1 1 Beers Law acts rera eae E EROR E E e RE duet ure n ERR RE MED 51 10 1 2 The Absorption Path cio riae erarnan p axe osa petu epa ded ceded det ends 52 10 1 3 The Reference Measurement Cycle renun rasa nahe saa nine ka dana 53 10 1 4 Digital Noise Filter iiec sunu esas unde gnatus e Da REFER FEST 54 10 2 Pneumatic Theory of esee esie mess esee e esie essen 55 10 2 1 Basic Pneumatic Flow And Flow Control menie 55 10 2 2 Internal Pump and Flow eee enn 55 10 2 3 Optional Sample Conditioning 56 10 2 3 1 H 0 Coalescing Filter eee etr dee terrea bu nana n ded t Ea Ee ERE 56 10 2 3 2 HO Vapor DPV ERs sro oi ny ey ieee naan dace xe SR D RA RR PEU ex ded RD 56 19 2 3 3 Ozone Destruct Scr bber REN aD RE ARTE tages Mae ane eM ra iE 57 10 3 Electronic Theory of Operation
5. Opto Isolator Provided by PLC Connection Ground 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 14 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 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 3 Control Inputs 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 Signal I O Connector Aa Analog Out Analog 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
6. ia enne ene ases ase ann 17 Table 3 6 Serial Port Configuration isis eei ria reir Fatih oe EX FR Xe rd ER ER eal a a 20 Table 6 1 Status LED xe Le am E Qu ceva VE vcn eR D AE DR EA 25 Table 6 2 Concentration Alarm Default Settings ssssssssssssse mme 26 Table 7 1 Serial Port Command 28 Table 7 2 VAR INDEX List for VGET Command 37 Table 7 3 VAR INDEX List for VSET 39 Table 10 1 Measurement Reference 54 Table 11 1 Digital Status Outputs Definitions 65 Table 11 2 Status LED Output Trouble shooting Truth 67 Table 11 3 Alarm Output TroubDleShooting ccceee cece eee eee 67 Table 12 1 Static Generation Voltages for Typical Activities 70 Table 12 2 Sensitivity of Electronic Devices to Damage by 70 05228 Rev B v DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Table of Contents 460L Instruction Manual LIST OF APPENDICES Appendix A Spare Parts List Appendix B List of Schematics vi 0
7. var index Name Description 0 ANALOG RANGE Full Scale concentration range for Analog Output scaling 0 disabled 1 ALARM ENABLE 1 enabled 0 latching 2 1 non latching Molecular weight of carrier gas e g 32 0 O2 Only used by 3 COREE EIGN 460L s with ppmw capability 4 COMM_MODE Not Used 5 IIR The sensitivity of the software filter used by the monitor to reduce T noise and hysteresis in the reported concentration reading 2 lt 6 CONC UNITS 3 ppm 7 HI ALARM LEVEL Sets the trigger limit of the HI alarm 8 HI HI ALARM LEVEL Sets the trigger limit of the HI HI alarm NOTE Only one yar index is allowed per iteration of the VGET command RESPONSE address var value checksum CR EXAMPLE Command 1VGET 8 lt CR gt Request limit value for HI concentration Alarm Response 1 300 02348 CR HI alarm limit is 300 0 ppb NOTE Response is in units of measure for which the monitor is set 05228 Rev B DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED 37 TELEDYNE INSTRUMENTS Serial Communications 460L Instruction Manual 7 3 10 VLIST SYNTAX lt address gt VLIST lt CR gt DESCRIPTION Returns a formatted easy to read list of an internal configuration variables VAR s and their current values DATA PARAMETERS SENT None RESPONSE VAR List See Below EXAMPLE Command 1VLIST lt CR gt Response 0 analog_range 1000 0 1 alarm_enable
8. TELEDYNE NSTRUMENTS 460L Instruction Manual Getting Started 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 e The display will briefly display the API logo followed by the software version e The display will then begin showing ozone concentration 2 Establish a flow of ozone to the monitor e 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 e Sensor OK LED should be ON e All other LED s should be OFF e 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
9. Relay Outputs amp Connectors Ground AC Line I Neutral AC POWER Connector Figure 3 6 Location of Electrical Connectors 05228 Rev B DCN 5164 12 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE I NSTRUMENTS 460L Instruction Manual Getting Started 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 O Analog Out 5 Zero Input 5 Aux Input 5 5 Status Out 1 Status Out 2 Status Out 3 5 Status Out 4 Status Com Serial TX Serial RX 5 Serial GND 5 Status Out 5 5 Status Out 6 5 T 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 monitor s serial number tag 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 05228 Rev B 13 DCN 5164 PRINTED DO
10. Scrubber Measure Cycle Gas Path Gas Particulate Filter ABSORPTION TUBE Pressure Sensor DESTRUCT Optional Figure 10 3 460L Internal Pneumatic Diagram Basic Configuration 10 2 2 Internal Pump and Flow Control Air flow through the M460L Monitor is supplied by a single diaphragm brushless DC pump that pulls air though the monitor Since diaphragm pumps necessarily heat and compress the air they are pumping and since both temperature and pressure fluctuations can effect the measurement the pump is placed down stream from the measurement cell to avoid any inadvertent effects resulting from the pumping action An adjustable needle restrictor valve and flow gauge located on the front panel of the monitor allow the user to manually adjust the gas flow rate through the monitor Particulate Filter To remove particles in the sample gas which might clog airways or foul the measurement cell optics the monitor is equipped with a glass fiber membrane filter of 25 mm diameter with a pore size of 1 5 microns The filter is located inside the black housing on the bottom of the monitor See Section 9 1 for location and instruction for replacing the filter element 05228 Rev B 55 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L Instruction Manual 10 2 3 Optional Sample Conditioning The source air measured by the 460L needs to be as dr
11. What do I do if I smell Ozone and suspect a leak Ensure that all the fittings are tight If the fittings are tight and ozone is still detected send the monitor back for repair to Teledyne Instruments customer service for repair What do I do if my CPU status light stops flashing The CPU has stopped working This is a major malfunction of the monitor Return it to Teledyne Instruments customer service for repair What do I do if the Status OK light turns off or doesn t turn on after 30 min If the status ok light is off and the Lamp low light is on then the monitor s UV lamp needs to be adjusted If the status ok light is off and the Lamp Low light is off then most likely the UV lamp output has drifted to 5000mv and needs to be adjusted What does it mean if the Invalid Reading light turns on This will happen if the e Ozone supply pressure exceeds 14 9 psia e Ozone concentration exceeds the Range of the monitor then this light will turn on e Ozone concentration goes excessively negative What do I do if my Lamp Low light turns on If the Lamp Low light turns on and the Status OK light is ON the UV reference value has dropped to 1000mv The monitor will continue to run with no problems until the UV reference drops below 500mv If the Lamp low light turns on and the Status OK light is OFF the UV reference has dropped below acceptable limits and will have to be adjusted Q When sho
12. aua WERE ARR A 29 ALMACK PITT NE 29 7 32 AEMSTAT s iieri ded caning ERR ERTRRFRYR TURA adda edag ATA E ER ERI 30 F336 rA ORE 31 7 3 4 DAGCS TEP cec EI PA 32 PBL O E M 33 7 36 SETADDRei sss T M 34 7 3 75 UDIMP i 35 7 3 Oe e PEE 36 aie beatae IL 37 73 10 VEIST m 38 E dae dee 39 8 CALIBRATION 41 Zero Point Calibration e eene aan rre ud avd 41 8 2 Span Point Calibration is e eeiam E Pete dort dint pul Muted exe Ha dente xin in nU bude EM NIE E de 41 8 3 Adjusting the Optional Current Loop 43 9
13. 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 05228 Rev B 3 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS I ntroduction 460L Instruction Manual USER NOTES 4 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 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 1 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 190 of selected range Response Time 9590 30 sec Repeatability 0 59
14. 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 amp RELAY 3 e RELAY 1 corresponds to the Sensor OK status output and LED e RELAY 2 corresponds to the HI concentration alarm and e 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 05228 Rev B 15 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Getting Started 460L Instruction Manual 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 1 RELAY 2 RELAY 3 Q N O COM N C N O COM N C N O STATUS LEDS Figure 3 10 Alarm Output Relays Table 3 4 Relay Output Operation RELAY PIN STATE RELAY FUNCTION POST COMMENTS 5 SENSOR OK ON oe D6 ON 460L is operating normally Problem with the O3 sensor module SENSOR OK OFF D6 OFF oe Section TL2 HI HI Alarm OFF HI Alarm OFF D7 HI HI Alarm ON oo D8 ON eem 16 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164
15. OZONE INLET Install AC EXHAUST Power Cord OUTLET Through Here Figure 3 5 460L Pneumatic Connections The gas flow rate through the monitor should be established between 1 0 and 2 0 L min 05228 Rev B 11 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Getting Started 460L Instruction Manual 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 P N 304 456 02 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 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 2 conduit fitting for routing the electrical wiring into the monitor through the hole provided see Figure 3 5 In order to maintain the IP 4 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
16. outpt Outputs Detector Assy T Measurement Amplifier Detector Status Output Sample Gas Drivers P ressure Sensor M R Valve Control M R Valve Relay Status Output Serialo Outputs UV Lamp Analog and Digital Connector Heater Sensor OK Relay HI Alarm Relay HI HI Alarm Relay Main Board Control Inputs Figure 10 5 460L Electronic Block Diagram Electronically the 460L is of modular design see Figure 10 5 Each Sub module performs a specific set of functions as described in Sections 10 3 1 through 10 3 5 10 3 1 Main Board This printed circuit assembly provides interconnection between the monitor s other electronic modules some opto isolated signal buffers for the digital status outputs and control inputs and is the location of the three solid state output relays see Section 3 5 5 The monitor s main power supply see Section 10 3 5 is also located on this assembly 58 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Theory of Operation 10 3 2 Sensor Module The heart of the 460 Monitor is the sensor module This electromechanical assembly located at the left hand side of the enclosure includes all of the pneumatic mechanical and electronic components needed to gather the data required to calculate the content of the source gas 10 3 2 1 Sensor Components UV La
17. 0 20 mA is also available 5 3 Ozone Destruct Option An externally mounted scrubber see Figure 3 5 is available for the 460L monitor for use when measuring O levels that are 2100 ppb Ozone levels this high will damage several of the components of the monitor downstream of the sensor module such as the flow meter and the pump High levels of are hazardous and should be removed from the gas stream exhaust CAUTION Make sure that the exhaust line is vented to an outside area 05228 Rev B 23 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Optional Hardware and Software 460L Instruction Manual USER NOTES 24 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Operating Instructions 6 OPERATING INSTRUCTIONS The 460L has been designed for simple and trouble free operation The sections below detail the operational features of the 460L 6 1 Front Panel Display 6 1 1 readout The current ozone concentration is displayed in the 4 digit readout in the center of the display The concentration is displayed in the currently selected units either wt g Nm3 or ppm ppb 6 1 2 Zero Point Calibration The 460L needs little or no calibration in the field however sometimes minor measurement offsets can occur To compensate for this a zero point calibration can be initiated by using the two ZERO buttons See Section 8 1 for mo
