Teledyne Dollhouse 400E Users Manual TECHNICAL PHOTOMETRIC OZONE ANALYZER
400E to the manual 768cbdc8-05f9-4f82-8454-32f24958ebc0
2015-02-03
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TECHNICAL MANUAL MODEL 400E PHOTOMETRIC OZONE ANALYZER © TELEDYNE INSTRUMENTS ADVANCED POLLUTION INSTRUMENTATION DIVISION (TAPI) 9480 CARROLL PARK DRIVE SAN DIEGO, CALIFORNIA 92121-5201 USA Toll-free Phone: Phone: Fax: Email: Website: Copyright 2007 Teledyne Advanced Pollution Instrumentation 800-324-5190 858-657-9800 858-657-9816 api-sales@teledyne.com http://www.teledyne-api.com/ 04316 Rev. E DCN 5473 16 June 2009 THIS PAGE IS INTENTIONALLY LEFT BLANK M400E Ozone Analyzer Operator’s Manual Table of Contents TABLE OF CONTENTS GENERAL INFORMATION .................................................................................. 1 1. INTRODUCTION .................................................................................................................. 3 1.1. Safety Messages............................................................................................................................................3 1.2. M400E Overview............................................................................................................................................4 1.3. Using This Manual .........................................................................................................................................5 2. SPECIFICATIONS, APPROVALS AND WARRANTY ......................................................... 7 2.1. Specifications .................................................................................................................................................7 2.2. EPA Equivalency Designation .......................................................................................................................9 2.3. CE Mark Compliance .....................................................................................................................................9 2.4. Warranty.......................................................................................................................................................10 3. GETTING STARTED .......................................................................................................... 11 3.1. Model 400E Analyzer Layout .......................................................................................................................11 3.2. Unpacking the M400E analyzer ...................................................................................................................15 3.2.1.1. Ventilation Clearance .....................................................................................................................16 3.3. Electrical Connections .................................................................................................................................16 3.3.1. Power Connection..................................................................................................................................16 3.3.2. Analog Output Connections...................................................................................................................17 3.3.3. Connecting the Status Outputs..............................................................................................................18 3.3.4. Connecting the Control Inputs ...............................................................................................................19 3.3.5. Connecting the Serial Ports ...................................................................................................................20 3.3.6. Connecting to a LAN or the Internet ......................................................................................................20 3.3.7. Connecting to a Multidrop Network........................................................................................................20 3.4. Pnenumatic Connections .............................................................................................................................21 3.4.1. About Zero Air and Calibration Gas.......................................................................................................21 3.4.2. Basic Pneumatic Setup for the M400E analyzer ...................................................................................22 3.4.3. Pneumatic Setup for the M400E Analyzer with Internal Zero/Span Option (IZS) .................................23 3.4.4. Pneumatic Setups for Ambient Air Monitoring with the M400E analyzer ..............................................24 3.4.4.1. Pneumatic Set Up for M400E’s Located in the Same Room Being Monitored. .............................24 3.4.4.2. Pneumatic Set Up for M400E’s Monitoring Remote Locations ......................................................25 3.5. Initial Operation ............................................................................................................................................26 3.5.1. Start Up..................................................................................................................................................26 3.5.2. Warm Up................................................................................................................................................27 3.5.3. Warning Messages ................................................................................................................................27 3.5.4. Functional Check ...................................................................................................................................29 3.6. Initial Calibration of the M400E Analyzer....................................................................................................30 3.6.1. Interferents for O3 Measurement ...........................................................................................................30 3.6.2. Initial Calibration Procedure for M400E analyzers without Options ......................................................31 3.6.2.1. Verifying the M400E Reporting Range Settings.............................................................................31 3.6.2.2. Verify the Expected O3 Span Gas Concentration:..........................................................................32 3.6.2.3. Initial Zero/Span Calibration Procedure: ........................................................................................33 3.7. Configuring the Internal Zero/Span Option (IZS) .........................................................................................34 3.7.1. Verify the O3 Generator and Expected O3 Span Concentration Settings: .............................................34 3.7.2. Setting the O3 Generator Low-Span (Mid Point) Output Level ..............................................................35 3.7.3. Turning on the Reference Detector Option............................................................................................36 3.7.4. Initial Calibration and Conditioning OF M400E analyzers with the IZS Option Installed.......................37 3.7.4.1. Initial O3 Scrubber Conditioning .....................................................................................................37 3.7.4.2. Verifying the M400E Reporting Range Settings.............................................................................38 3.7.4.3. Initial Zero/Span Calibration Procedure: ........................................................................................38 3.7.4.4. Initiate Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3 ..................................38 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY .................................................. 41 4.1. FAQ’s ...........................................................................................................................................................41 4.2. Glossary .......................................................................................................................................................43 04315 Rev. C1 i Table of Contents M400E Ozone Analyzer Operator’s Manual 5. OPTIONAL HARDWARE AND SOFTWARE ..................................................................... 45 5.1. Optional Pumps (OPT 10 thr Opt 13)...........................................................................................................45 5.2. Rack Mount Kits (OPT 20 to OPT 23)..........................................................................................................46 5.3. Carrying Strap Handle (OPT 29)..................................................................................................................46 5.4. Current Loop Analog Outputs (Opt 41) ........................................................................................................47 5.4.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs...............................................47 5.5. Spare Parts kits............................................................................................................................................48 5.5.1. M400E Expendables Kit (OPT 42A) ......................................................................................................48 5.5.2. M400E Spare Parts Kit for the IZS Option (OPT 43).............................................................................48 5.6. Calibration Valve Options ............................................................................................................................48 5.6.1. Zero/Span VALVES (Opt 50A) ..............................................................................................................48 5.6.1.1. Pneumatic Setup for the M400E Analyzer with Zero/Span Valve Option ......................................50 5.6.2. InternaL Zero Span (IZS) Option (OPT 51A).........................................................................................52 5.6.2.1. Disposable Charcoal O3 Filter ........................................................................................................53 5.6.3. Metal Wool Scrubber (Opt 68) ...............................................................................................................53 5.6.4. IZS Desiccant (Option 56) .....................................................................................................................53 5.7. Communication Options...............................................................................................................................54 5.7.1. Extra COMM Cables ..............................................................................................................................54 5.7.1.1. RS232 Modem Cables (OPTs 60A and 60B).................................................................................54 5.7.1.2. ETHERNET Cable (OPT 60C) .......................................................................................................54 5.7.2. RS-232 Multidrop (OPT 62) ...................................................................................................................54 5.7.3. Ethernet (OPT 63)..................................................................................................................................55 5.7.4. Ethernet + Multidrop (OPT 63C) ............................................................................................................56 5.8. Additional Manual (OPT 70A & OPT 70B)...................................................................................................56 OPERATING INSTRUCTIONS........................................................................... 57 6. BASIC OPERATION OF THE M400E ANALYZER........................................................... 59 6.1. Overview of Operating Modes .....................................................................................................................59 6.2. Sample Mode ...............................................................................................................................................60 6.2.1. Test Functions .......................................................................................................................................60 6.2.2. Warning Message Display .....................................................................................................................61 6.3. Calibration Mode ..........................................................................................................................................63 6.4. SETUP Mode ...............................................................................................................................................64 6.4.1. SETUP CFG: Configuration Information ...........................................................................................65 6.4.2. SETUP PASS: Enabling/Disabling Passwords .................................................................................66 6.4.3. SETUP CLK: Setting the M400E Analyzer’s Internal Clock..............................................................68 6.4.3.1. Setting the internal Clock’s Time and Day .....................................................................................68 6.4.3.2. Adjusting the internal Clock’s speed ..............................................................................................69 6.4.4. SETUP RNGE: Analog Output Reporting Range Configuration .......................................................70 6.4.4.1. Physical Range versus Analog Output Reporting Ranges.............................................................70 6.4.4.2. Analog Output Ranges for O3 Concentration .................................................................................70 6.4.4.3. RNGE MODE SNGL: Configuring the M400E analyzer for Single Range Mode..................72 6.4.4.4. RNGE MODE DUAL: Configuring the M400E analyzer for Dual Range Mode ...................73 6.4.4.5. RNGE MODE AUTO: Configuring the M400E analyzer for Auto Range Mode ....................74 6.4.4.6. SETUP RNGE UNIT: Setting the Reporting range Unit Type...............................................75 7. ADVANCED FEATURES OF THE M400E ANALYZER .................................................... 77 7.1. Using Using the Data Acquisition System (iDAS)........................................................................................77 7.1.1. IDAS STATUS .......................................................................................................................................77 7.1.2. iDAS Structure .......................................................................................................................................78 7.1.3. iDAS Channels.......................................................................................................................................78 7.1.3.1. Default iDAS Channels...................................................................................................................79 7.1.4. SETUP DAS VIEW: Viewing iDAS Channels and Individual Records ..........................................81 7.1.5. SETUP DAS EDIT: Accessing the iDAS Edit Mode ......................................................................82 7.1.5.1. Editing iDAS Data Channel Names................................................................................................83 7.1.5.2. Editing iDAS Triggering Events ......................................................................................................84 7.1.5.3. Editing iDAS Parameters................................................................................................................85 7.1.5.4. Editing Sample Period and Report Period......................................................................................87 7.1.5.5. Report periods in Progress when Instrument Is Powered Off ........................................................88 ii 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Table of Contents 7.1.5.6. Editing the Number of Records ......................................................................................................89 7.1.5.7. RS-232 Report Function.................................................................................................................90 7.1.5.8. Enabling / Disabling the HOLDOFF Feature ..................................................................................91 7.1.5.9. The Compact Report Feature.........................................................................................................92 7.1.5.10. The Starting Date Feature............................................................................................................92 7.1.6. Disabling/Enabling Data Channels ........................................................................................................92 7.1.7. Remote iDAS Configuration...................................................................................................................93 7.2. SETUP MORE VARS: Internal Variables (VARS)..............................................................................94 7.3. SETUP MORE DIAG :The Diagnostic Menu ......................................................................................96 7.4. Using the Model 400E Analyzer’s Analog Outputs. .....................................................................................98 7.4.1. Adjusting & Calibrating the Analog Output Signals ...............................................................................98 7.4.2. Calibration of the Analog Outputs....................................................................................................... 100 7.4.2.1. Enabling or Disabling the AutoCal for an Individual Analog Output............................................ 100 7.4.2.2. Automatic Calibration of the Analog Outputs .............................................................................. 101 7.4.2.3. Manual Calibration of the Analog Outputs configured for Voltage Ranges................................. 103 7.4.2.4. Manual Adjustment of Current Loop Output Span and Offset .................................................... 105 7.4.3. Analog Output Voltage / Current Range Selection ............................................................................. 108 7.4.4. Turning an analog output Over-Range Feature ON/OFF ................................................................... 109 7.4.5. Adding a Recorder Offset to an analog output ................................................................................... 110 7.4.6. Selecting a Test Channel Function for Output A4 .............................................................................. 111 7.4.7. AIN Calibration.................................................................................................................................... 113 8. REMOTE OPERATION OF THE M400E .......................................................................... 115 8.1. Using the Analyser’s Communication Ports.............................................................................................. 115 8.1.1. RS-232 DTE and DCE Communication.............................................................................................. 115 8.1.2. COMM Port Default Settings and Connector Pin Assignments.......................................................... 116 8.1.3. COMM Port Baud Rate ....................................................................................................................... 118 8.1.4. COMM Port Communication Modes ................................................................................................... 119 8.1.5. COMM Port Testing ............................................................................................................................ 121 8.1.6. Machine ID.......................................................................................................................................... 122 8.1.7. Terminal Operating Modes ................................................................................................................. 123 8.1.7.1. Help Commands in Terminal Mode............................................................................................. 123 8.1.7.2. Command Syntax ........................................................................................................................ 124 8.1.7.3. Data Types .................................................................................................................................. 124 8.1.7.4. Status Reporting.......................................................................................................................... 125 8.1.7.5. COMM Port Password Security................................................................................................... 126 8.2. Remote Access by Modem ....................................................................................................................... 