Teledyne API 465L%2bO2 User manual

Category
Oxygen Equipment
Type
User manual

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User Manual
MODEL 465L + O
2
Industrial Ozone Analyzer
with Oxygen Sensor
Teledyne API (TAPI)
9970 Carroll Canyon Road
San Diego, CA 92131-1106
Phone:
800-324-5190 (toll free)
+1 858-657-9800
FAX:
+1 858-657-9816
Email:
Website:
http://www.teledyne-api.com/
© 2013-2018 TAPI 07795E DCN8017
Teledyne API 31 October 2018
07795E DCN8017 i
WARRANTY
WARRANTY POLICY (02024J)
Teledyne API (TAPI), a business unit of Teledyne Instruments, Inc., provides that:
Prior to shipment, TAPI equipment is thoroughly inspected and tested. Should
equipment failure occur, TAPI assures its customers that prompt service and support
will be available. (For the instrument-specific warranty period, please refer to the
“Limited Warranty” section in the Terms and Conditions of Sale on our website at the
following link: http://www.teledyne-api.com/terms_and_conditions.asp).
COVERAGE
After the warranty period and throughout the equipment lifetime, TAPI stands ready
to provide on-site or in-plant service at reasonable rates similar to those of other
manufacturers in the industry. All maintenance and the first level of field
troubleshooting are to be performed by the customer.
NON-TAPI MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by TAPI is warranted and will be repaired
to the extent and according to the current terms and conditions of the respective
equipment manufacturer’s warranty.
PRODUCT RETURN
All units or components returned to Teledyne API should be properly packed for
handling and returned freight prepaid to the nearest designated Service Center.
After the repair, the equipment will be returned, freight prepaid.
The complete Terms and Conditions of Sale can be reviewed at
http://www.teledyne-api.com/terms_and_conditions.asp
CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling and
packing instructions and Return Merchandise Authorization (RMA) procedures
when returning parts for repair or calibration may void your warranty. For anti-
ESD handling and packing instructions please refer to the manual, Fundamentals
of ESD, PN 04786, in its “Packing Components for Return to Teledyne API’s
Customer Service” section. The manual can be downloaded from our website at
http://www.teledyne-api.com. RMA procedures can also be fou
nd on our
website.
ii 07795E DCN8017
NOTICE OF COPYRIGHT
© 2013-2018 TAPI.
Trademarks
All trademarks, registered trademarks, brand names or product names appearing
in this document are the property of their respective owners and are used herein
for identification purposes only.
07795E DCN8017 iii
IMPORTANT SAFETY INFORMATION
Important safety messages are provided throughout this manual for the purpose of avoiding personal
injury or instrument damage. Please read these messages carefully. Each safety message is associated
with a safety alert symbol and placed throughout this manual and inside the instrument. The symbols with
messages are defined as follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message
for specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or
the instrument.
Technician Symbol: All operations marked with this symbol are to be
performed by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central
safety grounding point for the instrument.
CAUTION
GENERAL SAFETY HAZARD
This instrument should only be used for the purpose and in the manner
described in this manual. If you use it in a manner other than that for
which it was intended, unpredictable behavior could ensue with possible
hazardous consequences.
NEVER use any gas analyzer to sample combustible gas(es).
iv 07795E DCN8017
CONSIGNES DE SÉCURI
Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter
des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes.
Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes
se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes
suivantes :
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne
complémentaire pour des renseignements spécifiques
MISE EN GARDE : Surface chaude
Ne pas toucher : Toucher à certaines parties de l’instrument sans
protection ou sans les outils appropriés pourrait entraîner des dommages
aux pièces ou à l’instrument.
Pictogramme « technicien » : Toutes les opérations portant ce symbole
doivent être effectuées uniquement par du personnel de maintenance
qualifié.
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le
point central de la mise à la terre sécuritaire de l’instrument.
MISE EN GARDE
Cet instrument doit être utilisé aux fins décrites et de la manière décrite
dans ce manuel. Si vous utilisez cet instrument d’une autre manière que
celle pour laquelle il a été prévu, l’instrument pourrait se comporter de
façon imprévisible et entraîner des conséquences dangereuses.
NE JAMAI
S utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!
07795E DCN8017 v
ABOUT THIS MANUAL
This manual is comprised of the following documents:
Part
Name/Description
465L +O
2
User Manual (this manual)
Spare Parts List (integrated into this manual as Section 11.1)
NOTE
We recommend that this manual be read in its entirety before making any attempt to operate the
instrument.