18. 1 0 2 alarm_mode 0 0 3 carrier_weight 32 0 4 comm_mode 0 0 5 iir_filt 0 25 6 conc_units 2 0 7 hi_al_level 100 0 8 hihi_al_level 300 0 NOTES No checksum is sent in the response to the VLIST command The 460L does not use the comm_mode so its value will always be hi al level and hihi al level are returned in the units of measure for which the monitor is set 38 PRINTED DOCUMENTS ARE UNCONTROLLED 05228 Rev B DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 11 VSET SYNTAX address VSET var index new value CR DESCRIPTION Sets value of an internal configuration variable VAR DATA PARAMETERS SENT index index number for internal VAR See VGET for index list new value new value for VAR RESPONSE address var value checksum CR Table 7 3 VAR INDEX List for VSET Command var index Name Description Allowable Range Sets the full scale concentration range for 1 ppb 1000 ppb 0 ANALOG RANGE Analog Output scaling 0 001 ppm 1 000 ppm 0 disabled 1 ALARM ENABLE Enables or disables the Concentration alarms t enabled 2 ALARM MODE Selects latching mode or non latching mode for p latching both alarms 1 non latching Sets the molecular weight of carrier gas for CARRIER WEIGHT wt calculations e g 32 0 02 PROT een 4 COMM_MODE Not Used N A Sets the sensitivity of the
19. 12 4 Basic Principles of Static 72 12 4 1 General Rules 2 E Da RN EE IRR RR 72 12 4 2 Basic anti ESD Procedures for Analyzer Repair and Maintenance 73 12 4 2 1 Working at the Instrument Rack agua aa nuin 73 12 4 2 2 Working at an Anti ESD Work 73 12 4 2 3 Transferring Components from Rack to Bench and 74 12 4 2 4 Opening Shipments from Teledyne Instruments Customer 75 12 4 2 5 Packing Components for Return to Teledyne Instruments Customer Service 76 iv 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Table of Contents List of Figures Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 12 Figure 8 1 Figure 8 2 Figure 9 1 Figure 9 2 Figure 9 3 Figure 9 4 Figure 9 5 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 12 1 Figure 12 2 M460L F
20. The normal state for the Sensor OK output in ON During the warm up period on start up this output will stay off until the UV lamp reaches a minimum intensity If this output remains OFF after the 15 minute warm up period or goes off during normal operation the 460L is in need of servicing If the Sensor OK output turns OFF e One of the analog voltages output by the sensor module reference measure is too high This could mean that the lamp output has drifted high e The reference voltage output by the sensor module reference measure is too low This could mean that the lamp intensity has drifted very low or the lamp is completely off 05228 Rev B DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED 65 TELEDYNE INSTRUMENTS Troubleshooting 460L Instruction Manual e The sensor is not responding to CPU requests for data This could represent a variety of electronic problems with the sensor module or internal communication between the CPU and the sensor module 11 2 2 Invalid Reading The normal state for the Invalid Reading output is OFF When this output turns ON the 460L is still operational but a system fault or calibration fault exists that may make the current ozone reading invalid The Invalid Reading output is turned ON for any of the following conditions e The measured pressure in the measurement cell exceeds too high indicating that the supply is under pressure e The measured pressure in the me
21. USER NOTES 64 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 4601 Instruction Manual TELEDYNE I NSTRUMENTS Troubleshooting 11 TROUBLESHOOTING This chapter gives guidelines for diagnosing system and sensor malfunctions using the five digital Status Outputs provided by the 4601 All troubleshooting should be done after the 460L has been turned on and allowed to warm up for at least 15 minutes 11 1 Status Output Summary Table 11 1 below gives a summary of the operation of the Status Outputs on the 460L See Section 3 5 2 Digital Status Outputs for information on connecting these outputs Table 11 1 Digital Status Outputs Definitions LED on ON STATE OFF STATE FRONT PANEL Measure 1230mV Sensor Reference 1230mV 5 UV Lamp Off Reference lt 250 mV YES No data from The sensor Pressure 14 9 psia Invalid Pressure 9 psia 2 Reading Negative Ozone Concentration Normal State YES Concentration Over Range 3 Lamp Low Reference 375 mV Normal State YES Alarm Either the HI or the HI HI Os 4 Active concentration Alarm is active No ConcentratiOon alarms are active YES Measured concentration is gt 5 HI Alarm than the HI alarm set point Normal State NO HI HI Measured O concentration 2 the 6 Alarm HI HI alarm set point Normal State NO 11 2 Troubleshooting Using Status Outputs 11 2 1 Sensor OK
22. UV Lamp Power Connector e Reset button Test Point 4 Test Point 11 Test Point 10 Figure 9 5 UV Lamp Set Screws and Calibration Test Points 05228 Rev B 49 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Maintenance 460L Instruction Manual 9 4 Cleaning Exterior Surfaces of the 460L If necessary the exterior surfaces of the 460L can be cleaned with a damp cloth Do not attempt to clean any of the other surfaces of the monitor Do not submerge any part of the monitor in water or cleaning solution 9 5 Degree of Protection The Model 460L has a water ingress rating of IP65 which indicates that it can withstand strong jets of water and is totally protected against dust USER NOTES 50 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Theory of Operation 10 THEORY OF OPERATION 10 1 Basic Measurement Principle 10 1 1 Beer s Law The detection of ozone molecules in a gas is based on the principle that ozone is a very strong absorber of UV light with a wavelength of 254 nm If the distance that this light travels through the gas is always the same the more ozone present in a gas the more UV light is absorbed If the distance the light travels through the gas the intensity of light passing through the ozone containing gas as well as the intensity of the light which does not pass through the gas are all known the amount of ozone pr
23. away at the defect over time causing the device to fail well before its designed lifetime is reached These latent failures are often the most costly since the failure of the equipment in which the damaged device is installed causes down time lost data lost productivity as well as possible failure and damage to other pieces of equipment or property Static Charges can t build up on a conductive surface There are two errors in this statement Conductive devices can build static charges if they are not grounded The charge will be equalized across the entire device but without access to earth ground they are still trapped and can still build to high enough levels to cause damage when they are discharged A charge can be induced onto the conductive surface and or discharge triggered in the presence of a charged field such as a large static charge clinging to the surface of a nylon jacket of someone walking up to a workbench As long as my analyzer is properly installed it is safe from damage caused by static discharges It is true that when properly installed the chassis ground of your analyzer is tied to earth ground and its electronic components are prevented from building static electric charges themselves This does not prevent discharges from static fields built up on 05228 Rev B 71 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS A Primer on Electro Static Discharge 460L Instruction Manual other things li
24. issii redemit xke dinde Rea YR RE dee rD RI ER IRR ded tetas 58 10 31 4 58 10 3 2 05 5 50 Mod le chicas 59 10 3 2 1 Os Sensor COMPONMENES eno cr RR ahd ERRARE 59 10 3 2 2 Sensor Mod lg PQA tne Rer aue sanders esti FUE Cen ebd lieti dn Er 60 10 3 3 CPU Board crie reme sies xir se dsc aud en de eie kar se naar 61 10 3 3 L I O F nctignsu iia vinesex pter oe eos aepo dae dae Ae x E ER RII Rr del RE Ree RE Lhe tae Senna 61 10 3 3 2 Status and Alarm F nctions ede eese exe haat see cepe Coe 61 10 3 4 Display Driver and Keyboard 62 19 3 4 1 Key Board ptm M 62 10 354 22 DISPIAY A an a a Ea E a e aan Vae A OaE Aaaa E EEEE Ea 62 10 3 4 3 Display DriVe ninder iais tas eed airaa aa ENa 62 10 3 57 Power enaa Dk aE a aaa e PNE cas atau ed tne aa aE A 63 11
25. levels of the output to ensure that it matches the input requirements of your recording device See Section 3 5 1 for details on making connections to the 4 20mA output To manually adjust the zero and span points of the 4 20mA analog output 1 Disconnect the monitor from AC power 2 Connect current measuring meter in series with the 4 20mA output For best results the 4 20mA output should be calibrated with the actual load measuring device attached If this cannot be done then a 250 500 ohm resistor should be placed in series with the current meter to simulate a load See Figure 3 6 for pin assignments of the signal I O connector on the rear panel ANALOG OUT ANALOG OUT Recording Monitor Device Figure 8 1 Setup for Measuring Current Output Signal Level 3 While reconnecting the monitor to AC power press and hold the Alarm Reset button on the front panel This will cause the monitor to enter the analog output step mode The display on the monitor will display A 0 indicating that it is in the analog output step mode and at the 090 point see Section 7 3 4 4 Atthis point the analog output should read somewhere near 4 0mA Adjust the Zero potentiometer on the 4 20mA PCA See Figure 8 2 as necessary 05228 Rev B 43 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Calibration 460L I nstruction Manual 5 The monitor will automatically generate the n
26. sent by the CPU via an I C bus and the individual segments of the display ON OFF The clock signal used to decode this data is supplied by the monitor s main CPU The four digits on the display are controlled by multiplexing between two pairs of 2 digits each The display is operated in static mode Each value sent by the CPU is held on the LED display until a new value is sent 62 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual Theory of Operation 10 3 5 Power Distribution The 460L operates on 90 to 260 VAC power at either 50Hz or 60Hz As illustrated in Figure 10 6 below power enters the monitor via a standard 3 conductor power cord through a hole provided in the bottom of the casing In order to maintain the IP 4 rating of the enclosure an appropriate sealed conduit connector should be used Status I O Serial I O Analog Port Outputs Status LEDS Sensor Assembly Power Supply Detector Sensor OK E Invalid Reading CPU 9 VDC Pressure E Board Sensor Lamp Low Cell Dirty UV LAMP TEMPERATURE SENSOR 5 VDC MEASUREMENT CELL TEMPERATURE SENSOR Keyboard Main Power Supply Main Power Supply 15 VDC 200VAC 3kHz 12 VDC UV Lamp 1000VAC Peak Heater Vacuum Pump Output Relays Display LED Display Driver Board UV Lamp Power Supply 4osues 50 VAC IN tt UV LAMP M
27. serial communications see Figure 3 12 Table 3 5 Serial I O Port Connection LABEL DESCRIPTION SERIAL TX Serial Transmit RS 485 A SERIAL RX Serial Receive RS 485 B SERIAL GND Serial Ground RS 232 Only 05228 Rev B 17 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Getting Started 460L Instruction Manual 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 5 232 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 e 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 2 can either be jumpered or not as it is already shorted on the board Reset Button Micro Controller i ED eot Connector for 2 Optional 4 20 mA O output JP3 set for RS 232 JP3 set for RS 485 Figure 3 11 RS 232 5 48
28. software filter used 0 05 1 0 5 IIR_FILT by the monitor to reduce noise and hysteresis i i in the reported concentration reading 6 CONC_UNITS O concentration measurement units A 10 ppb x 1000 ppb 7 HI AL LEVEL Sets the trigger limit of the HI alarm 0 010 ppm x 1 000 ppm _ 10 ppb x 1000 8 HIHI AL LEVEL Sets the trigger limit of the HI HI alarm 0 010 ppm x 1 000 ppm NOTE Only one yar index is allowed per iteration of the VSET command EXAMPLE1 Command 1VSET 8 275 0 CR Set HI HI concentration alarm to 275 0 ppb Response 1 0K 261 lt CR gt VSET Successful 1 FAIL 391 lt CR gt VSET Failed 05228 Rev B 39 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L I nstruction Manual EXAMPLE2 Command 1VSET 6 1 CR Set CONC UNITS VAR to ppm Response 1 0K 261 lt CR gt VSET Successful 1 FAIL 391 lt CR gt VSET Failed NOTES ANALOG_RANGE Setting is in whatever units selected by the CONC_UNITS VAR ALARM_ENABLE The concentration alarms cannot be enable disabled independently ALARM_MODE The mode of the concentration alarms cannot be set independently CARRIER_WEIGHT This variable is only used by 460L s with ppm by weight capability ppmw e The molecular weight of pure is 32 e The nominal molecular weight of ambient air is 28 96 COM_MODE The 460L does not use comm_mode VAR so its value