127 8.2.1. Multidrop RS-232 Set Up.................................................................................................................... 129 8.3. RS-485 Configuration of COM2 ................................................................................................................ 131 8.4. Remote Access via the Ethernet............................................................................................................... 133 8.4.1. Ethernet Card COM2 Communication Modes and Baud Rate ........................................................... 133 8.4.2. Configuring the Ethernet Interface Option using DHCP ..................................................................... 133 8.4.2.1. Manually Configuring the Network IP Addresses........................................................................ 136 8.4.3. Changing the Analyzer’s HOSTNAME ............................................................................................... 138 8.5. Using the M400E with a Hessen Protocol Network .................................................................................. 139 8.5.1. General Overview of Hessen Protocol................................................................................................ 139 8.5.2. Hessen COMM Port Configuration ..................................................................................................... 139 8.5.3. Activating Hessen Protocol................................................................................................................. 140 8.5.4. Selecting a Hessen Protocol Type...................................................................................................... 141 8.5.5. Setting The Hessen Protocol Response Mode................................................................................... 142 8.5.6. Hessen Protocol Gas List Entries ....................................................................................................... 143 8.5.6.1. Gas List Entry Format and Definitions......................................................................................... 143 8.5.6.2. Editing or Adding HESSEN Gas List Entries............................................................................... 144 8.5.6.3. Deleting HESSEN Gas List Entries ............................................................................................. 145 8.5.7. Setting Hessen Protocol Status Flags ................................................................................................ 146 8.5.8. Instrument ID Code............................................................................................................................. 147 8.6. APICOM Remote Control Program........................................................................................................... 148 04315 Rev. C1 iii Table of Contents M400E Ozone Analyzer Operator’s Manual 9. M400E CALIBRATION PROCEDURES........................................................................... 149 9.1. Before Calibration ..................................................................................................................................... 150 9.1.1. Required Equipment, Supplies, and Expendables ............................................................................. 150 9.1.2. Zero Air and Span Gas ....................................................................................................................... 150 9.2. Basic Manual Calibration Checks And Calibration of the M400E analyzer .............................................. 151 9.2.1. Setup for Basic Calibration Checks and Calibration of the M400E analyzer...................................... 151 9.2.2. Performing a Basic Manual Calibration Check ................................................................................... 152 9.2.3. Performing a Basic Manual Calibration .............................................................................................. 153 9.2.3.1. Setting the expected O3 Span Gas concentration....................................................................... 153 9.2.3.2. Zero/Span Point Calibration Procedure....................................................................................... 154 9.2.4. Manual Calibration Checks and Calibrations Using AUTO RANGE or DUAL RANGE Modes.......... 155 9.3. Manual Calibration Check and Calibration with Valve Options Installed .................................................. 156 9.3.1. Setup for Calibration Checks and Calibration with Valve Options Installed. ...................................... 156 Manual Calibration Checks with Valve Options Installed ............................................................................. 158 9.3.2. Manual Calibration Using Valve Options ............................................................................................ 159 9.3.2.1. Setting the Expected O3 Span Gas Concentration with the Z/S Option Installed ....................... 160 9.3.2.2. Zero/Span Point Calibration Procedure the Z/S Option Installed................................................ 161 9.3.2.3. Use of Zero/Span Valve with Remote Contact Closure .............................................................. 162 9.4. Automatic Zero/Span Cal/Check (AutoCal) .............................................................................................. 162 9.4.1. SETUP ACAL: Programming and AUTO CAL Sequence.............................................................. 164 9.5. O3 Photometer Electronic Calibration ...................................................................................................... 167 9.5.1. Photometer Dark Calibration .............................................................................................................. 167 9.5.2. O3 Photometer Gas Flow Calibration.................................................................................................. 168 9.6. Calibration the IZS Option O3 Generator .................................................................................................. 169 10. EPA PROTOCOL CALIBRATION ................................................................................. 171 10.1.1. M400E Calibration – General Guidelines ......................................................................................... 171 10.1.2. Calibration Equipment, Supplies, and Expendables......................................................................... 172 10.1.3. Calibration Gas and Zero Air Sources .............................................................................................. 172 10.1.4. Recommended Standards for Establishing Traceability................................................................... 173 10.1.5. Calibration Frequency....................................................................................................................... 174 10.1.6. Data Recording Device..................................................................................................................... 174 10.1.7. Record Keeping ................................................................................................................................ 174 10.2. Level 1 Calibrations versus Level 2 Checks........................................................................................... 175 10.3. Multipoint Calibration .............................................................................................................................. 175 10.3.1. General information .......................................................................................................................... 175 10.3.2. Multipoint Calibration Procedure....................................................................................................... 176 10.3.3. Dynamic Multipoint Calibration Check .............................................................................................. 177 10.3.4. Linearity Test .................................................................................................................................... 177 10.3.5. O3 Loss Correction Factor ................................................................................................................ 179 10.3.6. Span Drift Check............................................................................................................................... 179 10.4. Auditing Procedures ............................................................................................................................... 179 10.4.1. Multipoint Calibration Audit ............................................................................................................... 180 10.4.2. Data Processing Audit ...................................................................................................................... 180 10.4.3. System Audit..................................................................................................................................... 181 10.4.4. Assessment of Monitoring Data for Precision and Accuracy............................................................ 181 10.5. Summary of Quality Assurance Checks ................................................................................................. 181 10.6. References ............................................................................................................................................. 185 TECHNICAL INFORMATION ........................................................................... 186 11. THEORY OF OPERATION ............................................................................................ 189 11.1. Measurement Method............................................................................................................................. 189 11.1.1. Calculating O3 Concentration........................................................................................................... 189 11.1.2. The Photometer UV Absorption Path ............................................................................................... 191 11.1.3. The Reference / Measurement Cycle ............................................................................................... 192 11.1.4. Interferent Rejection ......................................................................................................................... 193 11.2. Pneumatic Operation .............................................................................................................................. 194 11.2.1. Sample Gas Air Flow ........................................................................................................................ 194 11.2.2. Flow Rate Control ............................................................................................................................. 195 iv 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Table of Contents 11.2.2.1. Critical Flow Orifice.................................................................................................................... 195 11.2.3. Particulate Filter ................................................................................................................................ 196 11.2.4. Pneumatic Sensors........................................................................................................................... 196 11.2.4.1. Sample Pressure Sensor .......................................................................................................... 196 11.2.4.2. Sample Flow Sensor ................................................................................................................. 196 11.3. Electronic Operation ............................................................................................................................... 197 11.3.1. Overview ........................................................................................................................................... 197 11.3.2. CPU .................................................................................................................................................. 198 11.3.3. Motherboard...................................................................................................................................... 198 11.3.3.1. A to D Conversion ..................................................................................................................... 198 11.3.3.2. Sensor Inputs ............................................................................................................................ 199 11.3.3.3. Thermistor Interface .................................................................................................................. 199 11.3.3.4. Analog Outputs.......................................................................................................................... 200 11.3.3.5. External Digital I/O..................................................................................................................... 200 11.3.3.6. I2C Data Bus .............................................................................................................................. 200 11.3.3.7. Power Up Circuit........................................................................................................................ 200 11.3.4. Relay PCA ........................................................................................................................................ 200 11.3.4.1. Status LED’s.............................................................................................................................. 203 11.3.4.2. Watchdog Circuitry .................................................................................................................... 203 11.3.4.3. Valve Control ............................................................................................................................. 204 11.3.4.4. Heater Control ........................................................................................................................... 204 11.3.4.5. Thermocouple Inputs and Configuration Jumper (JP5) ............................................................ 205 11.3.5. Power Supply/Circuit Breaker........................................................................................................... 206 11.3.5.1. Power Switch/Circuit Breaker.................................................................................................... 206 11.3.6. AC Power Configuration ................................................................................................................... 207 11.3.6.1. AC configuration – Internal Pump (JP7).................................................................................... 208 11.3.6.2. AC Configuration – Heaters for Option Packages (JP6) ........................................................... 209 11.3.7. Photometer Layout and Operation.................................................................................................... 210 11.3.7.1. Photometer Electronic Operation .............................................................................................. 211 11.3.7.2. O3 Photometer UV Lamp Power Supply ................................................................................... 212 11.3.7.3. Photometer Temperature .......................................................................................................... 213 11.3.7.4. Photometer Gas Pressure and Flow Rate................................................................................. 213 11.4. Interface .................................................................................................................................................. 214 11.4.1. Front Panel ....................................................................................................................................... 214 11.4.1.1. Front Panel Display ................................................................................................................... 215 11.4.1.2. Keypad ...................................................................................................................................... 215 11.4.1.3. Front Panel States LED’s .......................................................................................................... 215 11.5. Software Operation................................................................................................................................. 216 11.5.1. Adaptive Filter ................................................................................................................................... 216 11.5.2. Calibration - Slope and Offset........................................................................................................... 217 12. MAINTENANCE SCHEDULE & PROCEDURES .......................................................... 219 12.1. Predicting Failures Using the Test Functions ......................................................................................... 219 12.2. Maintenance Schedule ........................................................................................................................... 220 12.3. Maintenance Procedures........................................................................................................................ 223 12.3.1. Replacing the Sample Particulate Filter............................................................................................ 223 12.3.2. Rebuilding the Sample Pump ........................................................................................................... 224 12.3.3. Replacing the IZS Option Zero Air Scrubber .................................................................................... 224 12.3.4. Performing Leak Checks .................................................................................................................. 225 12.3.4.1. Vacuum Leak Check and Pump Check..................................................................................... 225 12.3.4.2. Pressure Leak Check ................................................................................................................ 225 12.3.5. Performing a Sample Flow Check .................................................................................................... 226 12.3.6. Maintenance of the Photometer Absorption Tube ............................................................................ 227 12.3.6.1. Cleaning or Replacing the Absorption Tube ............................................................................. 227 12.3.6.2. UV Lamp Adjustment................................................................................................................. 228 12.3.6.3. UV Lamp Replacement ............................................................................................................. 229 12.3.7. Adjustment or Replacement of Optional IZS Ozone Generator UV Lamp ....................................... 230 04315 Rev. C1 v Table of Contents M400E Ozone Analyzer Operator’s Manual 13. GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER................ 233 13.1. General Troubleshooting ........................................................................................................................ 233 13.1.1. Fault Diagnosis with WARNING Messages...................................................................................... 234 13.1.2. Fault Diagnosis With Test Functions ................................................................................................ 236 13.1.3. DIAG SIGNAL I/O: Using the Diagnostic Signal I/O Function .................................................... 237 13.2. Using the Analog Output Test Channel .................................................................................................. 239 13.3. Using the Internal Electronic Status LEDs.............................................................................................. 240 13.3.1. CPU Status Indicator ........................................................................................................................ 240 13.3.2. Relay PCA Status LED s .................................................................................................................. 240 13.3.2.1. I2C Bus Watchdog Status LEDs ................................................................................................ 240 13.3.2.2. O3 Option Status LED s............................................................................................................. 241 13.4. Gas Flow Problems ................................................................................................................................ 242 13.4.1. Typical Flow Problems...................................................................................................................... 242 13.4.1.1. Flow is Zero ............................................................................................................................... 