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07795E DCN8017 vii
TABLE OF CONTENTS
SAFETY MESSAGES ..........................................................................................iii
ABOUT THIS MANUAL ........................................................................................ v
1. INTRODUCTION ..........................................................................................11
1.1. PREFACE ................................................................................................11
2. SPECIFICATIONS AND AGENCY APPROVALS ........................................13
2.1. SPECIFICATIONS ......................................................................................13
2.2. APPROVALS ............................................................................................14
2.2.1. Safety ......................................................................................................... 14
2.2.2. EMC ........................................................................................................... 14
2.2.3. Other Type Certifications ............................................................................ 14
3. PRINCIPLES OF OPERATION ....................................................................15
3.1. OZONE MONITOR.....................................................................................15
3.2. OXYGEN SENSOR ....................................................................................16
3.2.1. Construction ............................................................................................... 17
3.2.2. Oxygen Measurements............................................................................... 17
4. GETTING STARTED ....................................................................................19
4.1. WIRING REQUIREMENTS FOR NEMA ENCLOSURES ....................................20
4.2. WIRING INSTRUCTIONS ............................................................................21
4.3. PNEUMATIC CONNECTIONS .......................................................................23
4.3.1. Sample Gas Connection ............................................................................. 23
4.3.2. Exhaust Connection ................................................................................... 27
4.3.3. Electrical Connections ................................................................................ 27
4.3.4. Location of I/O Connectors ......................................................................... 28
4.3.5. Analog Output ............................................................................................ 28
4.3.6. Status Outputs ............................................................................................ 28
4.3.7. Hi-Current Relay Outputs ........................................................................... 29
4.3.8. Digital Serial Interfaces ............................................................................... 30
5. OPTIONS ......................................................................................................31
5.1. DISPOSABLE SAMPLE INLET FILTERS .........................................................31
5.2. ELECTRONIC FLOWMETER ........................................................................31
5.3. SAMPLE CONDITIONER .............................................................................31
5.4. PERMEATION GAS DRYER ........................................................................31
6. OPERATION.................................................................................................33
6.1. FRONT PANEL OVERVIEW ........................................................................33
6.1.1. Gas Concentration Display ......................................................................... 33
6.1.2. Menu Navigation Keypad ............................................................................ 34
6.1.3. Concentration Alarm Status/Reset.............................................................. 34
6.1.4. Status LEDs ............................................................................................... 34
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6.2. FRONT PANEL MENUS .............................................................................35
6.2.1. Menu Navigation Basics ............................................................................. 35
6.2.2. Editing Numeric Values .............................................................................. 35
6.2.3. SETUP Menu ............................................................................................. 38
6.2.4. DIAG Menu ................................................................................................. 41
6.2.5. VIEW Menu ................................................................................................ 46
6.2.6. CONFIG Menu ........................................................................................... 46
7. DIGITAL COMMUNICATIONS .....................................................................47
7.1. DIGITAL COMMUNICATIONS OVERVIEW ......................................................47
7.2. CHANGING COM PORT HARDWARE CONFIGURATION ..................................47
7.3. RS-232 CONFIGURATION .........................................................................49
7.4. RS-485 CONFIGURATION .........................................................................50
7.5. ETHERNET CONFIGURATION .....................................................................51
7.5.1. Hardware Setup for Configuring the Ethernet Module ................................ 51
7.5.2. Verifying Network Hardware Connection .................................................... 51
7.5.3. Determining a Dynamically Assigned IP Address (DHCP Mode) ................ 52
7.5.4. Manually Assigning a Static IP Address ...................................................... 52
7.6. MODBUS REGISTER MAPS .....................................................................53
7.6.1. MODBUS Commands Supported ............................................................... 53
7.6.2. Notes on MODBUS registers ...................................................................... 53
7.6.3. Real-Time Concentration and Status Registers (Read Only) ...................... 54
7.6.4. Instrument Setup and Configuration Registers (Read / Write) .................... 55
8. MAINTENANCE AND ADJUSTMENTS .......................................................57
8.1. MAINTENANCE SCHEDULE ........................................................................57
8.2. INSTRUMENT LAYOUT ...............................................................................58
8.3. REPLACING THE INTERNAL PARTICULATE FILTER ........................................59
8.4. UV LAMP ADJUSTMENT ............................................................................59
8.5. UV LAMP REPLACEMENT .........................................................................60
8.6. SAMPLE PUMP REPLACEMENT ..................................................................61