29. union fitting 4 Unscrew the union fitting from the fitting at the top of the filter fitting B in Figure 9 2 Although the union fitting is no longer needed save it in case you wish to return the particulate filter to the inside of the monitor at a later date 5 Unscrew the pressure fitting at the bottom of the filter Fitting C in Figure 9 2 from the ozone inlet 6 Reattach the filter to the external side of the ozone inlet 7 Attach the internal gas line to the internal side of the ozone inlet using Fitting A 8 After reassembly the gas line should be pressurized with oxygen or dry air and checked for leaks using a bubble solution BEFORE AFTER Pressure Fitting B Pressure Fitting Pressure Fitting A m Pressure Pn lt t Fitting B Pressure No Inlet Gas Line p Fitting C Figure 9 2 Changing the Particulate Filter 46 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Maintenance 9 2 Maintaining the Optional H20 Coalescing Filter 9 2 1 Draining the Optional Coalescing Filter The coalescing filter component of the optional sample conditioning system may accumulate with water see Figure 9 3 for filter location It must be checked periodically and drained It is recommended that the filter be checked every 2 hours for the first several days of the monitor s operation to determine the fill rate of the filter s reservo
30. 0 of selected range Display Resolution 0001 ppm 1 ppb Gas Flow Rate 1 0 2 0 LPM Compensation Pressure Temperature 273 15K 760mmHg Gas Inlet Pressure Range 11 0 16 0 psia Temperature Range 5 45 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 amp Hi Hi Relay type amp Output Rating SPDT 250V AC 3A Degree of Protection IP Code IP65 NEMA 4X 05228 Rev B 5 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS 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
31. 0000031 WINDOW QUARTZ 1 2 DIA 063 THICK KB OR0000039 ORING BENCH OR0000050 ORING BENCH OR0000098 ORING BENCH OR0000099 ORING WATER DROP OUT FILTER PS0000035 EOS SWITCHING PS 15V 40W 05128C M460L SPL xls DCN5164 Page 1 of 1 02 18 09 THIS PAGE IS INTENTIONALLY LEFT BLANK 4601 Instruction Manual Appendix B Electronic Schematics Appendix B Electronic Schematics Table B 1 M460L List of Electronic Schematics DOCUMENT DESCRIPTION 03169 PCA FRONT PANEL DISPLAY 04992 PCA MAINBOARD 03493 PCA CPU 05230 Rev A Appendix B Electronic Schematics 460L Instruction Manual B 2 05230 Rev A
32. 1 lt CR gt Change Address Successful 1 FAIL 391 lt CR gt Change Address Failed NOTES The monitor response is from the previous address 1 in the example shown above but any further commands must be at new address 2 in the example shown above If the address change was successful after sending back the OK response the monitor will no longer respond to commands with address 1 34 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 7 TDUMP SYNTAX address TDUMP CR DESCRIPTION This command is best used if the response is intended as input for a database program or data acquisition system It returns a string made up of the current values of the following parameters in the following order O3 Concentration Cell Pressure psia Cell Temperature K Lamp Temperature K Measure Detector mV Calibrated Reference Detector mV Reference Detector mV DATA PARAMETERS SENT None RESPONSE lt address gt lt o3_conc gt lt pressure gt lt cell_temp gt lt lamp_temp gt lt measure gt lt cal_ref gt lt referenc e gt lt al hi stat gt lt al hi hi stat gt lt checksum gt lt CR gt EXAMPLE Command 1TDUMP lt CR gt Response 1 0 0282144 14 77461 300 7179 324 7713 2881 437 2940 903 4412 52 1 0 3413 lt CR gt NOTES While the concentration value returned shows more digits after the decimal than the front panel displa
33. 10 1 and records the intensity of the UV light passing through the bearing source gas e The second measurement occurs during the reference period of the cycle and records the intensity of the light passing though gas from which the has been removed This detector is a specially designed vacuum diode that only reacts to radiation at or very near a wavelength of 254nm and outputs a voltage that varies in direct relationship with the light s intensity The wavelength specificity of the detector is high enough that no extra optical filtering of the UV light is needed Two stages of the preamplifier are used to amplify the output signals of the detector to a level readable by the A D Converter circuitry of the monitor s sensor module The first stage of amplification is located on the PCA s on which the detector itself is mounted The second stage of amplification is located on the sensor module PCA 05228 Rev B 59 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L Instruction Manual Gas Pressure Sensor This absolute pressure sensor measures the gas pressure in the measurement cell upstream of the Pump The sample pressure is used by the CPU to calculate O5 Concentration see Formula 10 3 in Section 10 1 This sensor outputs an analog signal to the sensor microprocessor Measure Reference Valve This valve alternates the gas stream between a direct path to the absorption t
34. 164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS 460L Instruction Manual Spare Parts List USER NOTES 78 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 M460L I nstruction Manual Appendix A Spare Parts list Appendix A Spare Parts list e 05128 Spare Parts List M460L 05229 Rev B Appendix Spare Parts list M460L Instruction Manual A 2 05229 Rev B M460L Spare Parts List Part Number 025710100 PCA UV DETECTOR PREAMP M454 M460 030500400 OVERLAY FRONT PANEL SENSOR M460L 031680100 PCA FRONT PANEL M454 PRODUCTS 034920000 PCA EXPANSION BD M554 M460X 03 CAL 036280000 ASSY WATER DROP OUT FILTER PFA M450 036750000 AKIT ELEMENTS 47MM 30 MICRON 10 PCS 037420000 ASSY UV LAMP BIR M452 454 460X 465L 037490100 ASSY FLOWMETER 0 2 5L M460M L 040530000 CBL PS AC IN M454 NEMA 040540100 CBL DC POWER M460L NEMA 041980000 CBL ASSY GROUND STRAP 4 5 046170000 ABSORPTION TUBE M460L 046740000 ASSY PUMP 12VDC M460M M700E 047110000 ASSY VALVE M460L 048490100 PCA BENCH M460L M465L 049680000 ASSY SENSOR HI CONC M460L M465L 049910100 PCA MAINBOARD M460L 050120000 MANUAL OPERATORS M460L 050170000 ASSY DFU SAMPLE FILTER 050300000 ASSY REF SCRUBBER HI CONC M460L M465L 053010000 AKIT EXP KIT CARULITE 200 CN0000350 CONNECTOR 16 PIN W SCREW FLANGE DR0000006 DRYER 24 1 4 SS FITTINGS HW0000120 SHOCKMOUNT GROMMET ISOLATOR OP
35. 2 TELEDYNE ADVANCED POLLUTION INSTRUMENTATION A Teledyne Technologies Company INSTRUCTION MANUAL MODEL 460L Nema Ozone Monitor 9480 CARROLL PARK DRI VE SAN DI EGO CA 92121 5201 USA Toll free Phone 800 324 5190 Phone 858 657 9800 Fax 858 657 9816 Email api sales teledyne com Website http www teledyne api com 05012 REV D DCN 5164 2008 T API 22 January 2009 PRINT DATE 19 February 2009 TELEDYNE INSTRUMENTS HIGHLIGHTS Model 460L NEMA Ozone Monitor Instruction Manual THIS PAGE IS INTENTIONALLY LEFT BLANK H ii 05012 Rev D 22 January 2009 PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 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 PPP CAUTION The mo
36. 5 Jumper Location and Settings 18 05228 Rev B PRI NTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE I NSTRUMENTS 460L Instruction Manual Getting Started 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 connections RS 232 DB9 Female Serial TXD Serial RXD RS 485 Serial TXD Twisted Pair RS 485 A Serial RXD 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 05228 Rev B 19 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Getting Started 460L Instruction Manual e 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 e This can be a
37. 5228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual I ntroduction 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 e Printed format part number 050120100 e
38. 8 Rev B 9 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Getting Started 460L Instruction Manual Table 3 1 460L Ventilation Clearances AREA MINIMUM REQUIRED CLEARANCE Sides of the monitor 1 inch Above and below the monitor 1 inch 10 24 260 4 A in N i in Y Figure 3 4 4601 Mounting Hole Locations and Dimensions 3 3 Pneumatic Connections 1 Connect a 4 exhaust line to the fitting labeled Exhaust CAUTION If using the 460L to measure O levels that are 2100 ppb exhaust gas from the MODEL 460L may contain dangerous levels of ozone The optional ozone destruct see Section 5 3 should be installed and Make sure that the exhaust line is vented to an outside area 2 Connect the ozone delivery line to the inlet fitting labeled Ozone Inlet on the bottom face of the enclosure See Figure 3 5 10 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual Getting Started NOTE The ozone delivery pressure should be at ambient pressure 5 PSIG tubing used should be made of ozone resistant material such as Stainless Steel PTFE Teflon or API can supply appropriate tubing for connecting the ozone supply line Display Scrubber optional Gas Flowmeter amp Coalescence WERT ter optional Control
39. AN SLOPE This VAR is only available using the 929 password e Record both the slope value and the VAR Number it corresponds with 6 Make sure your ozone standard and analyzer are both reading the same span gas or ozone concentration 7 Calculate the slope using the following equations Equation 8 1 concentration on analyzer Slope True value of analyzer Equation 8 2 concentration on standard True O3 value of analyzer New slope EXAMPLE Where e Slope of analyzer 1 013 Current reading of analyzer 8 7090 e Current reading of standard 9 00 a concentration on analyzer Slope True value of analyzer 8 70 1 013 8 59 b concentration on standard True value of analyzer New slope 9 00 8 59 1 048 e 1 048 would be the New Slope Value that needs to be entered in the next step 42 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Calibration 8 Enter the New Slope into the M460M s memory enter it in Type address VSET VAR Number New Slope Value CR EXAMPLE 3VSET 16 1 048 CR Where e The address of the M460M is 3 e The SLOPE VAR is number 16 e The New Slope is 1 013 8 3 Adjusting the Optional Current Loop Output If your monitor includes the option current loop output you may need to check or adjust the actual current
40. CUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS 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 concentration alarms see Table 3 2 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 LABEL NAME OPERATION STATUS OUT 1 Sensor O K Normally On STATUS OUT 2 Invalid Reading Normally Off STATUS OUT 3 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 See Figure 3 7 for pin locations of the these output lines on the monitor s 16 pin I O connector 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 PLC OR OTHER DEVICE 5V Status Outputs 1 6 Collector 2 4 T STATUS COM Emitter
41. Electronic format a CD ROM part number 050120200 The electronic manual is in Adobe Systems Inc Portable Document Format The Adobe Acrobat Reader software which is necessary to view these files can be downloaded for free from the Internet at http www adobe com The electronic version of the manual has many advantages e Keyword and phrase search feature e Figures tables and internet addresses are linked so that clicking on the item will display the associated feature or open the website A list of chapters and sections as well as thumbnails of each page are displayed to the left of the text e Entries in the table of contents are linked to the corresponding locations in the manual e Ability to print sections or all of the manual 05228 Rev B 1 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS I ntroduction 460L Instruction Manual 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 co
42. R Valve OE Drivers Output Relays Figure 10 6 460L Power Distribution Block Diagram e MAIN POWER SUPPLY AC line power is converted and stepped down to several DC voltages by the main power supply 12 VDC Powers the vacuum pump the display driver and the alarm relay outputs e 5 VDC The basic voltage on which the CPU and logic level circuitry operates e 15 VDC Source voltage for the keyboard where it is regulated down to 5 VDC the UV lamp heater the measure reference valve a secondary power supply located on the sensor module assembly e SENSOR MODULE POWER SUPPLY Using 15 VDC from the main power supply this circuitry generates the 5 12 amp 9 VDC supplies needed to operate its own on board logic devices and the various components of the sensor module 05228 Rev B 63 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L Instruction Manual e UV LAMP POWER SUPPLY Using 12 VDC supplied by the main power supply this assembly generates the 30 kHz AC voltage for the monitor s mercury vapor UV lamp The output of this power supply is variable At startup voltage level of this output can reach as high a 1000 VAC Once the lamp is warmed up and operating at peak efficiency the output should be around 200 VAC The 460L has no onboard ON OFF switch A hardwired 2 Amp fuse is located on the main power supply assembly to provide over voltage current protection
43. RR Dede Ra Una tangs 25 6 1 1 readoUt ede ER Kn PERSE HXTML IURE RE QNS 25 6 1 2 Zero Point Calibrations extenta cedet Fuss ee big edite ean E REIR ERR ER 25 6 1 3 Status LED S iii sulco sete erede aa veces beset ed ae ta kiere d RR BRA 25 6 2 Conc ntration Alarms reet eve ine hea saec aa sa Re nea cod ange dda mE Rat au ada ERA EA E 26 6 2 1 1 Concentration Alarm 26 6 2 1 2 Remotely Sensing the Status of the 26 6 2 1 3 Clearing o iae ret erbe Ra ei Rd p 26 7 SERIAL 5 27 7 1 Serial Port Command 5 eta ace che rap deat ia 27 7 2 Serial Port Command Summary eese a nina nan sa asa wa rasa a aa nn naar rae rena ia 28 7 3 Serial Port Command Reference