242 13.4.1.2. Low Flow ................................................................................................................................... 242 13.4.1.3. High Flow................................................................................................................................... 243 13.4.1.4. Actual Flow Does Not Match Displayed Flow ........................................................................... 243 13.4.1.5. Sample Pump ............................................................................................................................ 243 13.5. Calibration Problems .............................................................................................................................. 243 13.5.1. Mis-Calibrated................................................................................................................................... 243 13.5.2. Non-Repeatable Zero and Span....................................................................................................... 243 13.5.3. Inability to Span – No Span Key (CALS) .......................................................................................... 244 13.5.4. Inability to Zero – No Zero Key (CALZ) ............................................................................................ 244 13.6. Other Performance Problems................................................................................................................. 244 13.6.1. Temperature Problems ..................................................................................................................... 244 13.6.1.1. Box Temperature....................................................................................................................... 244 13.6.1.2. Sample Temperature................................................................................................................. 244 13.6.1.3. UV Lamp Temperature .............................................................................................................. 245 13.6.1.4. IZS Ozone Generator Temperature (Optional) ......................................................................... 245 13.7. Subsystem Checkout.............................................................................................................................. 246 13.7.1. AC Main Power ................................................................................................................................. 246 13.7.2. DC Power Supply.............................................................................................................................. 246 13.7.3. I2C Bus .............................................................................................................................................. 247 13.7.4. Keyboard/Display Interface............................................................................................................... 248 13.7.5. Relay PCA ........................................................................................................................................ 248 13.7.6. Photometer Pressure /Flow Sensor Assembly ................................................................................. 249 13.7.7. Motherboard...................................................................................................................................... 250 13.7.7.1. Test Channel / Analog Outputs Voltage .................................................................................... 250 13.7.7.2. A/D Functions ............................................................................................................................ 251 13.7.7.3. Status Outputs........................................................................................................................... 251 13.7.7.4. Control Inputs ............................................................................................................................ 252 13.7.8. CPU .................................................................................................................................................. 252 13.7.9. RS-232 Communications.................................................................................................................. 253 13.7.9.1. General RS-232 Troubleshooting.............................................................................................. 253 13.7.9.2. Troubleshooting Analyzer/Modem or Terminal Operation ........................................................ 253 13.8. Trouble Shooting the photometer ........................................................................................................... 254 13.8.1. Checking Measure / Reference Valve .............................................................................................. 254 13.8.2. Checking The Photometer UV Lamp Power Supply......................................................................... 254 13.9. Trouble Shooting the IZS Options O3 generator..................................................................................... 255 13.9.1. Checking The O3 Generator UV Lamp Power Supply...................................................................... 255 13.10. Repair Procedures ............................................................................................................................... 256 13.10.1. Repairing Sample Flow Control Assembly ..................................................................................... 256 13.10.2. Replacing The Standard Reference O3 Scrubber .......................................................................... 257 13.10.3. Replacing the IZS O3 Scrubber ...................................................................................................... 257 13.10.4. Metal Wool Scrubber Option........................................................................................................... 258 13.10.5. Disk-On-Chip Replacement Procedure .......................................................................................... 258 13.11. Technical Assistance............................................................................................................................ 258 vi 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Table of Contents 14. A PRIMER ON ELECTRO-STATIC DISCHARGE......................................................... 259 14.1. How Static Charges are Created............................................................................................................ 259 14.2. How Electro-Static Charges Cause Damage ......................................................................................... 260 14.3. Common Myths About ESD Damage ..................................................................................................... 261 14.4. Basic Principles of Static Control............................................................................................................ 261 14.4.1. General Rules ................................................................................................................................... 261 14.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ................................................. 263 14.4.2.1. Working at the Instrument Rack ................................................................................................ 263 14.4.2.2. Working at an Anti-ESD Work Bench........................................................................................ 263 14.4.2.3. Transferring Components from Rack to Bench and Back......................................................... 264 14.4.2.4. Opening Shipments from Teledyne Instruments’ Customer Service. ....................................... 264 14.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service.......................... 265 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 3-13: Figure 5-1: Figure 5-2: Figure 5-3: Figure 5-4: Figure 5-5: Figure 5-6: Figure 5-7: Figure 5-8: Figure 5-9: Figure 6-1: Figure 6-2: Figure 6-3: Figure 7-1: Figure 7-2: Figure 7-3: Figure 7-4: Figure 7-5: Figure 7-6: Figure 7-7: Figure 8-1: Figure 8-2: Figure 8-3: Figure 8-4: Figure 8-5: Figure 8-6: Figure 8-7: Figure 8-8: Figure 9-1: 04315 Rev. C1 M400E Front Panel Layout ..........................................................................................................11 M400E Rear Panel Layout – Basic Version ................................................................................12 M400E Rear Panel Layout with Internal Zero/Span (IZS) Option (OPT-51A) .............................12 M400E Internal Layout – Top View with IZS Option....................................................................13 M400E Pneumatic Diagram – Basic Unit.....................................................................................14 M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) ...........................14 M400E Analog Output Connector................................................................................................17 Status Output Connector .............................................................................................................18 Energizing the M400E Control Inputs ..........................................................................................19 Gas Line Connections for the M400E Analyzer – Basic Configuration .......................................22 Gas Line Connections for the M400E Analyzer with IZS Option (OPT-51A) ..............................23 Gas Line Connections when the M400E Analyzer is Located in the Room Being Monitored.....24 Gas Line Connections when the M400E Analyzer is Monitoring a Remote Location .................25 M400E with Carrying Strap Handle and Rack Mount Brackets ...................................................46 Current Loop Option Installed......................................................................................................47 M400E Pneumatic Diagram with Zero/Span Valve Option (OPT-50A) .......................................48 M400E Rear Panel Layout with Zero/Span Valve Option (OPT-50A) .........................................49 Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) .........50 M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) ...........................52 M400E Multidrop Card .................................................................................................................54 M400E Ethernet Card ..................................................................................................................55 M400E Rear Panel with Ethernet Installed ..................................................................................55 Location of Mode field on M400E Analyzer Display ....................................................................59 Viewing M400E Test Functions ...................................................................................................60 Analog Output Connector Pin Out ...............................................................................................70 Default M400E iDAS Channels Setup .........................................................................................80 APICOMuser interface for configuring the iDAS..........................................................................93 Accessing the DIAG Submenus ..................................................................................................97 Accessing the Analog I/O Configuration Submenus....................................................................99 Setup for Calibrating An............................................................................................................ 103 Setup for Checking Current Output Signal Levels.................................................................... 105 Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels ............... 107 Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) ....... 116 Defaul Pin Assignments for CPU COM Port connector (RS-232). ........................................... 117 Location of JP2 on RS232-Multidrop PCA (option 62) ............................................................. 129 RS232-Multidrop PCA Host/Analyzer Interconnect Diagram ................................................... 130 CPU card Locations of RS-232/485 Switches, Connectors and Jumpers................................ 131 Back Panel connector Pin-Outs for COM2 in RS-485mode. .................................................... 132 CPU connector Pin-Outs for COM2 in RS-485 mode............................................................... 132 APICOM Remote Control Program Interface ........................................................................... 148 Pneumatic connections for Manual Calibration Checks without Z/S Valve or IZS Options..... 151 vii Table of Contents Figure 9-2: Figure 9-3: Figure 11-1: Figure 11-2: Figure 11-3: Figure 11-4: Figure 11-5: Figure 11-6: Figure 11-7: Figure 11-8: Figure 11-9: Figure 11-10: Figure 11-11: Figure 11-12: Figure 11-13: Figure 11-14: Figure 11-15: Figure 11-16: Figure 11-17: Figure 11-18: Figure 11-19: Figure 11-20: Figure 11-21: Figure 12-1 Figure 12-2 Figure 12-3: Figure 12-4: Figure 12-5: Figure 13-1: Figure 13-2: Figure 13-3: Figure 13-4: Figure 13-5: Figure 13-6: Figure 14-1: Figure 14-2: M400E Ozone Analyzer Operator’s Manual Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) ...... 157 Gas Line Connections for the M400E Analyzer with IZS Options (OPT-51A).......................... 157 O3 Absorption Path ................................................................................................................... 191 Reference / Measurement Gas Cycle....................................................................................... 192 M400E Pneumatic Diagram – Basic Unit.................................................................................. 194 Flow Control Assembly & Critical Flow Orifice ......................................................................... 195 M400E Electronic Block Diagram ............................................................................................. 197 Relay PCA Layout (P/N 04523-0100)....................................................................................... 201 Relay PCA P/N 045230100 with Safety Shield In Place .......................................................... 202 Relay PCA P/N 045230200 with AC Relay Retainer in Place .................................................. 202 Status LED Locations – Relay PCA.......................................................................................... 203 Heater Control Loop Block Diagram. ........................................................................................ 204 Thermocouple Configuration Jumper (JP5) Pin-Outs............................................................... 205 Power Distribution Block Diagram ............................................................................................ 206 Location of AC power Configuration Jumpers .......................................................................... 207 Pump AC Power Jumpers (JP7)............................................................................................... 208 Typical Jumper Set (JP2) Set Up of Optional Metal Wool Scrubber Heater ............................ 209 O3 Photometer Layout – Top Cover Removed ......................................................................... 210 O3 Photometer Electronic Block Diagram................................................................................. 211 O3 Photometer UV Lamp Power Supply Block Diagram .......................................................... 212 Interface Block Diagram ........................................................................................................... 214 Front Panel ............................................................................................................................... 214 Basic Software Operation ......................................................................................................... 216 Replacing the Particulate Filter................................................................................................. 223 Replacing the IZS Zero Air Scrubber........................................................................................ 224 Optical Bench – Lamp Adjustment/ Installation ........................................................................ 229 O3 Generator Temperature Thermistor and DC Heater Locations ........................................... 230 Location of O3 Generator Reference Detector Adjustment Pot ................................................ 230 Example of Signal I/O Function ................................................................................................ 238 CPU Status Indicator ................................................................................................................ 240 Relay PCA Status LEDS Used for Troubleshooting ................................................................. 241 Location of DC Power Test Points on Relay PCA .................................................................... 247 Critical Flow Orifice Assembly (Instruments without IZS)......................................................... 256 IZS O3 Generator Zero Air Scrubber Location.......................................................................... 257 Triboelectric Charging............................................................................................................... 259 Basic anti-ESD Work Station .................................................................................................... 261 LIST OF TABLES Table 2-1: Table 2-2: Table 2-3: Table 2-4: Table 3-1: Table 3-2: Table 3-3: Table 3-4: Table 3-5: Table 3-6: Table 3-7: Table 3-8: Table 3-9: Table 5-1: Table 5-2: Table 6-1: viii Model 400E Basic Unit Specifications ...........................................................................................7 Model 400E IZS Generator Specifications with Reference Feedback Option..............................8 Specifications for Model 400E IZS Generator w/o Reference Feedback Option .........................8 Software Settings for EPA Equivalence.........................................................................................9 Front Panel Nomenclature...........................................................................................................11 M400E Analyzer Gas Inlet/Outlet Nomenclature.........................................................................13 Ventilation Clearance...................................................................................................................16 Analog Output Pin Outs ...............................................................................................................17 Status Output Pin Assignments ...................................................................................................18 Control Input Pin Assignments ....................................................................................................19 Front Panel Display during System Warm-Up.............................................................................27 Possible Warning Messages at Start-Up .....................................................................................28 AUTOCAL Settings for Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3 .....38 Zero/Span Valve Operating States ..............................................................................................49 Internal Zero/Span Valve Operating States.................................................................................53 Analyzer Operating Modes ..........................................................................................................59 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Table 6-2: Table 6-3: Table 6-4: Table 6-5: Table 6-6: Table 7-1: Table 7-2: Table 7-3: Table 7-4: Table 7-5: Table 7-6: Table 7-7: Table 7-8: Table 7-9: Table 7-10: Table 8-1: Table 8-2: Table 8-3: Table 8-4: Table 8-5: Table 8-6: Table 8-7: Table 8-8: Table 9-1: Table 9-2: Table 9-3: Table 10-1: Table 10-2: Table 10-3: Table 10-4: Table 11-1: Table 11-2: Table 11-3: Table 11-4: Table 11-5: Table 11-6: Table 12-1: Table 12-2: Table 13-1: Table 13-2: Table 13-3: Table 13-4: Table 13-5: Table 13-6: Table 13-7: Table 13-8: Table 13-9: Table 13-10: Table 13-11: Table 14-1: Table 14-2: 04315 Rev. C1 Table of Contents Test Functions Defined ................................................................................................................61 Warning Messages Defined.........................................................................................................62 Primary Setup Mode Features and Functions .............................................................................64 Secondary Setup Mode Features and Functions ........................................................................64 Password Levels..........................................................................................................................66 Front Panel LED Status Indicators for iDAS................................................................................77 iDAS Data Channel Properties ....................................................................................................78 iDAS Data Parameter Functions..................................................................................................85 Variable Names (VARS) ..............................................................................................................94 Diagnostic Mode (DIAG) Functions .............................................................................................96 DIAG - Analog I/O Functions .......................................................................................................98 Voltage Tolerances for the TEST CHANNEL Calibration......................................................... 