8.7. O
3
SENSOR VALVE REPLACEMENT ............................................................62
8.8. O
2
SENSOR REPLACEMENT ......................................................................63
8.9. WATER DROP-OUT FILTER (OPTION) MAINTENANCE .................................63
8.10. CONFIGURING THE ANALOG OUTPUT .....................................................64
8.11. CLEANING EXTERIOR SURFACES OF THE M465L ....................................65
8.12. BOOT LOADER OPERATION ...................................................................65
8.12.1. Boot Loader Hardware Setup ................................................................ 65
8.12.2. Boot Loader Software Setup ................................................................. 65
9. TROUBLESHOOTING .................................................................................69
9.1. REFERENCE DRAWINGS ...........................................................................69
9.1.1. Interconnect Diagram ................................................................................. 69
9.2. TROUBLESHOOTING BY FRONT PANEL STATUS LED’S/STATUS OUTPUTS .....70
9.2.1. Sensor OK .................................................................................................. 72
9.2.2. Invalid Reading ........................................................................................... 72
9.2.3. Check Lamp ............................................................................................... 72
9.2.4. Pneumatic Error ......................................................................................... 72
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9.3. TECHNICAL SUPPORT ..............................................................................73
10. CALIBRATION .........................................................................................75
10.1. FACTORY CALIBRATION ........................................................................75
10.2. ZERO CALIBRATION ..............................................................................75
11. SPARE PARTS ........................................................................................77
11.1. M465L + O
2
SPARE PARTS LIST ...........................................................77
FIGURES
Figure 3-1. Fuel Cell Transducer .........................................................................17
Figure 4-1: Mounting Hole Locations and Dimensions .......................................20
Figure 4-2: AC Power Connection to Monitor .....................................................21
Figure 4-3: Pneumatic Connections ...................................................................23
Figure 4-4: Pneumatic Diagram with Sample Conditioner and Permeation Gas Dryer
Options ............................................................................................25
Figure 4-5: Electrical I/O Connections ................................................................27
Figure 4-6: Status Output Schematic .................................................................28
Figure 6-1: Front Panel Display ..........................................................................33
Figure 6-2: Front Panel Menu Diagram ..............................................................36
Figure 6-3: Front Panel Menu Diagram, VARS Menu Details ............................37
Figure 6-4: Front Panel Menu Diagram, O
2
Menu Details ...................................37
Figure 6-5: Span Cal Menu ................................................................................44
Figure 6-6: Flow Cal Menu .................................................................................45
Figure 7-1: DIP Switch Location (SW3) .............................................................48
Figure 7-2: Com Configuration Jumper Settings (SW2) .....................................48
Figure 8-1: Instrument Layout ............................................................................58
Figure 8-2: O
3
Sensor Detail ..............................................................................62
Figure 8-3: Mainboard Analog Output Configuration .......................................64
Figure 9-1: Interconnect Diagram .......................................................................70
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TABLES
Table 2-1: Model 465L+O
2
Specifications ..........................................................13
Table 4-1: Status Output Definitions ..................................................................29
Table 4-2: Relay Functions ................................................................................29
Table 6-1: Status LED’s .....................................................................................34
Table 6-2: STREAM Parameters .......................................................................38
Table 6-3: VARS List ..........................................................................................39
Table 6-4. O
2
Parameters ...................................................................................40
Table 6-5: Analog Step Test Values ..................................................................41
Table 6-6: Signal I/O List ....................................................................................42
Table 6-7: VIEW Menu Parameters ...................................................................46
Table 6-8: CONFIG Menu Parameters...............................................................46
Table 7-1: RS-232 Connector Details ................................................................49
Table 7-2: RS-232 Port Setup ............................................................................49
Table 7-3: RS-485 Connector Details ................................................................50
Table 7-4: RS-485 Port Setup ............................................................................50
Table 7-5: Ethernet LED Definitions ...................................................................51
Table 7-6: Supported MODBUS Commands .....................................................53
Table 8-1: Maintenance Schedule .....................................................................57
Table 8-2: Required Software ............................................................................65
Table 9-1: Status LED/Output Definitions ..........................................................71
.
07795E DCN8017 Teledyne API Model 465L O
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1. INTRODUCTION
1.1. Preface
The Teledyne API Model 465L +O
2
(typically referred to as M456L herein) is a UV photometric
ozone monitor designed and manufactured for industrial hygiene ozone analysis with the added
capability of O
2
sensing. It is a very stable analyzer, ideal for critical low-level PPM safety and
process applications. The M465L is designed to be highly reliable and simple to operate with
easy setup and user-friendly menu driven software that can also be set and monitored remotely.