44. Reconnect the supply line adjust flow to the monitor ON O Ul Open the flowmeter valve and adjust the gas flow to the appropriate rate TEFLON COALESCING MEMBRANE Figure 9 4 Replacing the Membrane of the Optional H20 Coalescing filter Replacement filter elements can be ordered from TAPI P N 036750000 48 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Maintenance 9 3 UV Lamp Replacement 1 Disconnect power from the monitor and open cover 2 Loosen but do not remove the two lamp set screws see Figure 9 5 below 3 Unplug lamp from the UV lamp power connector on Sensor Module PCA 4 Remove lamp from lamp housing Dispose of lamp in accordance with local regulations regarding disposal of Mercury containing waste 5 Install new lamp in housing and plug into the UV lamp power connector 6 Connect the ground lead of a voltmeter to TP4 7 Connect the positive lead of voltmeter to TP10 8 Reconnect power to the monitor 9 The voltage on TP10 must read between 0 6 and 1 6Vdc If this voltage is outside that range slowly rotate the lamp until the proper voltage is achieved then tighten the lamp set screws 10 Connect the positive lead of a voltmeter to TP11 Measure Detector Voltage 11 Adjust R26 until the voltage on TP11 is as high as possible within the range of 0 60 1 00 volts UV Lamp Set Screws UV Lamp
45. S ID RARE rre ee dia 15 3 6 Initial ob epe die Ehud ern e eden RU RR p RE ee 17 3 7 Setting up the Serial Communications eee 17 3 7 1 Physical Serial Port Configutation n ita ER ea ERR TREE 18 3 7 2 Software Setup for Serial Port 19 4 FREQUENTLY ASKED 21 5 OPTIONAL HARDWARE AND SOFTWARE 23 5 1 Sample Conditioning System tex A ERR area San ew Eee Riu e RR pra na au E arce Dans 23 5 2 Current Loop Analog OUtDUE oai nite sie 23 5 3 OZONE sss iieri CREER 23 6 OPERATING INSTRUCTIONS 25 6 1 Front Panel Displays erae ox vare a pene nir b en rere came plas
46. SING OUT OF OR RELATED TO THIS AGREEMENT OF T API S PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE 6 05228 PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 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 Set Screw Concentration Display Mn Status LED s ZERO Buttons Ozone Monitor E Alarm Acknowledge Gas 9 Key Flowmete amp Control Set Screw Figure 3 1 4601 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 05228 Rev B DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Getting Started 460L Instruction Manual CAUTION Never disconnect electronic circuit boards wiring harnes
47. ansistor output to less than 50 mA At 50 mA the transistor will drop approximately 1 2V from its collector to emitter 10 3 4 Display Driver and Keyboard Assembly 10 3 4 1 Keyboard The keyboard of the M460L is comprised of 3 contact closure button keys that are directly sensed by the monitor s CPU These Switches are Zero Switches When pressed simultaneously these switches activate the monitor s auto zero calibration feature see Section 8 1 Activating either switch independently has no affect on the monitor s operation Pressure Switch Pressing and holding this switch causes the monitor to display the current gas pressure of the source gas as measured by the gas pressure sensor located on the measurement cell Pressure is displayed in units of psia pounds per square inch absolute 10 3 4 2 Display The main display of the monitor is a 4 digit 7 segment LED display with decimal point Under normal operation it displays the current concentration of the source gas It can also momentarily display the gas pressure of the source gas 10 3 4 3 Display Driver The circuitry on the display has driver several functions Signal levels from the three front panel key buttons are passed through the driver unaltered directly to the CPU Under command of the CPU a control chip located on this assembly turns the four status LED s see Section 112 amp 11 3 ON OFF A bipolar integrated circuit decodes the serial data
48. asurement cell exceeds too low indicating that there could be a blockage in the monitor s internal pneumatic lines e The measured concentration has exceeded the measurement range selected for the monitor e The measured concentration is an excessively negative reading less than 0 10 ppm or 10 0 ppb 11 2 3 Lamp Low The normal state for the lamp low output is OFF This output turns on when the UV lamp intensity as measured by the reference detector has dropped below 375mV This could mean that the lamp has drifted has started to drift low and that the lamp output should be adjusted 11 2 4 Status LED Status Output Troubleshooting Summary Table 11 2 below is a logic truth table summarizing the recommended actions based on the states of the four status front panel status LED s A 1 indicates the LED is ON a O indicates the LED is OFF and X indicates the LED can be in either state 66 05228 Rev B PRI NTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual Troubleshooting Table 11 2 Status LED Output Trouble shooting Truth Table SENSOR INVALID LAMP OK READI NG LOW AGTVONS 1 0 0 Normal operation no action required The Lamp intensity has drifted and is too high for proper operation 0 0 0 2 Adjust the lamp The Os sensor is not responding to request from the CPU for data 1 X 1 UV Lamp output is starting to drift low 2 Adjust the lamp outpu
49. ber 05017 9 1 1 Filter Replacement Procedure 1 Turn the Monitor off and ensure that the gas delivery line is not under pressure 2 Purge the gas delivery line of ozone 3 Unscrew the pressure fitting at the top of the filter Fitting B in Figure 9 1 from the union fitting 4 Unscrew the pressure fitting at the bottom of the filter Fitting C in Figure 9 1 from the ozone Inlet 5 Discard the filter 6 Attach the new filter using the fittings supplied with it 7 After reassembly the gas line should be pressurized with oxygen or dry air and checked for leaks using a bubble solution Pressure Fitting A Pressure Union Fitting B Fitting Pressure Fitting C Figure 9 1 Changing the Particulate Filter 05228 Rev B 45 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Maintenance 460L Instruction Manual 9 1 2 Mounting the Particulate Filter Externally In applications where the 460L is sampling ambient air at its own location and no inlet gas line is being used the particulate filter can be mounted on the outside of the instrument so that it may be replaced without turning off the monitor or opening the case To mount the particulate filter outside the monitor enclosure 1 Turn the monitor off and ensure that the gas delivery line is not under pressure 2 Purge the gas delivery line of ozone 3 Unscrew the pressure attached to the internal gas line Fitting A in Figure 9 2 from the
50. bove the HI limit the ALMACK command will only clear the HI HI alarm 05228 Rev B 29 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L I nstruction Manual 7 3 2 ALMSTAT SYNTAX address ALSTAT CR DESCRIPTION Returns the current status of both of the concentration alarms 0 Inactive 1 Active DATA PARAMETERS SENT None RESPONSE address HI alarm state HI HI alarm state checksum CR EXAMPLE Command 1ALMSTAT CR Response 1 0 0 247 lt CR gt Both concentration alarms are INACTIVE 1 1 02248 CR The HI alarm is ACTIVE and the HI HI alarm is INACTIVE 1 1 1 249 lt gt Both concentration alarms are ACTIVE 30 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 3 CZERO SYNTAX address CZERO CR DESCRIPTION Performs a zero calibration using gas sourced from the ozone gas inlet DATA PARAMETERS SENT None RESPONSE address success flag lt gt CR EXAMPLE Command 1CZERO CR Response 1 0K 261 lt CR gt Calibration Successful 1 FAIL 391 lt CR gt Calibration Failed NOTE Once the CZERO function is activated the monitor will briefly display dashes after which the concentration should quickly go to zero The CZERO does not activate the zero gas solenoid valve therefore the gas flowing through the m
51. c bubble pack Styrofoam peanuts open cell foam closed cell foam and adhesive tape e DO NOT use standard adhesive tape as a sealer Use ONLY anti ESD tape 1 Never carry the component or assembly without placing it in an anti ESD bag or bin 2 Before using the bag or container allow any surface charges on it to dissipate e If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point e If you are at an anti ESD workbench lay the container down on the conductive work surface e In either case wait several seconds 3 Place the item in the container 76 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual A Primer on Electro Static Discharge 4 Seal the container If using a bag fold the end over and fastening it with anti ESD tape Folding the open end over isolates the component s inside from the effects of static fields e Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device NOTE If you do not already have an adequate supply of anti ESD gags or containers available Teledyne Instruments Customer Service department will supply them see Section 11 4 for contact information Follow the instructions listed above for working at the instrument rack and workstation 05228 Rev B 77 DCN 5
52. c electricity occurs why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring 12 1 How Static Charges are Created Modern electronic devices such as the types used in the various electronic assemblies of your analyzer are very small require very little power and operate very quickly Unfortunately the same characteristics that allow them to do these things also make them very susceptible to damage from the discharge of static electricity Controlling electrostatic discharge begins with understanding how electro static charges occur in the first place Static electricity is the result of something called triboelectric charging which happens whenever the atoms of the surface layers of two materials rub against each other As the atoms of the two surfaces move together and separate some electrons from one surface are retained by the other Materials Makes Contact Materials Separate PROTONS PRETONS S PROTONS ES ELECTRONS A ELECTRONS 3 ELECTRONS 3 LECTRONS NET CHARGE 0 NET CHARGE O CHARGE 1 NET CHARGE 1 Figure 12 1 Triboelectric Charging If one of the surfaces is a poor conductor or even a good conductor that is not grounded the resulting positive or negative charge cannot bleed off and becomes trapped in place or static The most common example of triboelectric charging happens when someone wearing leather or rubber soled shoes
53. calculated based on the current ozone content of the measurement cell DACSTEP Analog Output Test Mode Step Function Returns O3 concentration currently being measured SETADDR Sets communication address for this 460L to a specific value TDUMP Returns the current values of a set of measurement parameters as a single data string TLIST Returns list of measurement parameters and their current values as a formatted list VGET Returns the current value of a single VAR VLIST Lists all VARS and their current values VSET Sets value of internal VAR 28 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 Serial Port Command Reference 7 3 1 ALMACK SYNTAX address ALMACK CR DESCRIPTION Acknowledges any active concentration alarm and clears them if possible For more information see Section 6 2 DATA PARAMETERS SENT None RESPONSE address success flag lt gt CR EXAMPLE Command 1ALMACK CR Response 1 0K 261 lt CR gt Command successfully received All alarms capable of being cleared have been NOTE The alarm s will only clear if the condition causing the alarm no longer exists EXAMPLE If the current O3 concentration rises above the trigger levels for both the HI and HI HI alarms both alarms will activate If the O3 level falls below the HI HI alarm limit but is still above the is still a
54. ccomplished by repeating the command see Section 7 3 5 for each possible address 0 9 until the M460M responds EXAMPLE 003 CR 103 lt CR gt 203 lt CR gt 903 lt lt CR gt e When the instrument responds record the first number in the response line e This is the address of the analyzer 4 To determine if the M460L is operating correctly type 1TLIST lt CR gt 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 Check the analyzer s operation variables VARS These describe certain application specific conditions such as units of measure measurement ranges etc e 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 list of the nominal values for these functions 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 you can return the analyzer to normal operation e 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 USER NOTES 20 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Frequently Asked Questions 4 FREQUENTLY ASKED QUESTIONS