103 Current Loop Output Check...................................................................................................... 107 Analog Output Voltage Range Min/Max ................................................................................... 108 Test Channels Functions available on the M400E’s Analog Output ........................................ 111 COMM Port Communication Modes ......................................................................................... 119 Terminal Mode Software Commands ....................................................................................... 123 Teledyne Instruments Serial I/O Command Types................................................................... 124 Ethernet Status Indicators ........................................................................................................ 133 LAN/Internet Configuration Properties...................................................................................... 134 RS-232 Communication Parameters for Hessen Protocol ....................................................... 139 Teledyne Instruments Hessen Protocol Response Modes ...................................................... 142 Default Hessen Status Bit Assignments ................................................................................... 146 AUTOCAL Modes ..................................................................................................................... 162 AutoCal Attribute Setup Parameters......................................................................................... 163 Example AutoCal Sequence..................................................................................................... 163 Daily Activity Matrix................................................................................................................... 183 Activity Matrix for Audit Procedure............................................................................................ 183 Activity Matrix for Data Reduction, Validation and Reporting ................................................... 184 Activity Matrix for Calibration Procedures................................................................................. 184 Relay PCA Status LED’s .......................................................................................................... 203 Thermocouple Configuration Jumper (JP5) Pin-Outs............................................................... 205 Thermocouple Settings for Optional Metal Wool Scrubber ...................................................... 205 AC Power Configuration for Internal Pumps (JP7) ................................................................... 208 Power Configuration for Optional Metal Wool Scrubber Heater (JP6) ..................................... 209 Front Panel Status LED’s ......................................................................................................... 215 Predictive Uses for Test Functions ........................................................................................... 219 M400E Maintenance Schedule................................................................................................. 221 Front Panel Warning Messages ............................................................................................... 235 Test Functions - Indicated Failures........................................................................................... 237 Test Channel Outputs as Diagnostic Tools .............................................................................. 239 Relay PCA Watchdog LED Failure Indications......................................................................... 240 Relay PCA Status LED Failure Indications............................................................................... 241 DC Power Test Point and Wiring Color Codes ......................................................................... 246 DC Power Supply Acceptable Levels ....................................................................................... 247 Relay PCA Control Devices...................................................................................................... 248 Analog Output Test Function - Nominal Values Voltage Outputs ............................................ 250 Status Outputs Check ............................................................................................................... 251 M400E Control Input Pin Assignments and Corresponding Signal I/O Functions ................... 252 Static Generation Voltages for Typical Activities ...................................................................... 259 Sensitivity of Electronic Devices to Damage by ESD ............................................................... 260 ix Table of Contents M400E Ozone Analyzer Operator’s Manual LIST OF APPENDICES APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX A-1: Model 400E Software Menu Trees, Revision D.4 APPENDIX A-2: Model 400E Setup Variables Available Via Serial I/O, Revision D.4 APPENDIX A-3: Model 400E Warnings and Test Measurements via Serial I/O, Revision D.4 APPENDIX A-4: Model 400E Signal I/O Definitions, Revision D.4 APPENDIX A-5: Model M400E IDAS Functions, Revision D.4 APPENDIX A-6: Model M400E Terminal Command Designators, Revision D.4 APPENDIX B - M400E SPARE PARTS LIST APPENDIX C - REPAIR QUESTIONNAIRE - M400E APPENDIX D - ELECTRONIC SCHEMATICS USER NOTES: x 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Information SECTION I – GENERAL INFORMATION 04315 Rev. C1 1 General Information M400E Ozone Analyzer Operator’s Manual USER NOTES 2 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Introduction 1. INTRODUCTION 1.1. SAFETY MESSAGES Your safety and the safety of others are 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 are found in the manual and inside the M400E Photometric Ozone Analyzer. The definition of these symbols is described below: General Safety Hazard: Refer to the instructions for details on the specific hazard. CAUTION: Hot Surface Hazard. CAUTION: Electrical Shock Hazard. TECHNICIAN SYMBOL: All operations marked with this symbol are to be performed by qualified maintenance personnel only. NOTE Technical Assistance regarding the use and maintenance of the M400E 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/ 04315 Rev. C1 3 Introduction M400E Ozone Analyzer Operator’s Manual 1.2. M400E OVERVIEW The Model 400E photometric ozone analyzer is a microprocessor-controlled analyzer that measures low ranges of ozone in ambient air using a method based on the Beer-Lambert law, an empirical relationship that relates the absorption of light to the properties of the material through which the light is traveling over a given distance. The intensity of an ultra violate light is measured after it passes through a chamber, called the sample cell, where it is absorbed in proportion to the amount of ozone present. Every three seconds, a switching valve alternates measurement between a gas stream containing ozone and a stream that has been scrubbed of ozone. The analyzer also measures the ambient temperature and pressure of the gas being measured. Using results of these measurements and the Beer-Lambert equation, the M400E analyzer calculates the amount of ozone present in the sampler gas. The M400E analyzer’s multi-tasking software gives the ability to track and report a large number of operational parameters in real time. These readings are compared to diagnostic limits kept in the analyzers memory and should any fall outside of those limits the analyzer issues automatic warnings. Built-in data acquisition capability, using the analyzer's internal memory, allows the logging of multiple parameters including averaged or instantaneous concentration values, calibration data, and operating parameters such as pressure and flow rate. Stored data are easily retrieved through the serial port or optional Ethernet port via our APICOM software or from the front panel, allowing operators to perform predictive diagnostics and enhanced data analysis by tracking parameter trends. Multiple averaging periods of one minute to 365 days are available for over a period of one year. Some of the exceptional features of your M400E photometric ozone analyzer are: Ranges, 0-100 ppb to 0-10 ppm, user selectable Single pass ultraviolet absorption Microprocessor controlled for versatility Multi-tasking software allows viewing of test variables during operation Continuous self checking with alarms Dual bi-directional RS-232 ports for remote operation (optional RS-485 or Ethernet) Digital status outputs provide instrument operating condition Adaptive signal filtering optimizes response time Optional Internal Zero/Span check and dual span points Temperature & Pressure compensation Internal data logging with 1 min to 365 day multiple averages Several options can be purchased for the analyzer that allows the user to more easily supply and manipulate Zero Air and Span Gas. For more information of these options, see Sections 5.6.1and 5.6.2. CAUTION General Safety Hazard The M400E Photometric Ozone Analyzer should only be used for the purpose and in the manner described in this manual. If you use the M400E in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences. 4 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Introduction 1.3. USING THIS MANUAL NOTE Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent messages as they appear on the analyzer’s display. This manual is organized in the following manner: TABLE OF CONTENTS: Outlines the contents of the manual in the order the information are presented. This is a good overview of the topics covered in the manual. There is also a list of appendices, figures and tables. SECTION I – GENERAL INFORMATION INTRODUCTION A brief description of the M400E analyzer architecture as well as a description of the layout of the manual and what information is located in its various sections and chapters. SPECIFICATIONS AND WARRANTY A list of the analyzer’s performance specifications and if applicable a description of the conditions and configuration under which EPA equivalency was approved as well as the Teledyne Instruments’ warranty statement. GETTING STARTED Instructions for setting up, installing and running your analyzer for the first time. GLOSSARY: Answers to the most frequently asked questions about operating the analyzer and a glossary of acronyms and technical terms. OPTIONAL HARDWARE & SOFTWARE A description of optional equipment to add functionality to your analyzer. SECTION II – OPERATING INSTRUCTIONS BASIC OPERATION OF THE M400E ANALYZER Step-by-Step instructions for using the display/keyboard to set up and operate the M400E analyzer. ADVANCED FEATURES OF THE M400E ANALYZER Step-by-Step instructions for using the M400E analyzer’s more advanced features such as the iDAS system, the DIAG and VARSmenus and the and the TEST channel analog output. REMOTE OPERATION OF THE M400E Analyzer Information and instructions for interacting with the M400E analyzer via its several remote interface options (e.g. via RS-232, Ethernet, its built in digital control inputs/outputs, etc.) M400E VALIDATION AND VERIFICATION Methods and procedures for verifying the correct operation of your M400E Analyzer as well as step by step instructions for calibrating it EPA PROTOCOL CALIBRATION Specific information regarding calibration requirements for analyzers used in EPA monitoring. 04315 Rev. C1 5 Introduction M400E Ozone Analyzer Operator’s Manual SECTION III – TECHNICAL INFORMATION THEORY OF OPERATION An in-depth look at the various principals by which your analyzer operates as well as a description of how the various electronic, mechanical and pneumatic components of the analyzer work and interact with each other. A close reading of this section is invaluable for understanding the analyzer’s operation. MAINTENANCE SCHEDULE AND PROCEDURES Description of preventative maintenance procedures that should be regularly performed on you analyzer to assure good operating condition. GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER This section includes pointers and instructions for diagnosing problems with the analyzer in general and the Terminus as well as instructions on performing repairs of on the Terminus. A PRIMER ON ELECTRO-STATIC DISCHARGE This section describes how static electricity occurs; why it is a significant concern and; how to avoid it and avoid allowing ESD to affect the reliable and accurate operation of your analyzer. APPENDICES For easier access and better updating, some information has been separated out of the manual and placed in a series of appendices at the end of this manual. These include version-specific software menu trees, warning messages, definitions Modbus registers and serial I/O variables as well as spare part listings, repair questionnaires, interconnect drawing, detailed pneumatic and electronic schematics. USER NOTES: 6 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Specifications, Approvals and Warranty 2. SPECIFICATIONS, APPROVALS AND WARRANTY 2.1. SPECIFICATIONS Table 2-1: Min/Max Range (Physical Analog Output) Measurement Units Zero Noise Span Noise Lower Detectable Limit Zero Drift (24 hours) Zero Drift (7 days) Span Drift (24 hours) Span Drift (7 days) Linearity Precision Lag Time Rise/Fall Time Sample Flow Rate Temperature Range Humidity Range Pressure Range Altitude Range Temp Coefficient Voltage Coefficient Dimensions (H x W x D) Weight AC Power Environmental Conditions Analog Outputs Analog Output Ranges Analog Output Resolution Status Outputs Control Inputs Serial I/O Certifications 04315 Rev. C1 Model 400E Basic Unit Specifications Min: 0-100 PPB Max: 0-10,000 PPB ppb, ppm, µg/m3, mg/m3 (user selectable) < 0.3 ppb RMS (EPA Definition) < 0.5% of reading above 100 PPB (EPA Definition) < 0.6 PPB (EPA Definition) < 1.0 ppb (at constant temperature and voltage) < 1.0 ppb (at constant temperature and voltage) < 1% of reading (at constant temperature and voltage) < 1% of reading (at constant temperature and voltage) < 1% of full scale < 0.5% of reading (EPA Definition) < 10 sec (EPA Definition) < 20 sec to 95% (EPA Definition) 800 80 cc/min 5 - 40C 0-90% RH, Non-Condensing 25 – 31 “Hg-A 0-2000m < 0.05% per deg C < 0.05% per Volt AC (RMS) over range of nominal 10% 7” x 17” x 23.5” 30.6lbs. (13.8Kg) with IZS Option 100V 50/60Hz (3.25A), 115V 60Hz (3.0A), 220 – 240 V 50/60 Hz (2.5A) Installation Category (Over voltage Category) II Pollution Degree 2 Four (4) Outputs, Three (3) defined All Outputs: 100 mV, 1 V, 5 V, 10 V Two concentration outputs convertible to 4-20 mA isolated current loop All Ranges with 5% Under/Over Range 1 part in 4096 of selected full-scale voltage 8 Status outputs from opto-isolators 6 Control Inputs, 3 defined, 3 spare COM1: RS-232; COM2: RS-232 or RS-485 Baud Rate : 300 – 115200 USEPA: Equivalent Method Number EQOA-0992-087 CE Mark 7 Specifications, Approvals and Warranty Table 2-2: Model 400E IZS Generator Specifications with Reference Feedback Option Maximum Concentration 1.0 PPM Minimum Concentration 0.050 PPM Initial Accuracy +/- 5% of target concentration Stability (7 Days) 1% of reading Repeatability (7 days) 1% of reading Response Time < 5 min to 95% Resolution 0.5 ppb Table 2-3: 8 M400E Ozone Analyzer Operator’s Manual Specifications for Model 400E IZS Generator w/o Reference Feedback Option Maximum Concentration 1.0 PPM Minimum Concentration 0.050 PPM Initial Accuracy +/- 10% of target concentration Stability (7 Days) 2% of reading Repeatability (7 days) 2% of reading Response Time < 5 min to 95% Resolution 0.5 ppb 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Specifications, Approvals and Warranty 2.2. EPA EQUIVALENCY DESIGNATION Advanced Pollution Instrumentation, Inc., Model 400E photometric ozone analyzer is designated as Equivalent Method Number EQOA-0992-087 as defined in 40 CFR Part 53, when operated under the following conditions: Range: Any range from 100 ppb to 1 ppm. Ambient temperature range of 5 to 40ºC. Line voltage range of 105 – 125 VAC or 200 – 240 VAC, 50/60 Hz. With 5-micron PTFE filter element installed in the internal filter assembly. Sample flow of 800 ± 80 cc3/min at sea level. Gas flow supplied by Internal or External pump. Following Software Setting: Table 2-4: Software Settings for EPA Equivalence Dilution Factor 1.0 AutoCal ON or OFF Dynamic Zero ON or OFF Dynamic Span OFF Dual range ON or OFF Auto range ON or OFF Temp/Pres compensation ON Under the designation, the Analyzer may be operated with or without the following options: Rack mount with slides. Rack mount without slides, ears only. Zero/Span Valves option. Internal Zero/Span (IZS) generator. 4-20mA, isolated output. 2.3. CE MARK COMPLIANCE EMISSIONS COMPLIANCE The Teledyne Instruments Model 400E photometric ozone analyzer was tested and found to be fully compliant with: EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B section 15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A. Tested on 7/1/2002 to 7/2/2002 at CKC Laboratories, Inc., Report Number CE02-128. SAFETY COMPLIANCE The Teledyne Instruments Model 400E photometric ozone analyzer was tested and found to be fully compliant with: IEC 61010-1:90 + A1:92 + A2:95, Tested in 08/2002 to 09/2002 at NEMKO: Report Number 2002-10280. 04315 Rev. C1 9 Specifications, Approvals and Warranty M400E Ozone Analyzer Operator’s Manual 2.4. 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 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 ARISING OUT OF OR RELATED TO THIS AGREEMENT OF T-API'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE TERMS AND CONDITIONS All units or components returned to Teledyne Instruments Incorporated 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. USER NOTES: 10 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3. GETTING STARTED 3.1. MODEL 400E ANALYZER LAYOUT MODE FIELD FASTENER KEY DEFINITION FIELD LOCKING SCREW KEYBOARD Figure 3-1: Table 3-1: MESSAGE FIELD CONCENTRATION FIELD FASTENER ON / OFF SWITCH STATUS LED’s M400E Front Panel Layout Front Panel Nomenclature NAME SIGNIFICANCE Mode Field Displays the name of the analyzer’s current operating mode Message Field Displays a variety of informational messages such as warning messages, operational data, test function values and response messages during interactive tasks. Concentration Field Displays the actual concentration of the sample gas currently being measured by the analyzer in the currently selected units of measure Keypad Definition Field Displays dynamic, context sensitive definitions for the row of keys just below the display. STATUS LED’s NAME SAMPLE CAL COLOR Green Yellow STATE Unit is not operating in sample mode, iDAS is disabled. On Sample Mode active; Front Panel Display being updated; iDAS data being stored. Blinking Red 04315 Rev. C1 Unit is operating in sample mode, front panel display being updated, iDAS hold-off mode is ON, iDAS disabled Off Auto Cal disabled On Auto Cal enabled Blinking FAULT DEFINITION Off Off Blinking Unit is in calibration mode O3 warnings exist Warnings exist 11 Getting Started M400E Ozone Analyzer Operator’s Manual Cooling Fan Serial I/O LEDs Status Outputs Analog Outputs Sample Gas Inlet Exhaust Gas Outlet Power Receptacle DCE – DTE Switch Figure 3-2: Cooling Fan COM Port A COM Port B (RS-232 Only) (RS-232 or RS-485) Control Inputs Serial Number Tag M400E Rear Panel Layout – Basic Version Serial I/O LEDs Status Outputs Analog Outputs Sample Gas Inlet Exhaust Gas Outlet Dry Air Inlet Power Receptacle Figure 3-3: 12 DCE – DTE Switch COM Port A COM Port B (RS-232 Only) (RS-232 or RS-485) Control Inputs Serial Number Tag M400E Rear Panel Layout with Internal Zero/Span (IZS) Option (OPT-51A) 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Table 3-2: REAR PANEL LABEL Getting Started M400E Analyzer Gas Inlet/Outlet Nomenclature FUNCTION CONFIGURATION VARIATIONS Calibration gasses are also inlet here on: Base configuration and; SAMPLE Connect the source of sample gas here. EXHAUST Connect exhaust gas line here (must be <10 meters). SPAN Connect the source of calibrated span gas here. Only present with Zero/Span valves (OPT-50A) ZERO AIR Connect the source of zero air here. Only present with Zero/Span valves (OPT-50A) DRY AIR Attach the source of dry air here (< -20ºc dew point). Only present with the internal zero/span option (OPT-51A) Analyzers with the internal zero/span valve option installed (OPT-51A) All configurations Particulate Filter PC/104 Card IZS O3 Generator Front Panel Mother Board (Optional) Measure / Reference Valve Optical Bench Gas Flow Sensor Assy Relay Board ON/OFF SWITCH Pump Assy Figure 3-4: 04315 Rev. C1 Critical Flow Orifice Power Receptacle PS2 (+12 VDC) PS1 (+5 VDC; 15VDC) Rear Panel M400E Internal Layout – Top View with IZS Option 13 Getting Started M400E Ozone Analyzer Operator’s Manual Figure 3-5: Figure 3-6: 14 M400E Pneumatic Diagram – Basic Unit M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.2. UNPACKING THE M400E ANALYZER CAUTION General Safety Hazard TO AVOID PERSONAL INJURY, ALWAYS USE TWO PERSONS TO LIFT AND CARRY THE MODEL 400E. 1. Verify that there is no apparent external shipping damage. If damage has occurred, please advise the shipper first, then Teledyne Instruments. 