As the M465L was designed for stability, reliability and simplicity, it includes built-in tests and
diagnostics to facilitate maximum uptime. In addition to our warranty, Teledyne API is pleased
to provide you with any support required so that you may utilize our equipment to the fullest
extent. Our full time Technical Support department is available to answer your questions.
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07795E DCN8017 Teledyne API Model 465L O
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2. SPECIFICATIONS AND AGENCY
APPROVALS
2.1. Specifications
Table 2-1: Model 465L+O
2
Specifications
PARAMETER
DESCRIPTION
Ranges
O
3
O
2
User selectable to any full scale
range from:
1 PPM to 500 PPM or
1000 PPB to 10,000 PPB
Low conc scrubber configuration:
0 to 20 PPM
High conc scrubber configuration:
>20 PPM
User selectable to any full scale
range from 0.1% to 100%
Measurement Units
PPM, PPB
% by volume
Zero Noise
< .0015 PPM (rms)
0.001%
Span Noise
< .5% of reading (rms) (above 0.1
PPM)
0.05%
Lower Detectable Limit
< .003 PPM (rms)
0.01% by volume
Accuracy
+/- 1% of full scale range
+/- 1% of full scale range at
constant temperature and
pressure
Global Alarm Relays
SPDT (Form C) Dry Contact, 250
VAC, 5A (x2, HI and HI-HI)
SPDT (Form C) Dry Contact, 250
VAC, 5A (x2, HI/LO and HI-HI)
Pressure N/A
+/- 0.1% of the reading itself to
4500 ft (12.5 psi)
Response Time (95%)
<30 sec (<60 sec with the Sample Conditioner option)
Sample Flow Rate
0.8 L/min
Temperature Range
5-45
o
C
Humidity Range
10-90% RH, Non-Condensing
Dimensions (H x W x D)
16.85" x 15.60 (±0.25)" x 6.65" (428mm x 396 (±6.35)mm x 169mm)
with NEMA 4X enclosure, typical product envelope
Weight
15.2 lb. (6.91 kg)
Power
100-240 V~, 47-63 Hz, 74 W
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PARAMETER
DESCRIPTION
Environmental Conditions
Installation Category (Overvoltage Category) II
Pollution Degree 2
For Indoor Use Only
Maximum Operating Altitude 2000 meters
Analog Outputs, Voltage Mode
0 - 5V
Isolated Analog Outputs,
4-20mA Mode
Maximum voltage between outputs and ground 60V peak
System OK Status Relay
SPDT (Form C) Dry Contact, 250 VAC, 5A
Instrument Status Outputs
6 - SPST Dry Contact, 50VDC, 250mA Resistive Load
2.2. Approvals
This section presents Safety and Electromagnetic Compatibility (EMC) compliance approvals for
the Model 465L monitor.
2.2.1. Safety
IEC 61010-1:2001, Safety requirements for electrical equipment for
measurement, control, and laboratory use.
CE: 2006/95/EC, Low-Voltage Directive
2.2.2. EMC
EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial Immunity
EN 55011 (CISPR 11), Group 1, Class A Emissions
FCC 47 CFR Part 15B, Class A Emissions
CE: 2004/108/EC, Electromagnetic Compatibility Directive
2.2.3. Other Type Certifications
For additional certifications, please contact Technical Support:
Toll-free:
800-324-5190
Phone: 858-657-9800
Fax: 858-657-9816
Email: api-techsuppo[email protected]
07795E DCN8017 Teledyne API Model 465L O
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3. PRINCIPLES OF OPERATION
This section presents the principles of operation for the Ozone sensor and for the Oxygen sensor.
3.1. Ozone Monitor
The detection of ozone molecules is based on absorption of 254 nm UV light due to an internal
electronic resonance of the O
3
molecule. The Model 465L uses a mercury lamp constructed so
that a majority of the light emitted is at the 254nm wavelength. Light from the lamp shines down
a hollow quartz tube that is alternately filled with sample gas, then filled with gas scrubbed to
remove ozone. The ratio of the intensity of light passing through the scrubbed gas to that of the
sample forms a ratio I/I
o
. This ratio forms the basis for the calculation of the ozone
concentration.