55. ce charges on it to dissipate e If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point e If you are at an anti ESD workbench lay the container down on the conductive work surface e In either case wait several seconds 4 Place the item in the container 74 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual A Primer on Electro Static Discharge 5 Seal the container If using a bag fold the end over and fastening it with anti ESD tape e Folding the open end over isolates the component s inside from the effects of static fields e Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device 6 Once you have arrived at your destination allow any surface charges that may have built up on the bag or bin during travel to dissipate 7 Connect your wrist strap to ground e If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point e If you are at a anti ESD workbench lay the container down on the conductive work surface In either case wait several seconds 8 Open the container 12 4 2 4 Opening Shipments from Teledyne Instruments Customer Service Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of stat
56. corresponds to the HI concentration alarm and RELAY 3 corresponds to the HI HI concentration alarm Status LED s Based on data received from the sensor module it activates and deactivates the four status LED s located on the monitor s front panel see Section 11 2 4 Status Outputs Logic Level voltages are output via optically isolated NPN transistors which sink up to 50 mA of DC current They are accessed through connector J2 on the main board Several of these outputs convey good bad information about key monitor operational conditions see Section 11 2 Others reflect the status of the monitors concentration alarms These outputs can be used to interface with devices that accept logic level digital inputs such as programmable logic controllers PLC s Each Status bit is an open collector output that can withstand up to 40 VDC of the emitters of these transistors are tied together 05228 Rev B 61 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L Instruction Manual and available at the STATUS COM pin of J2 on the main board see Figure 3 7 This pin is normally connected to the input ground of the external device NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the tr
57. e status output Hi alarm or HI HI alarm status output is OFF when O concentration is gt related set point e Electronic failure of status output value 05228 Rev B 67 DCN 5164 PRI NTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Troubleshooting 460L Instruction Manual 11 4 Technical Assistance If this addendum and its trouble shooting repair sections do not solve your problems technical assistance may be obtained from Teledyne Instruments Advanced Pollution Instrumentation Division TAPI Customer Service 9480 Carroll Park Drive San Diego California 92121 5201USA Toll free Phone 800 324 5190 Phone 858 657 9800 Fax 858 657 9816 Email API CustomerService Teledyne com Website http www Teledyne API com Before you contact Teledyne Instruments Customer service fill out the problem report form in Appendix C which is also available online for electronic submission at http www Teledyne API com forms p fmapicom asp USER NOTES 68 05228 Rev B PRI NTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual A Primer on Electro Static Discharge 12 A PRIMER ON ELECTRO STATIC DISCHARGE Teledyne Instruments considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time This section describes how stati
58. ence Cycle consists of Table 10 1 Measurement Reference Cycle CYCLE VALVE STATE STATUS DURATION ACTIVITY FIG 10 3 Measure Reference Valve Opens to the Measure Path MEASURE 0 50 sec a Ensures i the tube has been adequately ids PERIOD ushed of any previously present gasses 0 15 sec Analyzer measures the average UV light intensity of bearing f Sample Gas 1 during this period Measure Reference Valve Opens to Reference Path Wait Period Ensures that the Absorption tube has been adequately REFERENCE 0 50 sec PERIOD flushed of bearing gas 223 0 15 sec Analyzer measures average UV light intensity of bearing i Sample Gas during this period 1 min 30 sec TOTAL CYCLE TIME 10 1 4 Digital Noise Filter The 460L software processes sample gas concentration data through a noise filter that stabilizes the concentration value reported to the display and via the monitor s analog outputs 54 PRINTED DOCUMENTS ARE UNCONTROLLED 05228 Rev B DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual Theory of Operation 10 2 Pneumatic Theory of Operation 10 2 1 Basic Pneumatic Flow And Flow Control E UI EL ACE QT ET AR TT EAS LS 1 Monitor Enclosure Flow Meter Valve Exhaust Out Measurement cell MEASURE REFERENCE VALVE Flow Meter Reference Cycle Gas Path
59. ensors as well as the data converted by its internal A D and sends it to the main CPU via an internal RS 485 serial data bus UV Lamp Heater Control The sensor microprocessor also provides direct control of the UV lamp heater by turning it on and off via a transistor using high frequency pulse width modulation The output of the UV Lamp sensor is converted by the micrprocessor s A D converter Based on this digital value the sensor microprocessor sends out pulses that turn the heater ON OFF The more heat needed the longer the width of the ON logic high pulse and the shorter the width of the OFF logic low portion of the pulse Measure Reference Valve Control The Measure Reference valve is actuated by a 12 VDC solenoid valve driver that is controlled by timing circuitry built into the sensor module board 60 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Theory of Operation 10 3 3 CPU Board In addition to being responsible for all I O functions and managing the state of the monitors various status indicators and alarms see below the 460L s CPU also calculates the monitor s offset during zero point calibration see Section 8 1 and converts concentration data from ppb units into ppm units if necessary 10 3 3 1 I O Functions Display Data Two way communications between the CPU and the Display driver module is handled via an IC interface 2 is two w
60. er removes from the exhaust gas stream of the monitor after it exits the instrument s absorption tube but before it can damage 460L s flow meter and pump It also prevents hazardously high levels of from exiting the monitors exhaust outlet When installed the scrubber is located outside the monitor s NEMA housing on the right side at the top see Figure 3 5 It is filled with a special catalytic ozone scrubbing material that removes all of the from the sample gas exiting the sensor module s absorption tube The catalyst used in the scrubber only converts ozone to oxygen and does not produce any toxic or hazardous gases The catalyst is 100 efficient at scrubbing ozone at room temperature It is a true catalytic converter therefore there are no maintenance requirements such as changing the scrubbing material as is required for charcoal based scrubbers 05228 Rev B 57 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Theory of Operation 460L Instruction Manual 10 3 Electronic Theory of Operation Eu E COME E CE 1 Front Panel Invalid Reading Display xx Alarm Active i ERES RSS Sensor Module RS 485 CPU Micro processor Lamp Temperature Sensor RS 232 RS 485 Measurement Port Low High Cell Resolution Resolution Temperature t AID AID Sensor Optional 4 20 mA Control
61. esent can be calculated according to the following equation called Beer s Law also referred to as the Beer Lambert equation I I Equation 10 1 Where I5 is the intensity of the light if there was no absorption I is the intensity with absorption L is the absorption path or the distance the light travels as it is being absorbed This distance determines how many molecules are present in the column of gas in the absorption cell is the concentration of the absorbing gas In the case of the Model 460L Ozone is the absorption coefficient absorption coefficient a number that reflects the inherent ability of ozone to absorb 254 nm light Most current measurements place this value at 308 1 1 at Standard Temperature and Pressure 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 05228 Rev B 51 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L Instruction Manual To solve this equation for C the concentration of the absorbing gas in this case the application of a little algebra is required to rearrange the equation as follows C 1 x I aL Equation 10 2 Unfortunately both ambient temperature and pressure influence the density of the sample gas and
62. essage was received After the function is complete the rest of the response will be sent No additional commands should be issued to the monitor until the function completes 32 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 5 SYNTAX address O3 CR DESCRIPTION Returns the current ozone concentration measured by the monitor DATA PARAMETERS SENT None RESPONSE address 03 conc checksum CR EXAMPLE Command 103 CR Response 1 250 1898 522 lt CR gt Current Concentration reading 250 2 ppb NOTES While the concentration value returned shows more digits after the decimal than the front panel in the example above 250 1898 display it is only valid to 4 significant digits in the example above 250 2 The returned value will be in whichever units of measure for which the monitor is set 05228 Rev B 33 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L I nstruction Manual 7 3 6 SETADDR SYNTAX address SETADDR new address CR DESCRIPTION Changes the communications address to a new value DATA PARAMETERS SENT new address is the new address for the monitor Range for new address is 1 9 RESPONSE address success flag lt gt CR EXAMPLE Command 1SETADDR 2 lt CR gt Change address from 1 to 2 Response 1 0K 26
63. f the Absorption Tube and is detected by a specially designed vacuum diode that only detects radiation at or very near a wavelength of 254nm The specificity of the detector is high enough that no extra optical filtering of the UV light is needed The detector reacts to the UV light and outputs a voltage that varies in direct relationship with the light s intensity This voltage is digitized and sent to the instrument s CPU to be used in computing the concentration of in the absorption tube i Window Window UV Detector ABSORPTION TUBE Figure 10 1 Absorption Path 10 1 3 The Reference Measurement Cycle In order to solve the Beer Lambert equation it is necessary to know the intensity of the light passing through the absorption path both when is present and when it is not The Model 460L accomplishes this by alternately passing the sample gas through a chemical scrubber that removes any present and sending it directly to the absorption tube Measure Path Reference 1 easure Valve Reference Path 3 Scrubber Particulate Filter From Sample Port 1o Valve switches every 3 seconds To Exhaust Port Fierce rere ED ES Er ems de ABSORPTION TUBE Figure 10 2 Reference Measurement Gas Cycle 05228 Rev B 53 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Theory of Operation 460L I nstruction Manual The Measurement Refer
64. ic electric charges To prevent damage from ESD Teledyne Instruments ships all electronic components and assemblies in properly sealed ant ESD containers Static charges will build up on the outer surface of the anti ESD container during shipping as the packing materials vibrate and rub against each other To prevent these static charges from damaging the components or assemblies being shipped make sure that you 1 Always unpack shipments from Teledyne Instruments Customer Service by 2 Open the outer shipping box away from the anti ESD work area 3 Carry the still sealed ant ESD bag tube or bin to the anti ESD work area 4 Follow steps 6 and 7 of Section 12 4 2 3 above when opening the anti ESD container at the work station 5 Reserve the anti ESD container or bag to use when packing electronic components or assemblies to be returned to Teledyne Instruments 05228 Rev B 75 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS A Primer on Electro Static Discharge 460L Instruction Manual 12 4 2 5 Packing Components for Return to Teledyne Instruments Customer Service Always pack electronic components and assemblies to be sent to Teledyne Instruments Customer Service in anti ESD bins tubes or bags CAUTION ESD Hazard DO NOT use pink poly bags NEVER allow any standard plastic packaging materials to touch the electronic component assembly directly This includes but is not limited to plasti