2. Included with your analyzer is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet (P/N 04314) is an important quality assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument. 3. Carefully remove the top cover of the analyzer and check for internal shipping damage. Remove the setscrew located in the top, center of the Front panel. Remove the two screws fastening the top cover to the unit (one per side towards the rear). Slide the cover backwards until it clears the analyzer’s front bezel. Lift the cover straight up. NOTE Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. See Chapter 12 for more information on preventing ESD damage. CAUTION Electrical Shock Hazard NEVER DISCONNECT PCAS, WIRING HARNESSES OR ELECTRONIC SUBASSEMBLIES WHILE UNDER POWER. 4. Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated. 5. Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated. 6. Verify that all of the optional hardware ordered with the unit has been installed. These are listed on the paperwork accompanying the analyzer. 04315 Rev. C1 15 Getting Started M400E Ozone Analyzer Operator’s Manual 3.2.1.1. Ventilation Clearance Whether the analyzer is set up on a bench or installed into an instrument rack, be sure to leave sufficient ventilation clearance. Table 3-3: Ventilation Clearance AREA MINIMUM REQUIRED CLEARANCE Back of the instrument 4 in. Sides of the instrument 1 in. Above and below the instrument 1 in. Various rack mount kits are available for this analyzer. See Section 5.1 of this manual for more information. 3.3. ELECTRICAL CONNECTIONS 3.3.1. POWER CONNECTION Attach the power cord to the analyzer and plug it into a power outlet capable of carrying at least 10 A current at your AC voltage and that it is equipped with a functioning earth ground. CAUTION Electrical Shock Hazard HIGH VOLTAGES ARE PRESENT INSIDE THE ANALYZERS CASE POWER CONNECTION MUST HAVE FUNCTIONING GROUND CONNECTION. DO NOT DEFEAT THE GROUND WIRE ON POWER PLUG. TURN OFF ANALYZER POWER BEFORE DISCONNECTING OR CONNECTING ELECTRICAL SUBASSEMBLIES. DO NOT OPERATE WITH COVER OFF. CAUTION General Safety Hazard THE M400E ANALYZER CAN BE CONFIGURED FOR BOTH 100-130 V AND 210-240 V AT EITHER 50 OR 60 HZ. TO AVOID DAMAGE TO YOUR ANALYZER, MAKE SURE THAT THE AC POWER VOLTAGE MATCHES THE VOLTAGE INDICATED ON THE ANALYZER’S SERIAL NUMBER LABEL TAG (SEE FIGURE 3-2) BEFORE PLUGGING THE M400E INTO LINE POWER. 16 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.3.2. ANALOG OUTPUT CONNECTIONS The M400E is equipped with several analog output channels accessible through a connector on the back panel of the instrument (see Figure 3-2). Channels A1 and A2 output a signal that is proportional to the O3 concentration of the sample gas. The default analog output voltage setting of these channels is 0 to 5 VDC with a reporting range of 0 to 500 ppb. An optional Current Loop output is available for each. The output labeled A4 is special. It can be set by the user to output any one a variety of diagnostic test functions. The default analog output voltage setting of these channels is also 0 to 5 VDC. See Section 7.4.6 for a list of available functions and their associated reporting range. There is no optional Current Loop output available for Channel A4. To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output connections on the rear panel of the analyzer. Pin-outs for the analog output connector are: ANALOG OUT + A1 - Figure 3-7: + 1 2 3 4 5 6 7 8 A2 - A4 + - Analog Output Pin Outs Analog Output A1 A3 + M400E Analog Output Connector Table 3-4: Pin A2 - Standard Voltage Output Current Loop Option V Out I Out + Ground I Out - V Out I Out + Ground I Out - A3 A4 NOT USED V Out Not Available Ground Not Available To change the settings for the analog output channels, see Section 7.4 04315 Rev. C1 17 Getting Started M400E Ozone Analyzer Operator’s Manual 3.3.3. CONNECTING THE STATUS OUTPUTS The status outputs report analyzer conditions via optically isolated NPN transistors, which sink up to 50 mA of DC current. These outputs can be used interface with devices that accept logic-level digital inputs, such as programmable logic controllers (PLCs). Each Status bit is an open collector output that can withstand up to 40 VDC. All of the emitters of these transistors are tied together and available at D. 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 transistor output to less than 50 mA. At 50 mA, the transistor will drop approximately 1.2V from its collector to emitter. The status outputs are accessed via a 12-pin connector on the analyzer’s rear panel labeled STATUS (see Figure 3-2). Pin-outs for this connector are: Figure 3-8: Table 3-5: 4 5 6 7 8 D + DIAG MODE 3 SPAN CAL CONC VALID 2 HIGH RANGE SYSTEM OK 1 ZERO CAL STATUS Status Output Connector Status Output Pin Assignments OUTPUT # STATUS DEFINITION 1 SYSTEM OK On if no faults are present. 2 CONC VALID On if O3 concentration measurement is valid. If the O3 concentration measurement is invalid, this bit is OFF. 3 HIGH RANGE On if unit is in high range of DUAL or AUTO Range Modes. 4 ZERO CAL On whenever the instrument is in CALZ mode. 5 SPAN CAL On whenever the instrument is in CALS mode. 6 DIAG MODE 7&8 Unassigned D Emitter BUSS CONDITION On whenever the instrument is in DIAGNOSTIC mode. The emitters of the transistors on pins 1 to 8 are bussed together. Spare + DC Power Digital Ground 18 + 5 VDC, 300 mA source (combined rating with Control Output, if used). The ground level from the analyzer’s internal DC power supplies. 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.3.4. CONNECTING THE CONTROL INPUTS The analyzer is equipped with three digital control inputs that can be used to activate the zero and span calibration modes remotely (see Section9.2). Access to these inputs is provided via an 8-pin connector labeled CONTROL IN on the analyzer’s rear panel (See Figure 3-2). Table 3-6: Control Input Pin Assignments Input # Status Definition A REMOTE ZERO CAL The Analyzer is placed in Zero Calibration mode. The mode field of the display will read ZERO CAL R. B REMOTE LO SPAN CAL The Analyzer is placed in Lo Span Calibration mode. The mode field of the display will read LO CAL R. C REMOTE SPAN CAL The Analyzer is placed in Span Calibration mode. The mode field of the display will read SPAN CAL R. D, E & F Spare U ON Condition Digital Ground The ground level from the analyzer’s internal DC Power Supplies (same as chassis ground). External Power input Input pin for +5 VDC required to activate pins A – F. + Internally generated 5V DC power. To activate inputs A – F, place a jumper between this pin and the “U” pin. The maximum amperage through this port is 300 mA (combined with the analog output supply, if used). 5 VDC output There are two methods for energizing the Control Inputs. The internal +5V available from the pin labeled “+” is the most convenient method however, to ensure that these inputs are truly isolated; a separate external 5 VDC power supply should be used. CONTROL IN CONTROL IN F U + A B C D Local Power Connections Figure 3-9: 04315 Rev. C1 E F U + SPAN E LO SPAN D ZERO C SPAN B LO SPAN ZERO A 5 VDC Power Supply + External Power Connections Energizing the M400E Control Inputs 19 Getting Started M400E Ozone Analyzer Operator’s Manual 3.3.5. CONNECTING THE SERIAL PORTS If you wish to utilize either of the analyzer’s two serial interface COMM ports, refer to Chapter 8 of this manual for instructions on their configuration and usage. 3.3.6. CONNECTING TO A LAN OR THE INTERNET If your unit has a Teledyne Instruments Ethernet card, plug one end into the 7’ CAT5 cable supplied with the option into the appropriate place on the back of the analyzer and the other end into any nearby Ethernet access port. NOTE The M400E firmware supports dynamic IP addressing or DHCP. If your network also supports DHCP, the analyzer will automatically configure its LAN connection appropriately (see Section 8.4.2). If your network does not support DHCP, see Section 8.4.2.1 for instructions on manually configuring the LAN connection. 3.3.7. CONNECTING TO A MULTIDROP NETWORK If your unit has a Teledyne Instruments RS-232 multidrop card, see Section 8.2.1 for instructions on setting it up. 20 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.4. PNENUMATIC CONNECTIONS CAUTION General Safety Hazard OZONE (O3) IS A TOXIC GAS. OBTAIN A MATERIAL SAFETY DATA SHEET (MSDS) FOR THIS MATERIAL. READ AND RIGOROUSLY FOLLOW THE SAFETY GUIDELINES DESCRIBED THERE. DO NOT VENT CALIBRATION GAS AND SAMPLE GAS INTO ENCLOSED AREAS SAMPLE AND CALIBRATION GASES SHOULD ONLY COME INTO CONTACT WITH PTFE, FEP OR GLASS. NOTE: Sample and calibration gases should only come into contact with PTFE, FEP or glass. 3.4.1. ABOUT ZERO AIR AND CALIBRATION GAS ZERO AIR Zero air is similar in chemical composition to the Earth’s atmosphere but scrubbed of all components that might affect the analyzer’s readings. It is recommended that an external zero air generator such as the Teledyne Instruments Model 701 be used CALIBRATION (SPAN) GAS Calibration gas is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired reporting range. Because ozone (O3) quickly breaks down into molecular oxygen (O2), this calibration gas cannot be supplied in precisely calibrated bottles like other gases. If the M400E analyzer is not equipped with the optional internal zero air generator (IZS), an external O3 generator capable supplying accurate O3 calibration mixtures must be used. Also, some applications, such as EPA monitoring, require multipoint calibration checks where Span gas of several different concentrations is needed. In either case, we recommend using a Gas Dilution Calibrator such as a T-API Model 700 with internal photometer option. In the case of O3 measurements made with the Model 400E photometric ozone analyzer, it is recommended that you use a span gas with an O3 concentration equal to 80% of the reporting range for your application. EXAMPLE: If the application is to measure between 0 ppm and 500 ppb, an appropriate span gas would be 400 ppb. If the application is to measure between 0 ppb and 1000 ppb, an appropriate span gas would be 800 ppb. 04315 Rev. C1 21 Getting Started M400E Ozone Analyzer Operator’s Manual 3.4.2. BASIC PNEUMATIC SETUP FOR THE M400E ANALYZER Figure 3-10: Gas Line Connections for the M400E Analyzer – Basic Configuration For the Model 400E photometric ozone analyzer in its basic configuration (i.e. without the optional internal zero air source or valves), attach the following pneumatic lines: 1. SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet fitting. Sample Gas pressure must equal ambient atmospheric pressure (1.0 psig) In applications where the sample gas is received from a pressurized manifold, a vent must be placed on the sample gas line. This vent line must be: At least 0.2m long No more than 2m long Vented outside the shelter or immediate area surrounding the instrument 2. CAL GAS & ZERO AIR SOURCES: The source of calibration gas is also attached to the SAMPLE inlet, but only when a calibration operation is actually being performed. 3. EXHAUST OUTLET: Attach an exhaust line to the EXHAUST outlet fitting. The exhaust line should be a maximum of 10 meters of ¼” PTEF tubing. CAUTION General Safety Hazard VENTING SHOULD BE OUTSIDE THE SHELTER OR IMMEDIATE AREA SURROUNDING THE INSTRUMENT AND CONFORM TO ALL SAFETY REQUIREMENTS REGARDING EXPOSURE TO O3. 4. Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using the procedures defined in Section 12.3.4. 22 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.4.3. PNEUMATIC SETUP FOR THE M400E ANALYZER WITH INTERNAL ZERO/SPAN OPTION (IZS) Figure 3-11: Gas Line Connections for the M400E Analyzer with IZS Option (OPT-51A) For the Model 400E photometric ozone analyzer with the optional internal zero air generator and span valve (IZS), attach the following pneumatic lines: 1. SAMPLE GAS SOURCE: Attach a sample inlet line to the sample inlet fitting. Sample Gas pressure must equal ambient atmospheric pressure (1.0 psig) In applications where the sample gas is received from a pressurized manifold, a vent must be placed on the sample gas line. This vent line must be: At least 0.2m long No more than 2m long Vented outside the shelter or immediate area surrounding the instrument 2. ZERO AIR SOURCE: Attach a gas line from the source of zero air (e.g. a Teledyne Instruments M701 zero air Generator) to the DRY AIR inlet. The gas from this line will be used internally as zero air and as source air for the internal O3 generator 3. EXHAUST OUTLET: Attach an exhaust line to the EXHAUST outlet fitting. The exhaust line should be a maximum of 10 meters of ¼” PTEF tubing. 04315 Rev. C1 23 Getting Started M400E Ozone Analyzer Operator’s Manual CAUTION General Safety Hazard VENTING SHOULD BE OUTSIDE THE SHELTER OR IMMEDIATE AREA SURROUNDING THE INSTRUMENT AND CONFORM TO ALL SAFETY REQUIREMENTS REGARDING EXPOSURE TO O3. 4. Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using the procedures defined in Section 12.3.4. 3.4.4. PNEUMATIC SETUPS FOR AMBIENT AIR MONITORING WITH THE M400E ANALYZER 3.4.4.1. Pneumatic Set Up for M400E’s Located in the Same Room Being Monitored. In this application is often preferred that the sample gas and the source gas for the O3 generator and internal zero air be the same chemical composition. Figure 3-12: Gas Line Connections when the M400E Analyzer is Located in the Room Being Monitored 1. SAMPLE GAS & DRY AIR SOURCES: For instruments located in the same room, being monitored there is no need to attach the gas inlet lines to the SAMPLE inlet or the dry air inlet. 2. EXHAUST OUTLET: Attach an outlet line to the EXHAUST outlet fitting. In order to prevent the instrument from re-breathing its own exhaust gas (resulting in artificially low readings) the end of the exhaust outlet line should be located at least 2 feet from the back panel of the instrument. 3. Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using the procedures defined in Section 12.3.4. 24 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.4.4.2. Pneumatic Set Up for M400E’s Monitoring Remote Locations In this application is often preferred that the Sample gas and the source gas for the O3 generator and internal zero air be the same chemical composition. Figure 3-13: Gas Line Connections when the M400E Analyzer is Monitoring a Remote Location 1. SAMPLE GAS SOURCE: Attach a sample inlet line leading from the room being monitored to the sample inlet fitting. 2. DRY AIR SOURCE: Attach a gas line leading from the room being monitored to the dry air inlet port. This can be a separate line or, as shown above the same line with a T- fitting. 3. EXHAUST OUTLET: No outlet line is required for the exhaust port of the instrument. 4. Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using the procedures defined in Section 12.3.4. USER NOTES: 04315 Rev. C1 25 Getting Started M400E Ozone Analyzer Operator’s Manual 3.5. INITIAL OPERATION If you are unfamiliar with the M400E theory of operation, we recommend that you read Chapter 11 For information on navigating the analyzer’s software menus, see the menu trees described in Appendix A.1. 3.5.1. START UP After all of the electrical and pneumatic connections are made, turn on the instrument. The exhaust fan and should start immediately. If the instrument is equipped with an internal photometer installed, the associated pump should also start up. The display should immediately display a single, horizontal dash in the upper left corner of the display. This will last approximately 30 seconds while the CPU loads the operating system. Once the CPU has completed this activity, it will begin loading the analyzer firmware and configuration data. During this process, string of messages will appear on the analyzer’s front panel display: System waits 3 seconds then automatically begins its initialization routine. NO ACTION REQUIRED. System is checking the validity and functionality of the Terminus memory and firmware. SELECT START OR REMOTE : 3 START CHECKING FLASH STATUS : 1 CHECKING FIRMWARE STATUS : 1 If at this point, **FLASH FORMAT INVALID** appears, contact Teledyne Instruments customer service. The instrument is loading configuration and calibration data from the flash chip STARTING INSTRUMENT CODE : 1 STARTING INSTRUMENT WITH FLASH : 1 M400E ANALYZER BOOTING [XXXXXXXXXX_ _ 40% _ _ _ _ _ _ _ _ _ ] The instrument is loading the M400E system firmware SOFTWARE REVISION X.X BOOTING [XXXXXXXXXXX 88% XXXXXXXXX_ _ _ ] SAMPLE TEST SYSTEM RESET CAL The startup process may hesitate at this point if: The Ethernet option is installed; DHCP mode is turned on and; The instrument is not connected to a functioning network. O3= XXXX MSG CLR EXIT The analyzer should automatically switch to SAMPLE mode after completing the boot-up sequence and start monitoring O3 gas. 26 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.5.2. WARM UP The Model 400E photometric ozone analyzer requires a minimum of 30 minutes for all of its internal components to reach a stable operating temperature. During that time, various portions of the instrument’s front panel will behave as follows. Table 3-7: Front Panel Display during System Warm-Up NAME COLOR BEHAVIOR SIGNIFICANCE Concentration Field N/A Displays current, compensated O3 Concentration N/A Mode Field N/A Displays blinking “SAMPLE” Instrument is in sample mode but is still in the process of warming up. Green On STATUS LED’s SAMPLE Unit is operating in sample mode; front panel display is being updated. Flashes On/Off when adaptive filter is active CAL Yellow Off The instrument’s calibration is not enabled. FAULT Red Blinking The analyzer is warming up and hence out of specification for a fault-free reading. Various warning messages will appear. 3.5.3. WARNING MESSAGES Because internal temperatures and other conditions may be outside be specified limits during the analyzer’s warm-up period, the software will suppress most warning conditions for 30 minutes after power up. If warning messages persist after the 30 minutes warm up period is over, investigate their cause using the troubleshooting guidelines in Chapter 13 of this manual. To view and clear warning messages, press: SAMPLE Suppresses the warning messages TEST SAMPLE TEST SAMPLE TEST SYSTEM SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET TEST Once the last warning has been cleared, the analyzer will automatically switch to SAMPLE mode STANDBY TEST MSG returns the active warnings to the message field. Press CLR to clear the current message. If more than one warning is active, the next message will take its place. CLR SETUP RANGE=500.0 PPB CAL MSG O3=XXXX SETUP NOTE: If a warning message persists after several attempts to clear it, the message may indicate a real problem and not an artifact of the warm-up period Table 3-8 lists brief descriptions of the warning messages that may occur during start up. 04315 Rev. C1 27 Getting Started M400E Ozone Analyzer Operator’s Manual Table 3-8: Possible Warning Messages at Start-Up MESSAGE MEANING ANALOG CAL WARNING BOX TEMP WARNING The A/D or at least one D/A channel have not been calibrated. The temperature inside the M400E chassis is outside the specified limits. 2 Contact closure span calibration failed while DYN_SPAN was set to ON. 3 CANNOT DYN ZERO Contact closure zero calibration failed while DYN_ZERO was set to ON. CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased. DATA INITIALIZED iDAS data storage was erased before the last power up occurred. CANNOT DYN SPAN FRONT PANEL WARN CPU is unable to communicate with the front panel. LAMP DRIVER WARN 2 CPU is unable to communicate with one of the I C UV Lamp Drivers. LAMP STABIL WARN Photometer lamp reference step-changes occur more than 25% of the time. O3 GEN LAMP WARN4 O3 GEN REF WARNING The UV Lamp or Detector in the IZS module may be faulty or out of adjustment. 