The Beer-Lambert equation, shown below, calculates the concentration of ozone from the ratio of
light intensities.
o
o
O
inHg
C
Ι
Ι
×
Ρ
×
Κ
Τ
×
×
=
ln
92.29
273
10
9
3
α
Equation 3-1. Ozone Concentration Calculation
Where:
I = Intensity of light passed through the sample
I
o
= Intensity of light through sample free of ozone
α
= absorption coefficient
= path length
3
O
C
= concentration of ozone in ppb
T = sample temperature in degrees Kelvin
P = pressure in inches of mercury
As can be seen the concentration of ozone depends on more than the intensity ratio. Temperature
and pressure influence the density of the sample. The density changes the number of ozone
molecules in the absorption tube which impacts the amount of light removed from the light
beam. These effects are addressed by directly measuring temperature and pressure and including
their actual values in the calculation. The absorption coefficient is a number that reflects the
inherent ability of ozone to absorb 254 nm light. Most current measurements place this value at
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308 cm
-1
atm
-1
at STP. The value of this number reflects the fact that ozone is a very efficient
absorber of UV radiation which is why stratospheric ozone protects the life forms lower in the
atmosphere from the harmful effects from solar UV radiation. Lastly, the absorption path length
determines how many molecules are present in the column of gas in the absorption tube.
The intensity of light is converted into a voltage by a high resolution A/D (analog-to-digital)
converter. The digitized signal and other variables are used by the CPU to compute the
concentration using the above formula.
About every 2.5 seconds the M465L completes a measurement cycle consisting of a 1 second
wait period for the sample tube to flush, followed by a 150 ms measurement of the UV light
intensity to obtain I. The sample valve is switched to admit scrubbed sample gas for 1 second,
followed by a 150 ms measurement of the UV light intensity to obtain I
o
. Measurement of the I
o
every 2.5 seconds eliminates instrument drift due to changing intensity of the lamp caused by
aging and dirt.
3.2. Oxygen Sensor
The oxygen sensor (Figure 3-1) is actually a hybrid fuel cell: an electrochemical oxygen
transducer that transforms oxygen to power in the 1 to 200 microwatt range. Of this fuel cell’s
three main components, an anode, a cathode, and an electrolyte, the cathode is the sensing
electrode – the site where oxygen is reduced by the following reaction where four electrons
combine with one oxygen molecule (in the presence of water from the electrolyte) to produce
four hydroxyl ions:
4e- + O2 + 2H2O -------> 4OH-
Equation 3-2. Reaction 1: Cathodic Half-reaction
This cathodic half-reaction occurs simultaneously with the following anodic half reaction:
Pb + 2OH --------> PbO + H2O + 2e-
Equation 3-3. Reaction 2: Anodic Half-Reaction
The anode (lead) is oxidized (in a basic media) to lead oxide, and in the process two electrons are
transferred for each atom of lead that is oxidized. The sum of the two half-reactions results in the
overall reaction:
O2 + 2Pb -------> 2PbO
Equation 3-4. Reaction 3: Overall Reaction
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07795E DCN8017 17
3.2.1. Construction
The fuel cell, ~ 1.25" diameter and .75" thickness, is designed as a unit that can be discarded
when the lead anode is consumed due to the sensing of oxygen. The cell is, therefore,
maintenance-free, requiring no replacement of membranes or electrolyte and no cleaning of
electrodes.
The rear of the cell is fitted with a contact plate composed of two concentric metal foils which
are electrically common to the anode and cathode, and mate to spring loaded contacts in the
various cell holding devices used throughout the product line. Inside the contact plate is a
flexible membrane that accommodates internal volume changes. Another membrane, the sensing
membrane which is made of Teflon of very accurately controlled thickness, covers the cathode.
Between the two membranes is a space filled with electrolyte (an aqueous solution), which
bathes all surfaces of the anode and cathode in a common pool of electrolyte.
The anode is composed of lead and is configured in such a manner (proprietary) so as to
maximize the amount of metal available for reaction. The cathode is a convex metal disc
approximately .75" in diameter with numerous perforations to facilitate continued wetting of the
upper surface with electrolyte and assure minimum internal resistance during the oxygen sensing
reaction. The external surfaces of the cathode are plated with an inert or noble metal.
Figure 3-1. Fuel Cell Transducer
The main body of the cell is fabricated from high density polyethylene. This results in an oxygen
sensor that can be placed in virtually any atmosphere or sample stream, protecting the
components of the sampled media from reaction with the cell assembly.
3.2.2. Oxygen Measurements
In the cathodic half-reaction (Equation 3-1), four electrons are transferred for each oxygen
molecule undergoing reaction. The oxygen molecule undergoes reaction by diffusing through the
both the sensing membrane and the electrolyte between the sensing membrane and the upper
surface of the cathode. The rate at which oxygen molecules reach the surface of the cathode
determines the electrical output. This rate is directly porportional to the concentration of oxygen
in the gaseous mixture surrounding the fuel cell. No oxygen produces no output.
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Teledyne API 465L%2bO2 User manual

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