65. ir To drain the filter 1 Disconnect ozone supply line from monitor and shut off flow to the monitor using needle valve on front panel 2 Remove the cap from the fitting on the bottom of the coalescing filter and allow the filter to drain 3 Replace cap 4 Reconnect the O supply line and adjust flow to the monitor 5 Open the flow meter valve and adjust the gas flow to the appropriate rate Coalescence Filter optional Coalescence Filter Drain Figure 9 3 Draining the Optional Coalescing filter 05228 Rev B 47 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Maintenance 460L Instruction Manual 9 2 2 Replacing the Coalescing Membrane The coalescing filter contains a replaceable Teflon coalescing membrane Under normal operating conditions this membrane should last for a long time however a significant reduction in the gas pressure measured in the O3 cell might indicate that this membrane needs replacement To replace the filter membrane 1 Disconnect ozone supply line from the monitor and shut off flow to the monitor using needle valve on front panel 2 Remove inlet and exit fittings from scrubber body and cap 3 Remove the orange cap from the top of the coalescing filter EN Remove the old membrane It is located on the underside of the cap assembly see Figure 9 4 Insert the new membrane into the cap assembly Tightly secure the cap back on the filter
66. ire clocked bi directional digital serial I O bus that is used widely in commercial and consumer electronic systems Keyboard Input The three keys buttons on the front panel two zero keys and the Alarm Resert key are sensed directly by the CPU as simple digital contact closures Analog Output The 460L is equipped with one analog output which reports the current concentration currently being measured by the monitor During auto zero operation the last valid concentration value is held until the auto zero procedure is completed This output is factory configurable as either a 0 5 VDC signal or a 4 20 mA signal Serial I O A standard RS 232 or RS 485 serial communications port Section 3 5 4 describes how to configure and make connections to this port Chapter 7 describes the syntax and commands available for use Control Inputs These inputs are used to initiate certain operations see Table 3 3 They are triggered by providing a contact closure or low impedance current path between the input and the ground pin GND see Figure 3 9 This can be done by using a mechanical switch or isolated transistor output from another device such as a PLC 10 3 3 2 Status and Alarm Functions Relay Outputs The 460L is equipped with three relay three SPDT relay They are located at the top right hand side of the main board and are labeled RELAY 1 RELAY 2 amp RELAY 3 e RELAY 1 corresponds to the Sensor OK status output and LED RELAY 2
67. ke you and your clothing from discharging through the instrument and damaging it 12 4 Basic Principles of Static Control It is impossible to stop the creation of instantaneous static electric charges It is not however difficult to prevent those charges from building to dangerous levels or prevent damage due to electro static discharge from occurring 12 4 1 General Rules Only handle or work on all electronic assemblies at a properly set up ESD station Setting up an ESD safe workstation need not be complicated A protective mat properly tied to ground and a wrist strap are all that is needed to create a basic anti ESD workstation Protective Mat di rist Stre Ground Point Figure 12 2 Basic anti ESD Workbench For technicians that work in the field special lightweight and portable anti ESD kits are available from most suppliers of ESD protection gear These include everything needed to create a temporary anti ESD work area anywhere Always wear an Anti ESD wrist strap when working on the electronic assemblies of your analyzer An anti ESD wrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels Anti ESD wrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug Also anti ESD wrist straps include a curren
68. lacing the Membrane of the Optional H20 Coalescing 48 UV Lamp Set Screws and Calibration Test 49 Absorption i um 53 Reference Measurement Gas Cycle 53 460L Internal Pneumatic Diagram Basic 55 460L Internal Pneumatic Diagram with Optional Sample Conditioning 56 460L Electronic Block Diagram 58 460L Power Distribution Block Diagram 63 Triboelectric Chargitig icirr eu tro trie eek bb ten Sule Fate a e Ru ed E PR E er RR Y 69 Basic anti ESD 72 LIST OF TABLES Table 2 1 460E SpecificatloHs sore eeu ved bude a a aaa Seer Qus paa vv ee raid nie xe 5 Table 3 1 4601 Ventilation Clearances 10 Table 3 2 Digital Status Output Descriptions essen meme 14 Table 3 3 Control Inputs eee De pU Ee Y Ed 15 Table 3 4 Relay Output 16 Table 3 5 Serial I O Port Connection
69. mp The ultraviolet light needed to detect is supplied by a mercury vapor UV lamp This lamp is coated in a material that optically screens the UV radiation output to remove the producing 185nm radiation Only light at 254nm is emitted UV Lamp Heater to operate efficiently the UV lamp must be kept at a temperature of 52 or higher While the heat created by the lamp itself is usually sufficient to cause this under some ambient conditions additional heating is required This additional heat is provided by a DC heater controlled by the sensor microprocessor Temperature Sensors Two solid state temperature sensors are located in the sensor module They are e Measurement Cell Temperature Sensor This sensor detects the temperature of the gas inside the measurement cell This information is used by the CPU as part of the concentration calculation see Formula 10 3 in Section 10 1 e UV Lamp Temperature Sensor This sensor attached to the UV lamp reports the current temperature of the Lamp to the sensor microprocessor via the sensor module A D converter Both Sensors have built in A D converters and send digitized data directly to the monitors CPU UV detector A UV detector measures the two primary variables I and 1 See Section 10 1 1 needed to compute the concentration of the source gas They are e The first measurement I is taken during the measure period of the measure reference cycle see Table
70. nd prevent discharges due to field effects and induction from occurring 2 Pause for a second or two to allow any static charges to bleed away 3 Only open any anti ESD storage bins or bags containing sensitive devices or assemblies after you have plugged your wrist strap into the workstation e Lay the bag or bin on the workbench surface e Before opening the container wait several seconds for any static charges on the outside surface of the container to be bled away by the workstation s grounded protective mat 4 Do not pick up tools that may be carrying static charges while also touching or holding an ESD sensitive Device 5 Only lay tools or ESD sensitive devices and assemblies on the conductive surface of your workstation Never lay them down on any non ESD preventative surface 6 Place any static sensitive devices or assemblies in anti static storage bags or bins and close the bag or bin before unplugging your wrist strap 7 Disconnecting your wrist strap is always the last action taken before leaving the workbench 12 4 2 3 Transferring Components from Rack to Bench and Back When transferring a sensitive device from an installed Teledyne Instruments analyzer to an Anti ESD workbench or back 1 Follow the instructions listed above for working at the instrument rack and workstation 2 Never carry the component or assembly without placing it in an anti ESD bag or bin 3 Before using the bag or container allow any surfa
71. nfiguration 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 amp 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 2 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual I ntroduction
72. nitor 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 as 05228 Rev B i DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Safety Messages 460L Instruction Manual THIS PAGE IS INTENTIONALLY LEFT BLANK ii 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Table of Contents TABLE OF CONTENTS 1 INTRODUCTION 1 Mui EET 1 1327 460 Documientatloris Sa Ese tert ele sS DER e ualent 1 1 3 Using Iis Manual iier renean reni Dep sad EEEE EA EENEI ai iaa 2 2 SPECIFICATIONS AND WARRANTY
73. ominal signal level by producing a 2590 increment output level on the current loop EXAMPLE OUTPUT LEVEL NOMINAL SIGNAL LEVEL 0 4mA 25 8mA 50 12mA 75 16mA 100 20mA 6 The display will then show A100 four times Adjust the Span potentiometer See Figure 8 2 as necessary Figure 8 2 Location Current Output Adjustment Potentiometers 7 Note that the zero and span adjustments are not completely independent and adjusting one point may slightly affect on the other Therefore steps 4 6 may need to be repeated several times in order to properly adjusted both points 8 When the adjustment process is complete the monitor will automatically restart in standard measurement after 5 cycles USER NOTES 44 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Maintenance 9 MAINTENANCE 9 1 Replacing the Particulate Filter Element The 460L is equipped with a particulate filter on the ozone inlet Only Teledyne Instruments filter elements should be used When the monitor is first installed the sample filters should be checked at least once a week for particulate loading and replaced if necessary Once the replacement frequency is determined a regular schedule for filter replacement should be instituted For replacement filter please contact Teledyne Instruments sales department and request part num
74. onitor is sourced from the ozone inlet and the zero calibration is calculated based on the current ozone content of that gas source Care must be taken to ensure that all ozone is purged from the monitor before activating the CZERO function Before activating the CZERO function disconnect the O3 supply line from the monitor and allow room air to flow through the monitor for several minutes Use a shutoff valve to make sure that the O3 source does not continue to feed O3 into the supply line while it is disconnected 05228 Rev B 31 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L I nstruction Manual 7 3 4 DACSTEP SYNTAX address DACSTEP CR DESCRIPTION Puts the monitor into Analog Output setup mode The Analog Output steps from zero to full scale in 2590 increments pausing for 10 seconds at each level This repeats 5 times after which the monitor returns to normal operation This mode is useful for testing the Analog Output and the operation of any equipment measuring the Analog Output DATA PARAMETERS SENT None RESPONSE address success flag lt gt CR EXAMPLE Command 1DACSTEP CR Response 1 0K 261 lt CR gt DACSTEP command acknowledged and initiated NOTES The DACSTEP function takes some time to complete When the command is sent to the monitor it will immediately respond with the lt address gt and colon as an acknowledgement that the m
75. port See Chapter 7 6 2 1 3 Clearing Alarms When set for non latching mode the alarms will only clear when the alarm condition disappears and will do so automatically When in latching mode the concentration alarms may be cleared in several ways e FRONT PANEL Pressing the ALARM ACKNOWLEDGE key on the monitor s front panel will clear all active alarms e SERIAL COMMUNICATION PORT The ALMACK command to clear all active alarms see Section 7 3 1 Table 6 2 Concentration Alarm Default Settings ALARM CONDITION MODE TRIGGER LIMIT HI 100 Enabled Latching HI HI 300 ppb 26 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 SERIAL COMMUNICATIONS The 460L comes equipped with a powerful digital Serial Communications Port that can be used for Data Acquisition and for changing the monitor s configuration This port can be configured for either RS 232 or RS 485 half duplex operation See Section 3 7 1 for details on configuring the port and connecting it to a computer or data acquisition system 7 1 Serial Port Command Syntax All characters sent and received are standard ASCII characters and all numbers are decimal numbers converted to ASCII text All commands are sent using the following syntax address command data1 data2 checksum optional CR Where e address is the monitor add
76. r Dryer Once all of the liquid water is removed from the source gas a separate Perma Pure single tube permeation tube dryer removes any vaporous water still present The dryer consists of a single tube of Nafion a co polymer similar to Teflon that absorbs water very well but not other chemicals The Nafion tube is mounted within an outer flexible plastic tube As gas flows through the inner Nafion tube water vapor is absorbed into the membrane walls The absorbed water is transported through the membrane wall and evaporates into the dry purge gas flowing through the outer tube countercurrent to the gas in the inner tube This process is called pervaporation and is driven by the humidity gradient between the inner and outer tubes as well as the flow rates and pressure difference between inner and outer tubing 56 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Theory of Operation To provide a dry purge gas for the outer side of the Nafion tube the 460L returns the dried free air from the measurement cell and destruct to the outer tube see Figure 10 4 When the monitor is first started the humidity gradient between the inner and outer tubes is not very large and the dryer s efficiency is low at first but improves as this cycle reduces the moisture in the sample gas and settles at a minimum humidity 10 2 3 3 Ozone Destruct Scrubber The ozone destruct scrubb