4 4 O3 GEN TEMP WARN O3 SCRUB TEMP WARN5 PHOTO REF WARNING The UV Lamp or Detector in the IZS module may be faulty or out of adjustment. The UV Lamp Heater or Temperature Sensor in the IZS module may be faulty. The Heater or Temperature Sensor of the O3 Scrubber may be faulty. The O3 Reference value is outside of specified limits. PHOTO TEMP WARNING The UV Lamp Temperature is outside of specified limits. REAR BOARD NOT DET Motherboard was not detected during power up. RELAY BOARD WARN CPU is unable to communicate with the relay PCA. SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits. SAMPLE PRESS WARN The pressure of the sample gas is outside the specified limits. SAMPLE TEMP WARN SYSTEM RESET1 The temperature of the sample gas is outside the specified limits. The computer has rebooted. 1 Clears 45 minutes after power up. 2 Clears the next time successful zero calibration is performed. 3 Clears the next time successful span calibration is performed. 4 Only Appears if the IZS option is installed. 5 Only appears if the optional metal wool O3 scrubber is installed. 28 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.5.4. FUNCTIONAL CHECK After the analyzer’s components have warmed up for at least 30 minutes, verify that the software properly supports any hardware options that are installed. For information on navigating through the analyzer’s software menus, see the menu trees described in Appendix A.1. Check to make sure that the analyzer is functioning within allowable operating parameters. Appendix C includes a list of test functions viewable from the analyzer’s front panel as well as their expected values. These functions are also useful tools for diagnosing problems with your analyzer (Section 13.1.2). The enclosed Final Test and Validation Data sheet (part number 04314) lists these values before the instrument left the factory. To view the current values of these parameters press the following key sequence on the analyzer’s front panel. Remember until the unit has completed its warm up these parameters may not have stabilized. 5. If your analyzer has an Ethernet card (Option 63) installed and your network is running a dynamic host configuration protocol (DHCP) software package, the Ethernet option will automatically configure its interface with your LAN. However, it is a good idea to check these settings to make sure that the DHCP has successfully downloaded the appropriate network settings from your network server (See Section 8.4). If your network is not running DHCP, you will have to configure the analyzer’s interface manually (See Section 8.4.2.1). 04315 Rev. C1 29 Getting Started M400E Ozone Analyzer Operator’s Manual 3.6. INITIAL CALIBRATION OF THE M400E ANALYZER To perform the following calibration you must have sources for zero air and calibration (span) gas available for input into the inlet/outlet fittings on the back of the analyzer (see Section 3.4). The method for performing an initial calibration for the Model 400E photometric ozone analyzer differs slightly depending on the whether or not any of the available internal zero air or valve options are installed. See Section 3.6.2 for instructions for initial calibration of the M400E analyzers in their base configuration. See Section 3.7.4 for instructions for initial calibration of M400E analyzers possessing IZS Valve Options (OPT-51A). See Section 9.3 for information regarding setup and calibration of M400E analyzers with Z/S Valve options (OPT-50A). If you are using the M400E analyzer for EPA monitoring, only the calibration method described in Chapter 10 should be used. 3.6.1. INTERFERENTS FOR O3 MEASUREMENT The detection of O3 is subject to interference from a number of sources including, SO2, NO2, NO, H2O AND aromatic hydrocarbon meta-xylene and mercury vapor. The Model 400E successfully rejects interference from all of these with the exception of mercury vapor. If the Model 400E is installed in an environment where the presence of mercury vapor is suspected, steps should be taken to remove the mercury vapor from the sample gas before it enters the analyzer. For more detailed information regarding O3 measurement interferences, see Section 11.1.4 NOTE The presence of mercury vapor is highly unlikely in the types of applications for which M400E analyzers with IZS options installed are normally used. 30 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.6.2. INITIAL CALIBRATION PROCEDURE FOR M400E ANALYZERS WITHOUT OPTIONS The following procedure assumes that: The instrument DOES NOT have any of the available Zero/Span Valve Options installed and Cal gas will be supplied through the SAMPLE gas inlet on the back of the analyzer (see Figure 3-2). The pneumatic setup matches that described in Section 3.4.2. 3.6.2.1. Verifying the M400E Reporting Range Settings While it is possible to perform the following procedure with any range setting we recommend that you perform this initial checkout using following reporting range settings: Unit of Measure: PPB Reporting Range: 500 PPB Mode Setting: SNGL While these are the default setting for the M400E analyzer, it is recommended that you verify them before proceeding with the calibration procedure, by pressing: 04315 Rev. C1 31 Getting Started M400E Ozone Analyzer Operator’s Manual 3.6.2.2. Verify the Expected O3 Span Gas Concentration: NOTE For this initial calibration, it is important to verify the PRECISE O3 Concentration Value of the SPAN gas independently. The O3 span concentration value automatically defaults to 400.0 PPB and it is recommended that an O3 calibration gas of that concentration be used for the initial calibration of the unit. To verify that the analyzer span setting is set for 400 PPB, press SAMPLECAL M-P CAL SETUP RANGE=500.0 PPB M-P CAL O3=XXXX CONC EXIT SPAN CONC MENU SPAN Verify that the RANGE is set for 400.0 PPB If it is not, toggle each numeric key until the proper range is set, then press ENTR. 32 EXIT M-P CAL 0 O3 SPAN CONC:400.0 Conc 0 4 0 0 .0 ENTR EXIT 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.6.2.3. Initial Zero/Span Calibration Procedure: To perform an initial Calibration of the Model 400E photometric ozone analyzer, press: SAMPLE CAL SETUP Set the Display to show the STABIL test function. This function calculates the stability of the O3 measurement Toggle TST> button until ... SAMPLE STABIL=XXXX PPB < TST TST > CAL O3= XXXX SETUP Allow zero gas to enter the sample port at the rear of the analyzer. Wait until STABIL falls below 1.0 PPM. This may take several minutes. SAMPLE STABIL=XXXX PPB < TST TST > CAL M-P CAL STABIL=XXXX PPB M-P CAL ZERO SETUP O3= XXXX CONC STABIL=XXXX PPB ENTR O3= XXXX EXIT O3= XXXX CONC EXIT Allow span gas to enter the sample port at the rear of the analyzer. Press ENTR to changes the OFFSET & SLOPE values based on the zero point measurement. Press EXIT to leave the calibration unchanged and return to the previous menu. Wait until STABIL falls below 1.0 PPM. This may take several minutes. The SPAN key now appears during the transition from zero to span. You may see both keys. If either the ZERO or SPAN buttons fail to appear see Section 11 for troubleshooting tips. M-P CAL STABIL=XXXX PPB < TST TST > CAL M-P CAL SETUP STABIL=XXXX PPB ZERO SPAN CONC M-P CAL STABIL=XXXX PPB ENTR M-P CAL CONC STABIL=XXXX PPB ENTR O3= XXXX CONC O3= XXXX EXIT O3= XXXX EXIT O3= XXXX EXIT Press ENTR to changes the OFFSET & SLOPE values based on the zero point measurement. Press EXIT to leave the calibration unchanged and return to the previous menu. EXIT at this point returns to the SAMPLE menu. THE MODEL 400E ANALYZER IS NOW READY FOR OPERATION. 04315 Rev. C1 33 Getting Started M400E Ozone Analyzer Operator’s Manual 3.7. CONFIGURING THE INTERNAL ZERO/SPAN OPTION (IZS) In order to use the IZS option to perform calibration checks, it is necessary to configure certain performance parameters of the O3 Generator. 3.7.1. VERIFY THE O3 GENERATOR AND EXPECTED O3 SPAN CONCENTRATION SETTINGS: As is true for M400E analyzers without options, when the IZS option is present the O3 span concentration value also automatically defaults to 400.0 PPB. In this case, no external source of calibration gas is required; however, it is necessary to verify that the internal O3 generator is set to produce an O3 concentration of 400.0 PPB To verify/set that these levels, press 34 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.7.2. SETTING THE O3 GENERATOR LOW-SPAN (MID POINT) OUTPUT LEVEL To set the ozone LO SPAN (Midpoint) concentration for the IZS O3 generator, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X 8 Toggle these keys to enter the correct PASSWORD EXIT DIAG EXIT ENTER PASSWORD:818 1 SETUP X.X 8 ENTR EXIT 0) DAS_HOLD_OFF=15.0 Minutes PREV NEXT JUMP EDIT PRNT EXIT Continue pressing NEXT until ... SETUP X.X 4) O3_GEN_LOW1=100.0 PPB PREV NEXT JUMP SETUP X.X 0 1 EDIT PRNT EXIT To Set the LOW SPAN point for RANGE2 in DUAL or AUTO range modes … Press NEXT key once more to select O3_GEN_LOW2 then continue as shown. 4) O3_GEN_LOW1=100.0 PPB 0 0 .0 ENTR EXIT Toggle these keys to change setting Only Values from 0 to 1500 will be accepted.. A value of 0 turns the lamp OFF. The ENTR key will disappear if an invalid setting is attempted. 04315 Rev. C1 Sets LOW SPAN Point for RANGE1. EXIT discards the new setting ENTR accepts the new setting 35 Getting Started M400E Ozone Analyzer Operator’s Manual 3.7.3. TURNING ON THE REFERENCE DETECTOR OPTION If the IZS feedback option is purchased the analyzer must be told to accept data from the Reference Detector and actively adjust the IZS output to maintain the reference set point(s) previously chosen by the user (see Section 3.7.2). To perform this operation: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X MODE SECONDARY SETUP MENU DIAG O3 EXIT O3 CONFIG ADJ SETUP X.X CNST EXIT REF O3 CONFIG ENTR EXIT CNST - Constant Mode: In this mode, the analyzer sets the O3 Generator drive voltage at a constant level. REF - Reference Mode: In this mode, the analyzer uses feedback from the O3 Reference Detector to adjust the DO3 Generator Drive Voltage and stabilize the O3 Generator Output. 36 EXIT discards the new setting ENTR accepts the new setting 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Getting Started 3.7.4. INITIAL CALIBRATION AND CONDITIONING OF M400E ANALYZERS WITH THE IZS OPTION INSTALLED The following procedure assumes that: The instrument has of the IZS Options installed. The pneumatic setup matches that described in Section 3.4.3 or Section 3.4.4. 3.7.4.1. Initial O3 Scrubber Conditioning The IZS option includes a charcoal O3 scrubber that creates zero air for the auto zero calibration feature. This charcoal scrubber must be conditioned for the relative humidity of locale being monitored. To start this conditioning cycle, press: 04315 Rev. C1 37 Getting Started M400E Ozone Analyzer Operator’s Manual 3.7.4.2. Verifying the M400E Reporting Range Settings While it is possible to perform the following procedure with any range setting, we recommend that you perform this initial checkout using following reporting range settings: Unit of Measure: PPB Reporting Range: 500 ppb Mode Setting: SNGL These are the default setting for the M400E analyzer; however, it is a good idea to verify them before proceeding with the calibration procedure. Use the same method as described in Section 3.6.2.1. 3.7.4.3. Initial Zero/Span Calibration Procedure: Unlike other versions of the M400E, analyzers with the IZS option installed do not require the expected span gas concentration be set during initial start-up because no initial span calibration is performed. 3.7.4.4. Initiate Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3 To ensure that the analyzer maintains maximum performance levels when monitoring low levels of O3, the instrument’s AUTOCAL feature (only active on analyzers with the IZS option installed) should be used to initiate a zero-point calibration once every day. The appropriate AUTOCAL sequence settings are: Table 3-9: AUTOCAL Settings for Daily Zero-Point Auto-Cal of M400E’s Monitoring Low Levels of O3 MODE AND ATTRIBUTE VALUE SEQUENCE 1 MODE ZERO TIMER ENABLE Define sequence #1 1 ON Select zero calibration mode Enable the timer Start running sequence after January 1, 2003 STARTING DATE 01 – JAN – 031 STARTING TIME 00:001 DELTA DAYS 11 DELTA TIME 00:001 Do Sequence #1 at the same time every day DURATION 15.01 Operate zero-cal valve for 15 min CALIBRATE 1 COMMENT ON Start initial zero-point calibration at starts at midnight. Do Sequence #1 every day The instrument will re-set the slope and offset values for the O3 measurement calculation at the end of the auto-cal sequence While most of the settings required for this sequence are the instrument’s default settings, and therefore do not need to be changed, they should be verified. If any of these settings do not match those shown, see the instructions in Section 9.4. To activate this daily zero point calibration: 38 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual SAMPLE RANGE = 500.0 PPB Getting Started O3 =XXXX < TST TST > CAL CALZ CALS SETUP X.X SETUP CFG ACAL DAS RNGE PASS CLK MORE EXIT SETUP X.X SETUP X.X SETUP X.X EXIT SETUP X.X EXIT Default value is: 00:00 EXIT Default value is: 15.0 MODE: DISABLED NEXT SETUP X.X ENTR EXIT DURATION:15.0 MINUTES EDIT SETUP X.X MODE: ZERO PREV SETUP X.X ENTR EXIT (Midnight) DELTA TIME00:00 EDIT CALIBRATE: OFF EDIT SETUP X.X Default value is: 1 SEQ 1) DISABLED PREV NEXT MODE Default value is: 01-JAN-03 EXIT DELTA DAYS: 1 EDIT SETUP X.X Default value is: 00:00 PRIMARY SETUP MENU SETUP X.X Default value is: ON EXIT STARTING TIME:00:00 EDIT EXIT TIMER ENABLE: ON SET> EDIT EXIT SETUP X.X CALIBRATE: OFF ON ENTR EXIT Toggle ON/OFF key then press ENTER STARTING DATE: 01–JAN–03 EDIT EXIT SETUP X.X CALIBRATE: ON EDIT SETUP X.X EXIT SEQ 1) ZERO, 1:00:00 PREV NEXT MODE SET EXIT EXIT returns to the SETUP Menu THE MODEL 400E ANALYZER IS NOW READY FOR OPERATION. NOTE Once you have completed the above set-up procedures, please fill out the Quality Questionnaire that was shipped with your unit and return it to T-API. This information is vital to our efforts in continuously improving our service and our products. THANK YOU USER NOTES: 04315 Rev. C1 39 Getting Started M400E Ozone Analyzer Operator’s Manual USER NOTES: 40 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Frequently Asked Questions and Glossary 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY 4.1. FAQ’S The following list was compiled from the T-API Customer Service Department's 10 most commonly asked questions relating to the Model 400E O3 Analyzer. Q: How do I get the instrument to zero / Why is the zero key not displayed? A: See Section 13.5.4 Inability to zero. Q: How do I get the instrument to span / Why is the span key not displayed? A: See Section13.5.3 Inability to span. Q: How do I enter or change the value of my Span Gas? A: Press the CONC key found under the CAL or CALS buttons of the main SAMPLE display menus to enter the expected O3 span concentration. See Section 9.2.3.1or for more information. Q: How do I perform a midpoint calibration check? A: Midpoint calibration checks can be performed using the instrument’s AutoCal feature (see Section 9.4) or by using the control inputs on the rear panel of the instrument (see Section 9.3.2.3). The IZS option is required in order to perform a mid-point span check. Q: Why does the ENTR key sometimes disappear on the Front Panel Display? A: During certain types of adjustments or configuration operations, the ENTR key will disappear if you select a setting that is nonsensical (such as trying to set the 24-hour clock to 25:00:00) or out of the allowable range for that parameter (such as selecting an iDAS Holdoff period of more than 20 minutes). Once you adjust the setting in question to an allowable value, the ENTR key will re-appear. Q: How do I make the RS-232 Interface Work? A: See Section 8.1. Q: How do I use the iDAS? A: See Section 7.1. Q: How do I make the instrument’s display and my data logger agree? A: This most commonly occurs when an independent metering device is used besides the data logger/recorded to determine gas concentration levels while calibrating the analyzer. These disagreements result from the analyzer, the metering device and the data logger having slightly different ground levels. It is possible to enter a DC offset in the analog outputs to compensate. This procedure is located in Section 7.4.5 of this manual. Alternately, use the data logger itself as the metering device during calibration procedures. 04315 Rev. C1 41 Frequently Asked Questions and Glossary M400E Ozone Analyzer Operator’s Manual Q: When should I change the Particulate Filter and how do I change it? A: The Particulate filter should be changed weekly. See Section 12.3.1 for instructions on performing this replacement. Q: When should I change the Sintered Filter and how do I change it? A: The Sintered Filter does not require regular replacement. Should its replacement be required as part of a troubleshooting or repair exercise, see Section 13.10.1 for instructions. Q: When should I change the Critical Flow Orifice and how do I change it? The Critical Flow Orifice does not require regular replacement. Should its replacement be required as part of a troubleshooting or repair exercise, see Section 13.10.1 for instructions. Q: How do I set up and use the Contact Closures (Control Inputs) on the Rear Panel of the analyzer? A: See Section 3.3.4. Q: Can I automatically calibrate or check the calibration of my analyzer? A: Any analyzer into which a Zero/Span Valve Option can be automatically calibrated using the instrument’s AutoCal Feature. Be aware that while the AutoCal feature can be used with the IZS Option to perform Calibration Checks, The IZS should never be used to perform Calibrations. See Section 9.4 for instructions on setting up and activating the AutoCal feature. Q: How often should I rebuild the Sample Pump on my analyzer? A: The diaphragm of the Sample Pump should be replaced annually. A sample rebuild kit is available. See Appendix B of this manual for the part number of the pump rebuild kit. Instructions and diagrams are included with the kit. Q: How long does the UV Sourcelast? A: The typical lifetime is about 2-3 years. 