Teledyne API 465L+O2 User manual

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:

api-[email protected]

Website:

http://www.teledyne-api.com/

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

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 SÉCURITÉ

Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but d’éviter

des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement ces consignes.

Chaque consigne de sécurité est représentée par un pictogramme d’alerte de sécurité; ces pictogrammes

se retrouvent dans ce manuel et à l’intérieur des instruments. Les symboles correspondent aux consignes

suivantes :

AVERTISSEMENT : Risque de choc électrique

DANGER : Oxydant puissant

AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne

complémentaire pour des renseignements spécifiques

MISE EN GARDE : Surface chaude

Ne pas toucher : Toucher à certaines parties de l’instrument sans

protection ou sans les outils appropriés pourrait entraîner des dommages

aux pièces ou à l’instrument.

Pictogramme « technicien » : Toutes les opérations portant ce symbole

doivent être effectuées uniquement par du personnel de maintenance

qualifié.

Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le

point central de la mise à la terre sécuritaire de l’instrument.

MISE EN GARDE

Cet instrument doit être utilisé aux fins décrites et de la manière décrite

dans ce manuel. Si vous utilisez cet instrument d’une autre manière que

celle pour laquelle il a été prévu, l’instrument pourrait se comporter de

façon imprévisible et entraîner des conséquences dangereuses.

NE 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

Number

Name/Description

07795

465L +O

2

User Manual (this manual)

059100100

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

.

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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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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

inHg

C

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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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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