77. re information 6 1 3 Status LED s The four status LED s to the right of the display indicate the general status of the 460L Monitor During normal operation after the monitor has warmed up the green Sensor OK LED should be on and all other Status LED s should be off For information on troubleshooting using the Status LED s see Sections 11 2 4 Table 6 1 Status LED s NAME ON STATE OFF STATE OFF when SENSOR O K Normal State is STEADY GLOW e Reference or Measure gt 4995mV e Reference 1000mV STEADY GLOW if INVALID e Ozone Pressure gt 14 9 psia READING e Negative Ozone Concentration Concentration Over Range Normal State STEADY GLOW if Reference LAMP LOW Detector lt 2500mV Normal State ALARM BLINKS whenever the measured concentration exceeds either the alarm Normal State ACTIVE limits Definitions for these four LED s correspond to the definitions of the monitor s four digital status outputs with identical names See Sections 11 2 and 11 3 for more detailed information 05228 Rev B 25 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE NSTRUMENTS Operating nstructions 460L Instruction Manual 6 2 Concentration Alarms There are two concentration alarms HI and HI HI Both alarms are triggered when the measured concentration equals or rises above the set limit for that alarm The set limit for HI alarm must always be a lower value than that of
78. ress default 21 e command is the command string being sent colon is the data separator and is only included if data is being sent as part of the command See Command Details below to see if a command requires data or not data1 is the first data parameter if required data2 is the second data parameter if required e is the Checksum separator sent only if optional checksum is included The checksum is an ASCII checksum of all characters up to the character The checksum is optional Commands sent without the checksum and checksum separator are also valid CR is a carriage return ASCII 13 Examples Valid Commands with no data Checksum Included 1ALMACK 474 lt CR gt e No Checksum 1ALMACK CR Valid Commands with data e Checksum Included 1VSET 1 20 620 lt CR gt e No Checksum 1VSET 1 20 lt CR gt 05228 Rev B 27 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L Instruction Manual 7 2 Serial Port Command Summary Table 7 1 below lists the commands available and a summary of their function Table 7 1 Serial Port Command Summary COMMAND DESCRIPTION ALMACK Acknowledges and clears any active concentration alarms ALMSTAT Returns the current state of the concentration alarms CZERO Perform a manual zero calibration The CZERO does not activate the zero gas solenoid valve therefore the calibration is
79. rface these bags will allow charges to bleed away but the very charges that build up on the surface of the bag itself can be transferred through the bag by induction onto the circuits of your ESD sensitive device Also the liquid impregnating the plastic is eventually used up after which the bag is as useless for preventing damage from ESD as any ordinary plastic bag Anti Static bags made of plastic impregnated with metal usually silvery in color provide all of the charge equalizing abilities of the pink poly bags but also when properly sealed create a Faraday cage that completely isolates the contents from discharges and the inductive transfer of static charges Storage bins made of plastic impregnated with carbon usually black in color are also excellent at dissipating static charges and isolating their contents from field effects and discharges Never use ordinary plastic adhesive tape near an ESD sensitive device or to close an anti ESD bag The act of pulling a piece of standard plastic adhesive tape such as Scotch tape from its roll will generate a static charge of several thousand or even tens of thousands of volts on the tape itself and an associated field effect that can discharge through or be induced upon items up to a foot away 12 4 2 Basic anti ESD Procedures for Analyzer Repair and Maintenance 12 4 2 1 Working at the Instrument Rack When working on the analyzer while it is in the instrument rack and plugged into a p
80. ront Cover LayOUt escena x te ea ax C E nx eat ney viata en dees CHR E RR 7 ASINI 8 460L Sensor Module 9 460L Mounting Hole Locations and Dimensions 10 460L Pneumatic Connections oraraa oaa aAA aAa EaR KEKERE ANEA AN 11 Location of Electrical 12 Signal I O Connector Pin 13 Digital Status Output Connections cesses mme 14 Control Input Connections senem nmn nnne nnns 15 Alarm Qutput Relays ecce Ya Ea ER RUE ER 16 RS 232 RS 485 Jumper Location and 18 Typical RS 232 and RS 485 nennen 19 Setup for Measuring Current Output Signal 43 Location Current Output Adjustment Potentiometers 44 Changing the Particulate 45 Changing the Particulate Filter eret rre Lo ER et Ce va a Sa 46 Draining the Optional H20 Coalescing 47 Rep
81. roperly grounded power supply 1 Attach you anti ESD wrist strap to ground before doing anything else Use a wrist strap terminated with an alligator clip and attach it to a bare metal portion of the instrument chassis e This will safely connect you to the same ground level to which the instrument and all of its components are connected 2 Pause for a second or two to allow any static charges to bleed away 3 Open the casing of the analyzer and begin work Up to this point the closed metal casing of your analyzer has isolated the components and assemblies inside from any conducted or induced static charges 4 If you must remove a component from the instrument do not lay it down on a non ESD preventative surface where static charges may lie in wait 5 Only disconnect your wrist strap after you have finished work and closed the case of the analyzer 12 4 2 2 Working at an Anti ESD Work Bench When working on an instrument of an electronic assembly while it is resting on a anti ESD workbench 1 Plug your anti ESD wrist strap into the grounded receptacle of the work station before touching any items on the work station and while standing at least a foot or so away 05228 Rev B 73 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS A Primer on Electro Static Discharge 460L Instruction Manual This will allow any charges you are carrying to bleed away through the ground connection of the workstation a
82. ses or electronic subassemblies while the unit is under power 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 CPU Analog Relay Vapor Dryer Board Outputs optional Optional Ozone Scrubber Not Shown HE Signal I O Connector AC Power Input Connector Flow Meter Sensor Module Coalescing Filter optional Particulate Filter Ozone Exhaust Inlet Outlet Figure 3 2 4601 Layout 8 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE I NSTRUMENTS 460L Instruction Manual Getting Started UV Lamp Housing UV Lamp Power Connector Ozone Outlet UV Lamp Manifold Power Supply Reference Scrubber Absorption Tube Ozone Intlet Manifold Measure Reference Valve Detector Figure 3 3 4601 Sensor Module Layout 3 2 Mechanical Installation Mount the enclosure securely to a vertical surface e Figure 3 4 below shows the locations of the four mounting holes e 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 0522
83. t The UV lamp is either completely off or its intensity has drifted so low 0 1 that the monitor can not reliable measure 2 Replace the UV lamp see Section 9 3 e O reading is above the upper limit of the range selected for the monitor gt Check or change the range setting see Sections 7 3 9 to 7 3 11 e Os reading is too negative X 1 X gt Calibrate zero point see Section 8 1 Possible Internal blockage gt check or replace the filter see Section 9 1 1 supply under high pressure Check gas lines from O source 11 3 Concentration Alarm Outputs Table 11 3 Alarm Output Troubleshooting FAULT CONDITION POSSIBLE CAUSES e Alarm mode is set for Non Latching and Concentration value is Pressing ALARM ACKNOWLEDGE button does relevant alarm set point not clear alarm or turn off Alarm Active LED IV ALARM ACKNOWLEDGE button 15 bad Using the ALMACK command over the serial port does not clear alarm or turn off Alarm IV e Alarm mode is set for Non Latching and Concentration value is relevant alarm set point Active LED Alarm Active LED doesn t blink when one or LED has Failed both Alarms are active e Display driver PCA malfunction Alarm does not activate at expected concentration e Set point for alarm is set incorrectly Alarm Active Status Output OFF when HI alarm or HI HI Alarm is active e Electronic failure of Alarm Activ
84. t limiting resistor usually around one meg ohm that protects you should you accidentally short yourself to the instrument s power supply Simply touching a grounded piece of metal is insufficient While this may temporarily bleed off static charges present at the time once you stop touching the grounded metal new static charges will immediately begin to re build In some conditions a charge large enough to damage a component can rebuild in just a few seconds Always store sensitive components and assemblies in anti ESD storage bags or bins Even when you are not working on them store all devices and assemblies in a closed anti Static bag or bin This will prevent induced charges from building up on the device or assembly and nearby static fields from discharging through it Use metallic anti ESD bags for storing and shipping ESD sensitive components and assemblies rather than pink poly bags The famous pink poly bags are made of a plastic that is impregnated with a liquid similar to liquid laundry detergent which very slowly sweats onto the surface of the plastic creating a slightly conductive layer over the surface of the bag 72 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual A Primer on Electro Static Discharge While this layer may equalizes any charges that occur across the whole bag it does not prevent the build up of static charges If laying on a conductive grounded su
85. the HI HI alarm If the concentration is between the HI limit and the HI HI limit the HI alarm will be active but the HI HI alarm will be inactive When either the HI or the HI HI alarms are active the ALARM ACTIVE status LED on the front panel see Figure 3 1 will blink In addition when the HI alarm is active alarm trigger LED D7 on the main PCA see Figure 3 12 will glow and when the HI HI alarm is active alarm trigger LED D8 will glow 6 2 1 1 Concentration Alarm Configuration Either of the concentration alarms can be independently configured via the 460L s serial communication port see Section 7 3 11 The user can set the alarms to operate in either the latching or non latching as well as independently adjust the trigger levels of the alarm limits In non latching mode the alarms will be triggered when concentration equals or exceeds the associated limit is reached and will automatically return to an inactive state if the O4 concentration falls below the limit level In latching mode once an alarm is triggered it will stay active until cleared by the user regardless of how the concentration measurement changes 6 2 1 2 Remotely Sensing the Status of the Alarm Besides the LEDs located on the front panel and on the monitor s main PCA the status of each alarm can be sensed externally via a single pull double throw relay see Section 3 5 4 or determined from a remote location via the monitor s serial communication
86. 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 ARI
87. the result of damage due to electro static discharge Table 12 2 Sensitivity of Electronic Devices to Damage by ESD DAMAGE SUSCEPTIBILITY VOLTAGE RANGE DEVICE DAMAGE BEGINS CATASTROPHIC OCCURRING AT DAMAGE AT MOSFET 10 100 VMOS 30 1800 NMOS 60 100 GaASFET 60 2000 EPROM 100 100 JFET 140 7000 SAW 150 500 Op AMP 190 2500 CMOS 200 3000 Schottky Diodes 300 2500 Film Resistors 300 3000 n cc 7000 ECL 500 500 SCR 500 1000 Schottky TTL 500 2500 Potentially damaging electro static discharges can occur 70 PRINTED DOCUMENTS ARE UNCONTROLLED 05228 Rev B DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual A Primer on Electro Static Discharge e Any time a charged surface including the human body discharges to a device Even simple contact of a finger to the leads of a sensitive device or assembly can allow enough discharge to cause damage A similar discharge can occur from a charged conductive object such as a metallic tool or fixture e When static charges accumulated on a sensitive device discharges from the device to another surface such as packaging materials work surfaces machine surfaces or other device In some cases charged device discharges can be the most destructive e Atypical example of this is the simple act of installing an electronic assembly into the connector or wiring harness of the equipment in which it is to func