42 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Frequently Asked Questions and Glossary 4.2. GLOSSARY Acronym – A short form or abbreviation for a longer term. Often artificially made up of the first letters of the phrase’s words. APICOM – Name of a remote control program offered by Teledyne-API to its customers ASSY - Acronym for Assembly. cm3 – metric abbreviation for cubic centimeter. Same as the obsolete abbreviation “cc”. Chemical formulas used in this document: CO2 – carbon dioxide C2H8 – propane CH4 – methane H2O – water vapor HC – general abbreviation for hydrocarbon HNO3 – nitric acid H2S – hydrogen sulfide NOX – nitrogen oxides, here defined as the sum of NO and NO2 NO – nitric oxide NO2 – nitrogen dioxide NOy – nitrogen oxides, often called odd nitrogen, the sum of NO, NO2 (NOX) plus other compounds such as HNO3. Definitions vary widely and may include nitrate (NO3-), PAN, N2O and other compounds. NH3 – ammonia O2 - molecular oxygen O3 - ozone SO2 – sulfur dioxide DAS - Acronym for Data Acquisition System, the old acronym of iDAS DIAG - Acronym for diagnostics, the diagnostic menu or settings of the system DHCP: acronym for dynamic host configuration protocol. A protocol used by LAN or Internet servers that automatically sets up the interface protocols between themselves and any other addressable device connected to the network. DOC – Acronym for Disk on Chip, the system’s central storage area for system operating system, firmware and data. This is a solid-state device without mechanical, moving parts that acts as a computer hard disk drive under DOS with disk drive label “C”. DOC chips come with 8 mb space in the E-series system standard configuration but are available in larger sizes DOS - Disk Operating System. The E-series systems use DR DOS EEPROM - also referred to as a FLASH chip. FEP - Acronym for Fluorinated Ethylene Propylene polymer, one of the polymers that du Pont markets as Teflon® (along with PFA and PTFE). FLASH - flash memory is non-volatile, solid-state memory. I2C bus – read: I-square-C bus. A serial, clocked serial bus for communication between individual system components 04315 Rev. C1 43 Frequently Asked Questions and Glossary M400E Ozone Analyzer Operator’s Manual IC – Acronym for Integrated Circuit, a modern, semi-conductor circuit that can contain many basic components such as resistors, transistors, capacitors etc in a miniaturized package used in electronic assemblies. iDAS - Acronym for Internal Data Acquisition System, previously referred to as DAS. LAN - Acronym for local area network. LED - Acronym for Light Emitting Diode. LPM – Acronym for liters per minute MFC – Acronym for “mass flow controller”. MOLAR MASS – The molar mass is the mass, expressed in grams, of 1 mole of a specific substance. Conversely, one mole is the amount of the substance needed for the molar mass to be the same number in grams as the atomic mass of that substance. EXAMPLE: The atomic weight of Carbon is 12 therefore the molar mass of Carbon is 12 grams. Conversely, one mole of carbon equals the amount of carbon atoms that weighs 12 grams. Atomic weights can be found on any Periodic Table of Elements PCA - Acronym for Printed Circuit Assembly, this is the PCB with electronic components installed and ready to use PCB - Acronym for printed circuit board, the bare circuit board without components PLC – Acronym for programmable logic controller, a device that is used to control instruments based on a logic level signal coming from the system PFA – Acronym for Per-Fluoro-Alkoxy, an inert polymer. One of the polymers that du Pont markets as Teflon® (along with FEP and PTFE). PTFE – Acronym for Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases that may react on other surfaces. One of the polymers that du Pont markets as Teflon® (along with FEP and PFA). PVC – Acronym for Poly Vinyl Chloride. RS-232 - An electronic communication protocol of a serial communications port RS-485 - An electronic communication protocol of a serial communications port SLPM – Acronym for standard liters per minute; liters per minute of a gas at standard temperature and pressure TCP/IP - Acronym for Transfer Control Protocol / Internet Protocol, the standard communications protocol for Ethernet devices and the Internet VARS - Acronym for variables, the variables menu or settings of the system USER NOTES: 44 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software 5. OPTIONAL HARDWARE AND SOFTWARE NOTE Throughout this chapter are various diagrams showing external pneumatic connections between the M400E and various other pieces of equipment (such as calibrators and zero air sources) and internal pneumatic lines. The equipment, fittings, gas lines and components in these diagrams are arranged to enhance clarity and do not reflect actual physical locations, order or orientation. This includes a brief description of the hardware and software options available for the M400E photometric ozone analyzer. For assistance with ordering these options, please contact the Sales department of Teledyne – Advanced Pollution Instruments at: TOLL-FREE: FAX: TEL: E-MAIL: WEB SITE: 800-324-5190 858-657-9816 858-657-9800 api-sales@teledyne.com www.teledyne-api.com 5.1. OPTIONAL PUMPS (OPT 10 THR OPT 13) A variety of external pumps are available for the Model 400E photometric analyzer. The range of available pump options meets all typical AC power supply standards while exhibiting the same pneumatic performance. OPTION NUMBER 10A External Pump 115V/60Hz 10B External Pump 220V/50Hz 10C External Pump 220V/60Hz 10D External Pump 100V/50Hz 10E External Pump 100V/60Hz 11A No pump (If one is standard either internal or external) 13 04315 Rev. C1 DESCRIPTION High Voltage Internal Pump 240V/50Hz 45 Optional Hardware and Software M400E Ozone Analyzer Operator’s Manual 5.2. RACK MOUNT KITS (OPT 20 TO OPT 23) There are several options for mounting the analyzer in standard 19” racks. The slides are three-part extensions, one mounts to the rack, one mounts to the analyzer chassis and the middle part remains on the rack slide when the analyzer is taken out. The analyzer locks into place when fully extended and cannot be pulled out without pushing two buttons, one on each side. The rack mount brackets for the analyzer require that you have a support structure in your rack to support the weight of the analyzer. The brackets cannot carry the full weight of an analyzer and are meant only to fix the analyzer to the front of a rack, preventing it from sliding out of the rack accidentally. OPTION NUMBER DESCRIPTION OPT 20A Rack mount brackets with 26 in. chassis slides. OPT 20B Rack mount brackets with 24 in. chassis slides. OPT 21 Rack mount brackets only Opt 23 Rack Mount for External Pump Pack (No Slides) 5.3. CARRYING STRAP HANDLE (OPT 29) The chassis of the M400E analyzer allows the user to attach a strap handle for carrying the instrument. The handle is located on the right side and pulls out to accommodate a hand for transport. When pushed in, the handle is nearly flush with the chassis, only protruding out about 9 mm (3/8”). Figure 5-1: M400E with Carrying Strap Handle and Rack Mount Brackets Installing the strap handle prevents the use of the rack mount slides, although the rack mount brackets, Option 21, can still be used. CAUTION General Safety Hazard A FULLY LOADED M400E WITH BOTH THE O3 GENERATOR AND PHOTOMETER OPTIONS INSTALLED WEIGHS ABOUT 17 KG (40 POUNDS). TO AVOID PERSONAL INJURY WE RECOMMEND TWO PERSONS LIFT AND CARRY THE ANALYZER. MAKE SURE TO DISCONNECT ALL CABLES AND TUBING FROM THE ANALYZER BEFORE CARRYING IT. 46 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software 5.4. CURRENT LOOP ANALOG OUTPUTS (OPT 41) This option adds isolated, voltage-to-current conversion circuitry to the analyzer’s Analog Outputs enabling them to produce current loop signals. This option may be ordered separately for Analog Outputs A1 and A2. It can be installed at the factory or added later. Call the factory for price and availability. Current Loop Option Installed on Analog Output A2 Figure 5-2: Current Loop Option Installed The Current Loop Option can be configured for any output range between 0 and 20mA DC. Most current loop applications require either 2-20 mA or 4-20 mA spans. Information on calibrating or adjusting these outputs can be found in Section 7.4.2.4 5.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS. To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation: 1. Turn off power to the analyzer. 2. If a recording device was connected to the output being modified, disconnect it. 3. Remove the top cover Remove the set screw located in the top, center of the rear panel Remove the screws fastening the top cover to the unit (one per side). Slide the cover back and lift the cover straight up. 4. Disconnect the current loop option PCA from the appropriate connector on the motherboard (see Figure 5-2). 5. Place a shunt between the leftmost two pins of the connector (see Figure 5-2). 6 spare shunts (P/N CN0000132) were shipped with the instrument attached to JP1 on the back of the instruments keyboard and display PCA 6. Reattach the top case to the analyzer. 7. The analyzer is now ready to have a voltage-sensing, recording device attached to that output Note See Chapter 14for more information on preventing ESD damage. 04315 Rev. C1 47 Optional Hardware and Software M400E Ozone Analyzer Operator’s Manual 5.5. SPARE PARTS KITS 5.5.1. M400E EXPENDABLES KIT (OPT 42A) This kit includes a recommended set of expendables and spare parts for one year of operation of the M400E. See Appendix B for a detailed listing of the contents. 5.5.2. M400E SPARE PARTS KIT FOR THE IZS OPTION (OPT 43) This kit includes a recommended set of spare parts for one year of operation of M400E’s that have the optional O3 generator and photometers installed. See Appendix B for a detailed listing of the contents. 5.6. CALIBRATION VALVE OPTIONS 5.6.1. ZERO/SPAN VALVES (OPT 50A) The Model 400E photometric ozone analyzer can be equipped with a zero/span valve option for controlling the flow of calibration gases generated from sources external to the instrument. This option consists of a set of two solenoid valves located inside the analyzer that allow the user to switch the active source of gas flowing into the instrument’s optical bench between the sample inlet, the span gas inlet and the zero air inlet. The user can control these valves from the front panel keyboard either manually or by activating the instruments AUTOCAL feature (See Section 9.4). ABSORPTION TUBE The valves may also be opened and closed remotely via the RS-232/485 Serial I/O ports (see Section 8.1.7) or External Digital I/O Control Inputs (See Section 9.3.2.3) Figure 5-3: 48 M400E Pneumatic Diagram with Zero/Span Valve Option (OPT-50A) 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software The instrument’s zero air and span gas flow rate required for this option is 800 cc/min, however, the US EPA recommends that the cal gas flow rate be at least 1600 cc/min. Table 5-1: Option Zero/Span Valve Operating States Mode Valve SAMPLE 50 ZERO CAL SPAN CAL Condition Sample/Cal Open to SAMPLE inlet Zero/Span Open to ZERO AIR inlet Sample/Cal Open to ZERO/SPAN Valve Zero/Span Open to ZERO AIR inlet Sample/Cal Open to ZERO/SPAN Valve Zero/Span Open to SPAN GAS inlet The state of the Sample/Cal valves can be controlled: Manually via the analyzer’s front panel; By activating the instrument’s AutoCal feature (See Section 9.4); Remotely by using the External Digital I/O Control Inputs (See Section 9.3.2.3), or; Remotely via the RS-232/485 Serial I/O ports (See Section 8.1.7). Cooling Fan Serial I/O LEDs Status Outputs Analog Outputs Sample Gas Inlet Exhaust Gas Outlet Span Gas Inlet Zero air Inlet Power Receptacle Figure 5-4: 04315 Rev. C1 DCE – DTE Switch COM Port A COM Port B (RS-232 Only) (RS-232 or RS-485) Control Inputs Serial Number Tag M400E Rear Panel Layout with Zero/Span Valve Option (OPT-50A) 49 Optional Hardware and Software Figure 5-5: M400E Ozone Analyzer Operator’s Manual Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) 5.6.1.1. Pneumatic Setup for the M400E Analyzer with Zero/Span Valve Option For a Model 400E photometric ozone analyzer with the optional zero/span valves, attach the following pneumatic lines: SAMPLE GAS SOURCE: Attach a sample inlet line to the SAMPLE inlet fitting. Sample Gas pressure must equal ambient atmospheric pressure (1.0 psig) In applications where the sample gas is received from a pressurized manifold, a vent must be placed on the sample gas line. This vent line must be: At least 0.2m long No more than 2m long Vented outside the shelter or immediate area surrounding the instrument CALIBRATION GAS SOURCES: SPAN GAS: Attach a gas line from the source of calibration gas (e.g. a Teledyne Instruments M700E Dynamic Dilution Calibrator) to the SPAN inlet. Span gas can by generated by a M700E Mass Flow Calibrator equipped with a Photometer Option or an M703E UV Photometric Ozone Calibrator. 50 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software ZERO AIR: ATTACH a gas line from the source of zero air (e.g. a Teledyne Instruments M701 zero air Generator) to the ZERO AIR inlet. Zero air can be supplied by the API M701 zero air generator. A restrictor is required to regulate the gas flow at 2 x’s the gas flow of the analyzer. VENTING: In order to prevent back diffusion and pressure effects, both the span gas and zero air supply lines should be: Vented outside the enclosure. Not less than 2 meters in length Not greater than 10 meters in length. EXHAUST OUTLET: Attach an exhaust line to the EXHAUST OUTLET fitting. The exhaust line should be: ¼” PTEF tubing. A maximum of 10 meters long. Vented outside the M400E analyzer’s enclosure CAUTION General Safety Hazard VENTING SHOULD BE OUTSIDE THE SHELTER OR IMMEDIATE AREA SURROUNDING THE INSTRUMENT AND CONFORM TO ALL SAFETY REQUIREMENTS REGARDING EXPOSURE TO O3. Once the appropriate pneumatic connections have been made, check all pneumatic fittings for leaks using the procedures defined in Section 12.3.4. 04315 Rev. C1 51 Optional Hardware and Software M400E Ozone Analyzer Operator’s Manual 5.6.2. INTERNAL ZERO SPAN (IZS) OPTION (OPT 51A) The Model 400E photometric ozone analyzer can also be equipped with an internal zero air and span gas generator. This option includes an ozone scrubber for producing zero air, a variable ozone generator for producing calibration span gas and a valve for switching between the sample gas inlet and the output of the scrubber/generator. A reference detector monitors the operating level of the IZS’ ozone generator. The detector senses the intensity of the UV lamp internal to the IZS generator and coverts this into a DC voltage. This voltage is used by the CPU as part of a feedback loop to directly adjust the brightness of the lamp producing a more accurate and stable ozone concentration. The ozone output level of the generator is directly controllable by the user via the front panel of the instrument or remotely via the analyzer’s RS-232 Serial I/O ports. See Section 9.3 for instructions on setting the span gas level of the ozone generator. See Section 8.1 for information on configuring this option and using the Serial I/O ports. See Appendix A.2 for a list of variables used to control this parameter. See Section 9.6 for information on calibrating the output of the O3 Generator Figure 5-6: M400E Pneumatic Diagram with Internal Zero/Span (IZS) Option (OPT-51A) For instructions on setting up a M400E analyzer equipped with the IZS option see Section 3.4.3 and Section 3.4.4 52 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software The state of the Sample/Cal valves can be controlled: Manually via the analyzer’s front panel; By activating the instrument’s AutoCal feature (See Section 9.4); Remotely by using the External Digital I/O Control Inputs (See Section 9.3), or; Remotely via the RS-232/485 Serial I/O ports (See Section 8.1.7). Table 5-2: Option Mode SAMPLE 51A Internal Zero/Span Valve Operating States Valve Condition Sample/Cal Valve Open to SAMPLE inlet Ozone Generator OFF ZERO CAL Sample/Cal Valve Open to Ozone Generator Ozone Generator OFF SPAN CAL Sample/Cal Valve Open to Ozone Generator Ozone Generator ON at intensity level set by user 5.6.2.1. Disposable Charcoal O3 Filter M400E’s equipped with IZS options have a disposable filter that is used by the instrument for creating zero air for the auto-cal zero-point calibration. This filter is filled with activated charcoal and should last for approximately 1 year of continual usage. Call Teledyne Instruments customer service for replacement filters. 5.6.3. METAL WOOL SCRUBBER (OPT 68) This option replaces the standard scrubber with a heated Metal Wool Scrubber that works similarly to the catalytic converters found on many automobile’s exhaust systems and improves the analyzer’s performance in certain higher humidity applications. 5.6.4. IZS DESICCANT (OPTION 56) The M400E can be fitted with a desiccant dryer to provide a dry air source to the IZS sub-system. This option consists of a rear panel mounted scrubber cartridge filled with anhydrous calcium sulfate (CaSO4) desiccant. The desiccant material is expendable and must be replaced at regular intervals. The material exhibits a color change when it has been saturated with water vapor, turning from blue to pink. The scrubber cartridge should be refilled before the entire scrubber turns pink. Replacement interval will depend on how often the IZS is used, as well as ambient levels of humidity in your application. Initially the desiccant should be frequently monitored until a standard replacement interval can be established. 04315 Rev. C1 53 Optional Hardware and Software M400E Ozone Analyzer Operator’s Manual 5.7. COMMUNICATION OPTIONS 5.7.1. EXTRA COMM CABLES 5.7.1.1. RS232 Modem Cables (OPTs 60A and 60B) OPTION 60A A shielded, straight-through serial cable of about 1.8 m length to connect the analyzer’s COM1 port to a computer, a code activated switch or any other communications device that is equipped with a DB-25 female connector. The cable is terminated with one DB-9 female connector and one DB-25 male connector. The DB-9 connector fits the analyzer’s RS-232 port. OPTION 60B A standard, shielded, straight-through DB-9F to DB-9F cable of about 1.8 m length, which should fit most computers of recent build. The M400E analyzer is shipped with one of these cables included. 5.7.1.2. ETHERNET Cable (OPT 60C) A seven-foot long, CAT-5 network cable, terminated at both ends with standard RJ-45 connectors. This cable is used to connect the M400E to any standard ETHERNET socket. 5.7.2. RS-232 MULTIDROP (OPT 62) The multidrop option is used with any of the RS-232 serial ports to enable communications of up to eight analyzers with the host computer over a chain of RS-232 cables via the instruments COM1 Port. It is subject to the distance limitations of the RS 232 standard. Rear Panel CPU Card (as seen from inside) Multidrop Card Figure 5-7: M400E Multidrop Card The option consists of a small printed circuit assembly, which is plugs into to the analyzer’s CPU card (see Figure 5-7) and is connected to the RS-232 and COM2 DB9 connectors on the instrument’s back panel via a cable to the motherboard. One option 62 is required for each analyzer along with one 6’ straight-through, DB9 male DB9 Female cable (P/N WR0000101). 54 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Optional Hardware and Software 5.7.3. ETHERNET (OPT 63) The ETHERNET option allows the analyzer to be connected to any Ethernet local area network (LAN) running TCP/IP. The local area network must have routers capable of operating at 10BaseT. If Internet access is available through the LAN, this option also allows communication with the instrument over the public Internet. Maximum communication speed is limited by the RS-232 port to 115.2 kBaud. When installed, this option is electronically connected to the instrument’s COM2 serial port making that port no longer available for RS-232/RS-485 communications. The option consists of a Teledyne Instruments designed Ethernet card (see figures below), and a 7-foot long CAT-5 network cable, terminated at both ends with standard RJ-45 connectors. Figure 5-8: Ethernet Card M400E Ethernet Card CPU Card Rear Panel (as seen from inside) Female RJ-45 Connector LNK LED ACT LED TxD LED RxD LED RS-232 Connector To Motherboard Interior View Figure 5-9: Exterior View M400E Rear Panel with Ethernet Installed For more information on setting up and using this option, see Section 8.4 04315 Rev. C1 55 Optional Hardware and Software M400E Ozone Analyzer Operator’s Manual 5.7.4. ETHERNET + MULTIDROP (OPT 63C) This option allows the instrument to communicate on both RS-232 and ETHERNET networks simultaneously. It includes the following: RS232 MODEM CABLE (OPT 60B) ETHERNET CABLE (OPT 60C) RS-232 MULTIDROP (OPT 62) ETHERNET (OPT 63) 5.8. ADDITIONAL MANUAL (OPT 70A & OPT 70B) Additional copies of the printed user’s manual can be purchased from the factory as Option 70A. Please specify the serial number of your analyzer so that we can match the manual version. This operator’s manual is also available on CD as option 70B. The electronic document is stored in Adobe Systems Inc. Portable Document Format (PDF) and is viewable with Adobe Acrobat Reader® software, which can be downloaded for free at http://www.aobe.com/ The electronic version of this manual can also be downloaded for free at http://www.teledyne-api.com/manuals/. Note that the online version is optimized for fast downloading and may not print with the same quality as the manual on CD. USER NOTES: 56 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual OPERATING INSTRUCTIONS SECTION II – OPERATING INSTRUCTIONS 04315 Rev. C1 57 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual USER NOTES: 58 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6. BASIC OPERATION OF THE M400E ANALYZER 6.1. OVERVIEW OF OPERATING MODES The M400E analyzer software has a variety of operating modes. Most commonly, the analyzer will be operating in SAMPLE mode. In this mode, a continuous read-out of the O3 concentrations is displayed on the front panel and is available to be output as analog signals from the analyzer’s rear panel terminals. The SAMPLE mode also allows: TEST functions and WARNING messages to be examined. Manual calibration operations to be initiated The second most important operating mode is SETUP mode. This mode is used for configuring the various sub systems of the analyzer such as for the iDAS system, the reporting ranges, or the serial (RS-232/RS485/Ethernet) communication channels. The SET UP mode is also used for performing various diagnostic tests during troubleshooting. Mode Field SAMPLE CAL O3= XXXX SETUP Location of Mode field on M400E Analyzer Display The mode field of the front panel display indicates to the user which operating mode the unit is currently running. Besides SAMPLE and SETUP, other modes the analyzer can be operated in are: Table 6-1: MODE SAMPLE SAMPLE A1 M-P CAL SETUP [X.X] Analyzer Operating Modes EXPLANATION Sampling normally, flashing text indicates adaptive filter is on. Indicates that unit is in SAMPLE mode while AUTOCAL feature is active (IZS Only). This is the basic calibration mode of the instrument and is activated by pressing the CAL key. SETUP mode is being used to configure the analyzer. The gas measurement will continue during this process. The revision of the M400E firmware being run will appear after the word “SETUP” ZERO CAL [type] Unit is performing ZERO calibration procedure LO CAL A [type] Unit is performing LOW SPAN (midpoint) cal check procedure SPAN CAL [type] Unit is performing SPAN calibration procedure DIAG Mode One of the analyzer’s diagnostic modes is active (Section 6.13). [type:] 1 A : Initiated automatically by the AUTOCAL feature (IZS Only). M: initiated manually by the user. R: initiated remotely through the COM ports or digital control inputs. 