88. therefore the number of ozone molecules present in the absorption path thus changing the amount of light absorbed In order to account for this effect the following addition is made to the equation C In d T 14 695 psi I L 273 Equation 10 3 Where T sample ambient temperature in degrees Kelvin P ambient pressure in pound per square inch psi Finally to convert the result into Parts per Million PPM the following change is made I 10 14 695psi e n ee oe d I al 273 P Equation 10 4 10 1 2 The Absorption Path In the most basic terms the Model 460L uses a high energy mercury vapor lamp to generate a beam of UV light This beam passes through a window of material specifically chosen to be both non reactive to and transparent to UV radiation at 254nm and into an absorption tube filled with Sample Gas Because ozone is a very efficient absorber of UV radiation the Absorption Path Length required to create a measurable decrease in UV intensity is short enough approximately 16 cm that the light 52 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE NSTRUMENTS 460L Instruction Manual Theory of Operation beam is only required to make pass through the Absorption Tube Therefore no complex mirror system is needed to lengthen the effective path by bouncing the beam back and forth Finally the UV then passes through a similar window at the other end o
89. tion If the assembly is carrying a static charge as it is connected to ground a discharge will occur e Whenever a sensitive device is moved into the field of an existing electro static field a charge may be induced on the device in effect discharging the field onto the device If the device is then momentarily grounded while within the electrostatic field or removed from the region of the electrostatic field and grounded somewhere else a second discharge will occur as the charge is transferred from the device to ground 12 3 Common Myths About ESD Damage I didn t feel a shock so there was no electro static discharge The human nervous system isn t able to feel a static discharge of less than 3500 volts Most devices are damaged by discharge levels much lower than that I didn t touch it so there was no electro static discharge Electro Static charges are fields whose lines of force can extend several inches or sometimes even feet away from the surface bearing the charge It still works so there was no damage Sometimes the damaged caused by electro static discharge can completely sever a circuit trace causing the device to fail immediately More likely the trace will be only partially occluded by the damage causing degraded performance of the device or worse weakening the trace This weakened circuit may seem to function fine for a short time but even the very low voltage and current levels of the device s normal operating levels will eat
90. ubber is installed allow the monitor to operate until the reading stabilizes This may take approximately 15 minutes 3 Check the O reading e If the reading is within the repeatability specification of the monitor see Section 2 1 no adjustment is needed e If the reading is higher than the repeatability specification of the monitor but still relatively minor 10 to 20 ppb for example press the two ZERO keys on the front panel and hold them for 3 seconds e If the offset is greater than 30 ppb or pressing the zero key has no effect contact Teledyne Instruments customer service department 8 2 Span Point Calibration 1 Connect the MAOM to a computer running a terminal emulation program such as Hyper terminal See Section 3 7 for instructions 2 Flow zero air or pure O through the analyzer and wait 15minutes 3 After the analyzer has stabilized perform a zero calibration by pressing both zero buttons on the front panel at the same time 4 Type address LOGIN 929 CR 05228 Rev B 41 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Calibration 460L I nstruction Manual Where e address is the network address of the M460M being calibrated 929 is a special password allowing you to calibrate the analyzer 5 List the current values of the MA60M s VARS Type address VLIST CR e Look through the list for one with the a special VARS named either SLOPE or SP
91. ube and a path that first passes it the scrubber The state of this valve is the Sensor Module PCA see Section 10 3 2 2 10 3 2 2 Sensor Module PCA The sensor module PCA performs the real work of operating the sensor module It gathers the various measurements used to calculate the concentration and performs all basic computations related to determining the concentration of the source gas It includes Sensor Signal A D Conversion The output of the monitor s sensor and the pressure sensor are converted into digital signals that the CPU can understand by two analog to digital converters A D located on the sensor PCA LOW RESOLUTION A D A 12 bit SAR converter that digitizes the output of the monitors pressure sensor e HIGH RESOLUTION A D This component digitizes the signal output by the UV detector of the monitor s measurement detector Since the reference detector output requires a large dynamic range and superior noise rejection a Delta Sigma type A D Converter is used here Sensor Microprocessor This IC provides two important functions A D Converter Signal Selection The A D converter can only convert one signal at a time The sensor microprocessor selects which of the sensor inputs is to be converted pressure sensor or measurement detector starts the conversion process stops it and extracts the digital data Data Output The sensor microprocessor collects data from the various digital s
92. uld I change the Particulate Filter and how do I change it A The Particulate filter should be changed monthly See Section 9 1 for instructions on performing this replacement 05228 Rev B 21 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Frequently Asked Questions 460L Instruction Manual USER NOTES 22 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Optional Hardware and Software 5 OPTIONAL HARDWARE AND SOFTWARE This section includes descriptions of the hardware and software options available for the 460L monitor For assistance with ordering these options please contact the sales department of Teledyne Instruments at TOLL FREE 800 324 5190 TEL 1 858 657 9800 FAX 1 858 657 9816 E MAIL apisales teledyne com WEB SITE http www teledyne api com 5 1 Sample Conditioning System This option is required for 460L s that will be used in applications where the sample gas includes liquid or vaporous water This option includes two major components e A coalescing water drop out filter and e permeation tube dryer 5 2 Current Loop Analog Output This option adds isolated voltage to current conversion circuitry to the monitor s CPU card This option be installed at the factory or added later Call Teledyne Instruments sales for pricing and availability The standard configuration of the current loop option is 4 20 mA
93. walks across a nylon carpet or linoleum tiled floor With each step electrons change places and the resulting electro static charge builds up quickly reaching significant levels Pushing an epoxy printed circuit board across a workbench using a plastic handled screwdriver or even the constant jostling of Styrofoam pellets during shipment can also build hefty static charges 05228 Rev B 69 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS A Primer on Electro Static Discharge 460L Instruction Manual Table 12 1 Static Generation Voltages for Typical Activities Poly bag picked up from Moving around in a chair padded with urethane foam rd 18 000V 12 2 How Electro Static Charges Cause Damage Damage to components occurs when these static charges come into contact with an electronic device Current flows as the charge moves along the conductive circuitry of the device and the typically very high voltage levels of the charge overheat the delicate traces of the integrated circuits melting them or even vaporizing parts of them When examined by microscope the damage caused by electro static discharge looks a lot like tiny bomb craters littered across the landscape of the component s circuitry A quick comparison of the values in Table 12 1 with the those shown in Table 12 2 listing device susceptibility levels shows why Semiconductor Reliability News estimates that approximately 6090 of device failures are
94. will always 0 IIR_FILT The lower the setting value the more significant the effect of the filter 1 0 No filtering 0 05 Maximum filtering 0 0 is not allowed HIHI_AL_LEVEL must be greater than HI_AL_LEVEL New_value should be in the units of measure the monitor for which the monitor is set EXAMPLE 1VSET 8 275 0 CR Set HI HI concentration alarm to 275 0 ppb 1VSET 8 0 275 lt CR gt Set HI HI concentration alarm to 0 275 ppm USER NOTES 40 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Calibration 8 CALIBRATION 8 1 Zero Point calibration Variations in ambient conditions most notably changes in ambient humidity and minor changes in the performance of certain electronic components over time may cause slight offsets in the zero point measurement of the monitor To check for and compensate for these minor offsets use the following procedure 1 Supply zero air to the monitor by inserting a Os scrubber filled with activated charcoal into the ozone supply gas line just before it enters the monitor A scrubber of this type is available from Teledyne Instruments Carbon Filter DAU 000 Grade P N FL0000020 NOTE Since variations in humidity is a common cause of these types of offsets use of bottled O which is extremely dry as zero air is not recommended particularly in areas where the ambient humidity is high 2 Once the scr
95. y in the example above 0 0282144 it is only valid to 4 significant digits in the example above 0 028 05228 Rev B 35 DCN 5164 PRINTED DOCUMENTS ARE UNCONTROLLED TELEDYNE INSTRUMENTS Serial Communications 460L I nstruction Manual 7 3 8 TLIST SYNTAX address TLIST CR DESCRIPTION Returns a formatted easy to read list of the parameters by name with the current values for each DATA PARAMETERS SENT None RESPONSE Test Parameter List See Below EXAMPLE Command 1TLIST lt CR gt Response O3 0 0226168 Press 14 7753 Cell Temp 300 7116 Lamp Temp 324 7965 Ref 2881 52 Meas 2941 092 Raw Ref 4412 646 HI Alarm ON HI HI Alarm OFF NOTES The set of parameters is not the same as those returned by the TDUMP command While the concentration value returned shows more digits after the decimal than the front panel display in the example above 0 0226168 it is only valid to 4 significant digits in the example above 0 022 No checksum is sent in the response to the TLIST command 36 05228 Rev B PRINTED DOCUMENTS ARE UNCONTROLLED DCN 5164 TELEDYNE INSTRUMENTS 460L Instruction Manual Serial Communications 7 3 9 VGET SYNTAX address VGET var index CR DESCRIPTION Returns value of an internal configuration variable VAR DATA PARAMETERS SENT var index is index number for internal VAR as follows Table 7 2 VAR INDEX List for VGET Command
96. y as possible Significant amounts of liquid or vaporous water present in the source gas can foul the measurement cell optics Also water absorbs and interferes with the 460L s ability to accurately measure the in the source gas To counteract this problem several optional components can be added to the 460L Exhaust Out MEASURE REFERENCE VALVE Flow Meter Particulate Filter ABSORPTION TUBE H20 Vapor Dryer Optional Pressure Sensor DESTRUCT Optional H20 Coalescing Filter Optional Figure 10 4 460L Internal Pneumatic Diagram with Optional Sample Conditioning 10 2 3 1 H20 Coalescing Filter The first step of this drying process is to remove any liquid water from the source gas The 460L uses a Teflon membrane coalescing filter to accomplish this This filter works in two ways First droplets of water that are large enough to precipitate out of the air on their own simply fall to the bottom of the filters container Second smaller droplets small enough to stay combined and bourn along with the air encounter the Teflon membrane 47 mm diameter 20 micron pore size at the top of the filter and because Teflon is inherently water repellent these tiny droplets collect along the Teflon fibers combining and growing until they are large enough to drip down into the reservoir 10 2 3 2 H20 Vapo

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