04315 Rev. C1 59 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.2. SAMPLE MODE This is the analyzer’s standard operating mode. In this mode, the instrument is a calculating O3 concentrations. The M400E analyzer is a computer-controlled analyzer with a dynamic menu interface for easy and yet powerful and flexible operation. All major operations are controlled from the front panel display and keyboard through these user-friendly menus. To assist in navigating the system’s software, a series of menu trees can be found in Appendix A of this manual. NOTE The flowcharts in this chapter depict the manner in which the front panel display/keyboard interface is used to operate the M400E photometric ozone analyzer. They depict typical representations of the display during the various operations being described. They are not intended to be exact and may differ slightly from the actual display of your system. NOTE The ENTR key may disappear if you select a setting that is invalid or out of the allowable range for that parameter, such as trying to set the 24-hour clock to 25:00:00. Once you adjust the setting to an allowable value, the ENTR key will re-appear. This section covers the software features of the M400E analyzer that are designed as a computer controlled 6.2.1. TEST FUNCTIONS A variety of TEST functions are available for viewing at the front panel whenever the analyzer is at the MAIN MENU. These functions provide information about the present operating status of the analyzer and are useful during troubleshooting (see Chapter 13). Table 6-2 lists the available TEST functions. To view these TEST functions, press, Figure 6-2: 60 Viewing M400E Test Functions 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer Table 6-2: DISPLAY Test Functions Defined PARAMETER UNITS RANGE -RANGE1 RANGE2 RANGE PPB, PPM, UGM & MGM STABIL STABILITY MV O3 MEAS PHOTOMEAS MV O3 REF PHOTOREF MV O3 GEN2 O3GENREF MV O3 DRIVE1 O3GENDRIVE MV PHOTO POWER PHOTOPOWER MV PRES SAMPPRESS IN-HG-A SAMP FL SAMPFLOW CC/MIN SAMPLE TEMP SAMPTEMP C The Full Scale limit at which the reporting range of the analyzer’s ANALOG OUTPUTS is currently set. THIS IS NOT the Physical Range of the instrument. See Section 6.4.4.1 for more information. If DUAL or AUTO Range modes have been selected, two RANGE functions will appear, one for each range. Standard deviation of O3 Concentration readings. Data points are recorded every ten seconds. The calculation uses the last 25 data points. The average UV Detector output during the MEASURE portion of the analyzer’s measurement cycle. The average UV Detector output during the REFERENCE portion of the analyzer’s measurement cycle. The current output of the O3 generator reference detector representing the relative intensity of the O3 generator UV (2) Lamp. The Drive voltage used to control the intensity of the O3 (1) generator UV Lamp. Photometer lamp drive output. The absolute pressure of the Sample Gas as measured by a solid-state pressure sensor. Sample Gas mass flow rate as measured by the Flow Sensor located between the Optical Bench and the Sample Pump. The Temperature of the gas inside the Sample Chamber. PHOTO LAMP PHOTOLTEMP C The Temperature of the UV Lamp in the Optical Bench. O3SCRUBTEMP C The current temperature of the Metal Wool Scrubber.(3) O3 GEN TMP O3GENTEMP C The Temperature of the UV Lamp in the O3 Generator.(1) BOX TEMP BOXTEMP C The temperature inside the analyzer chassis. 3 O3 SCRUB 1 SLOPE SLOPE -- OFFSET OFFSET PPB TEST4 TESTCHAN MV TIME CLOCKTIME HH:MM:SS DESCRIPTION The Slope of the instrument as calculated during the last calibration activity. When the unit is set for SINGLE or DUAL Range mode, this is the SLOPE of RANGE1. When the unit is set for AUTO Range mode, this is the SLOPE of the currently active range. The Offset of the instrument as calculated during the last calibration activity. When the unit is set for SINGLE or DUAL Range mode, this is the OFFSET of RANGE1. Displays the signal level of whatever Test function is currently being output by the Analog Output Channel A4.(4) The current time. This is used to create a time stamp on iDAS readings, and by the AutoCal feature to trigger calibration events. 1 Only appears if IZS option is installed. Only appears if IZS Reference Sensor option is installed. 3 Only appears if Metal Wool Scrubber option is installed. 4 Only appears if Analog Output A4 is actively reporting a Test Function. 2 6.2.2. WARNING MESSAGE DISPLAY The most common and serious instrument failures will activate Warning Messages that are displayed on the analyzer’s Front Panel. These are: 04315 Rev. C1 61 Basic Operation of the M400E Analyzer Table 6-3: M400E Ozone Analyzer Operator’s Manual Warning Messages Defined MESSAGE MEANING ANALOG CAL WARNING BOX TEMP WARNING The A/D or at least one D/A channel has not been calibrated. The temperature inside the M400E chassis is outside the specified limits. 2 Contact closure span calibration failed while DYN_SPAN was set to ON. 3 CANNOT DYN ZERO Contact closure zero calibration failed while DYN_ZERO was set to ON. CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased. DATA INITIALIZED iDAS data storage was erased before the last power up occurred. CANNOT DYN SPAN FRONT PANEL WARN CPU is unable to communicate with the front panel. LAMP DRIVER WARN 2 CPU is unable to communicate with one of the I C UV Lamp Drivers. LAMP STABIL WARN Photometer lamp reference step-changes occur more than 25% of the time. O3 GEN LAMP WARN4 O3 GEN REF WARNING The UV Lamp or Detector in the IZS module may be faulty or out of adjustment. 4 4 O3 GEN TEMP WARN O3 SCRUB TEMP WARN5 PHOTO REF WARNING The UV Lamp or Detector in the IZS module may be faulty or out of adjustment. The UV Lamp Heater or Temperature Sensor in the IZS module may be faulty. The Heater or Temperature Sensor of the O3 Scrubber may be faulty. The O3 Reference value is outside of specified limits. PHOTO TEMP WARNING The UV Lamp Temperature is outside of specified limits. REAR BOARD NOT DET Motherboard was not detected during power up. RELAY BOARD WARN CPU is unable to communicate with the relay PCA. SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits. SAMPLE PRESS WARN The pressure of the sample gas is outside the specified limits. SAMPLE TEMP WARN SYSTEM RESET1 The temperature of the sample gas is outside the specified limits. The computer has rebooted. 1 Clears 45 minutes after power up. 2 Clears the next time successful zero calibration is performed. 3 Clears the next time successful span calibration is performed. 4 Only Appears if the IZS option is installed. 5 Only appears if the optional metal wool O3 scrubber is installed. See Section 13.1.1 for more information on using these messages to troubleshoot problems. 62 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6.3. CALIBRATION MODE In this mode the user can, in conjunction with introducing of zero or span gases of known concentrations into the analyzer, cause it to adjust and recalculate the slope (gain) and offset of the its measurement range. This mode is also used to check the current calibration status of the instrument. For more information about setting up and performing standard calibration operations or checks, see Chapter 9. For more information about setting up and performing EPAPressing the CAL key, switches the M400E into calibration mode. If the instrument includes one of the available zero/span valve options, the SAMPLE mode display will also include CALZ and CALS keys. Pressing either of these keys also puts the instrument into calibration mode. The CALZ key is used to initiate a calibration of the analyzer’s zero point using internally generated zero air. The CALS key is used to calibrate the span point of the analyzer’s current reporting range using internally generated O3 span gas. For more information concerning calibration valve options, see Section 5.6. For information on using the automatic calibrations feature (ACAL) in conjunction with the one of the calibration valve options, see Sections 9.3.2 and 9.4. NOTE It is recommended that this span calibration be performed at 80% of full scale of the analyzer’s currently selected reporting range. EXAMPLES: If the reporting range is set for 0 to 500 ppb, an appropriate span point would be 400 ppb. If the of the reporting range is set for 0 to 1000 ppb, an appropriate span point would be 800 ppb. 04315 Rev. C1 63 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4. SETUP MODE The SETUP mode contains a variety of choices that are used to configure the analyzer’s hardware and software features, perform diagnostic procedures, gather information on the instruments performance and configure or access data from the internal data acquisition system (iDAS). For a visual representation of the software menu trees, refer to Appendix A-1. The areas accessed under the SETUP mode are: Table 6-4: Primary Setup Mode Features and Functions MODE OR FEATURE KEYPAD LABEL MANUAL SECTION Analyzer Configuration CFG Auto Cal Feature ACAL Internal Data Acquisition (iDAS) DAS Analog Output Reporting Range Configuration RNGE Used to configure the output signals generated by the instruments analog outputs. 6.4.4 Calibration Password Security PASS Turns the calibration password feature ON/OFF 6.4.2 Internal Clock Configuration CLK Used to Set or adjust the instrument’s internal clock 6.4.3 Advanced SETUP features MORE DESCRIPTION Lists key hardware and software configuration information 6.4.1 Used to set up and operate the AutoCal feature. Table 6-5: Only appears if the analyzer has one of the calibration valve options installed (see Section 5.6). 9.4 Used to set up the iDAS system and view recorded data 7.1 See Table 6-5 This button accesses the instruments secondary setup menu Secondary Setup Mode Features and Functions MODE OR FEATURE KEYPAD LABEL External Communication Channel Configuration COMM MANUAL SECTION DESCRIPTION Used to set up and operate the analyzer’s various external I/O channels including RS-232; RS-485, modem communication and/or Ethernet access. 8 Used to view various variables related to the instruments current operational status System Status Variables VARS Changes made to any variable are not acknowledged and recorded in the instrument’s memory until the ENTR key is pressed. 7.2 Pressing the EXIT key ignores the new setting. If the EXIT key is pressed before the ENTR key, the analyzer will beep alerting the user that the newly entered value has been lost. System Diagnostic Features and Analog Output Configuration 64 DIAG Used to access a variety of functions that are used to configure, test or diagnose problems with a variety of the analyzer’s basic systems. 7.3 & 7.4 Most notably, the menus used to configure the output signals generated by theinstruments’ analog outputs are located here. 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6.4.1. SETUP CFG: CONFIGURATION INFORMATION Pressing the CFG key displays the instrument’s configuration information. This display lists the analyzer model, serial number, firmware revision, software library revision, CPU type and other information. Special instrument or software features or installed options may also be listed here. Use this information to identify the software and hardware installed in your Model 400E photometric analyzer when contacting customer service. To access the configuration table, press: SAMPLE CAL SETUP X.X MODEL TYPE AND NUMBER PART NUMBER SERIAL NUMBER SOFTWARE REVISION LIBRARY REVISION iCHIP SOFTWARE REVISION (Only SETUP X.X PREV NEXT SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE Press NEXT of PREV to move back and forth through the following list of Configuration information: O3= XXXX EXIT M700E Cailbrator EXIT Press exit at any time to return to the SETUP menu appears if INET option is installed) CPU TYPE & OS REVISION DATE FACTORY CONFIGURATION SAVED 04315 Rev. C1 65 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4.2. SETUP PASS: ENABLING/DISABLING PASSWORDS The M400E provides password protection of the calibration and setup functions to prevent unauthorized adjustments. When the passwords have been enabled in the PASS menu item, the system will prompt the user for a password anytime a password-protected function is requested. There are three levels of password protection, which correspond to operator, maintenance and configuration functions. Each level allows access to all of the functions in the previous level. Table 6-6: Password Levels PASSWORD LEVEL MENU ACCESS ALLOWED No password Operator All functions of the MAIN menu: TEST, GEN, initiate SEQ , MSG, CLR 101 Maintenance Access to Primary Setup and Secondary Setup Menus except for VARS and DIAG 818 Configuration Secondary SETUP Submenus VARS and DIAG To enable or disable passwords, press: 66 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer Example: If all passwords are enabled, the following keypad sequence would be required to enter the VARS or DIAG submenus: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS DIAG Press individual keys to set number EXAMPLE: This password enables the SETUP mode SYSTEM 0 EXIT ENTER SETUP PASS:0 0 SYSTEM 8 EXIT 0 ENTR EXIT ENTER SETUP PASS:0 1 8 ENTR EXIT M400E enters selected menu NOTE The instrument still prompts for a password when entering the VARS and DIAG menus, even if passwords are disabled, but it displays the default password (818) upon entering these menus. The user only has to press ENTR to access the password-protected menus but does not have to enter the required number code. 04315 Rev. C1 67 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4.3. SETUP CLK: SETTING THE M400E ANALYZER’S INTERNAL CLOCK 6.4.3.1. Setting the internal Clock’s Time and Day The M400E has a time of day clock that supports the DURATION step of the automatic calibration (ACAL) sequence feature, time of day TEST function, and time stamps on for the iDAS feature and most COMM port messages. To set the clock’s time and day, press: 68 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6.4.3.2. Adjusting the internal Clock’s speed In order to compensate for CPU clocks which run faster or slower, you can adjust a variable called CLOCK_ADJ to speed up or slow down the clock by a fixed amount every day. The CLOCK_AD variable is accessed via the VARS submenu: To change the value of this variable, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 EXIT ENTER SETUP PASS:0 1 SETUP X.X 8 ENTR EXIT 0) DAS_HOLD_OFF=15.0 Minutes PREV NEXT JUMP EDIT ENTR EXIT Continue pressing NEXT until ... SETUP X.X 7) CLOCK_ADJUST=0 Sec/Day PREV NEXT EDIT ENTR EXIT SETUP X.X + 0 7 CLOCK_ADJUST=0 Sec/Day 0 EDIT ENTR EXIT Enter sign and number of seconds per day the clock gains (-) or loses(+) SETUP X.X 7) CLOCK_ADJUST=0 Sec/Day PREV NEXT JUMP EDIT ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 04315 Rev. C1 69 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4.4. SETUP RNGE: ANALOG OUTPUT REPORTING RANGE CONFIGURATION 6.4.4.1. Physical Range versus Analog Output Reporting Ranges Functionally, the Model 400E photometric analyzer has one hardware “physical range” that is capable of determining O3 concentrations between 0 ppb and 10,000 ppb. This architecture improves reliability and accuracy by avoiding the need for extra, switchable, gain-amplification circuitry. Once properly calibrated, the analyzer’s front panel will accurately report concentrations along the entire span of its physical range. Because, most applications use only a small part of the analyzer’s physical range, the width of the M400E analyzer’s physical range can create data resolution problems for most analog recording devices. For example, in an application where the expected concentration of O3 is typically less than 500 ppb, the full scale of expected values is only 5% of the instrument’s 10,000 ppm physical range. Unmodified, the corresponding output signal would also be recorded across only 5% of the range of the recording device. The M400E solves this problem by allowing the user to select a scaled reporting range for the analog outputs that only includes that portion of the physical range relevant to the specific application. NOTE Only the reporting range of the analog outputs is scaled. Both the iDAS values stored in the CPU’s memory and the concentration values reported on the front panel are unaffected by the settings chosen for the reporting range(s) of the instrument. 6.4.4.2. Analog Output Ranges for O3 Concentration The analyzer has two active analog output signals related to O3 concentration that are accessible through a connector on the rear panel (see Figure 3-2). ANALOG OUT O3 concentration outputs A1 + LOW range when DUAL mode is selected Figure 6-3: Not Used on M400E A2 - + A3 - + Test Channel See Section 7.4.6 A4 - + - HIGH range when DUAL mode is selected Analog Output Connector Pin Out The A1 and A2 channels output a signal that is proportional to the O3 concentration of the sample gas. They can be configured: With independent reporting ranges reporting a “single” output signal (SNGL Mode, see Section 6.4.4.3) o Be to operate completely independently (DUAL mode, see Section 6.4.4.4). Or to automatically switch between the two ranges dynamically as the concentration value fluctuates (AUTO modes, see Section 6.4.4.5). 70 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer The user can set the units of measure, measure span and signal scale of each output in a variety of combinations. EXAMPLE: A1 OUTPUT: Output Signal = 0-5 VDC representing 0-1000 ppb concentration values A2 OUTPUT: Output Signal = 0 – 10 VDC representing 0-500 ugm concentration values. Both the A1 and A2 outputs can be: Configured full scale outputs of: 0 - 0.1 VDC; 0 - 1VDC; 0 - 5VDC or; 0 - 10VDC. Equipped with optional 0-20 mADC current loop drivers (OPT 41, see Section 5.4) and configured for any current output within that range (e.g. 0-20, 2-20, 4-20, etc.). The user may also add a signal offset independently to each output (see Section 7.4.5) to match the electronic input requirements of the recorder or data logger to which the output is connected. DEFAULT SETTINGS The default setting for these the reporting ranges of the analog output channels A1 and A2 are: SNGL mode 0 to 400.0 ppb 0 to 5 VDC Reporting range span may be viewed via the front panel by viewing the RANGE test function. If the DUAL or AUTO modes are selected, the RANGE test function will be replaced by two separate functions, RANGE1 & RANGE2. Reporting range status is also available as output via the external digital I/O status bits (see Section 3.3.3). NOTE Upper span limit setting for the individual range modes are shared. Resetting the span limit in one mode also resets the span limit for the corresponding range in the other modes as follows: SNGL Range 04315 Rev. C1 DUAL Range1 (Low) Range2 (Hi) AUTO Low Range High Range 71 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4.4.3. RNGE MODE SNGL: Configuring the M400E analyzer for Single Range Mode The single range mode sets a single maximum range for the both the A1 and A2 analog outputs. If the single range is selected both outputs are slaved together and will represent the same reporting range span (e.g. 0-500 ppb), however their electronic signal levels may be configured for different ranges (e.g. 0-10 VDC vs. 0-.1 VDC; See Section 7.4.3). This Reporting range can be set to any value between 0.1 ppb and 10,000 ppb. To select SINGLE range mode and set the upper limit of the reporting range, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X MODE SET SETUP X.X RANGE MODE MENU UNIT EXIT RANGE MODE:SNGL SNGL DUAL AUTO SETUP X.X ENTR EXIT RANGE MODE:SNGL SNGL DUAL AUTO SETUP X.X MODE SET SETUP X.X 0 0 EXIT ENTR EXIT RANGE MODE MENU UNIT EXIT RANGE:500.0 Conc 5 0 0 Toggled these keys to select the upper SPAN limit for the reporting range .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting NOTE This is the default reporting range mode for the analyzer. 72 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6.4.4.4. RNGE MODE DUAL: Configuring the M400E analyzer for Dual Range Mode DUAL range mode allows the A1 and A2 outputs to be configured with separate reporting range spans as well as separate electronic signal levels. The analyzer software calls these two ranges LOW and HI. The LOW range setting corresponds with the analog output labeled A1 on the rear panel of the instrument and is viewable via the test function RANGE1. The HIGH range setting corresponds with the A2 output and is viewable via the test function RANGE2. While the software labels these two ranges as LOW and HI, when in DUAL mode their upper limits need not conform to that convention. The upper span limit of the LOW/RANGE1 can be a higher number than that of HI/RANGE2 To set the ranges press following keystroke sequence: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X MODE SET SETUP X.X RANGE MODE MENU UNIT EXIT RANGE MODE:SNGL SNGL DUAL AUTO The LOW and HIGH ranges have separate slopes and offsets for computing the O3 concentration. The two ranges must be independently calibrated. SETUP X.X ENTR EXIT RANGE MODE:SNGL SNGL DUAL AUTO SETUP X.X MODE SET SETUP X.X 0 0 EXIT ENTR EXIT RANGE MODE MENU UNIT EXIT LOW RANGE:500.0 Conc 5 0 0 .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting SETUP X.X 0 Toggled these keys to select the upper SPAN limit for the reporting range . 04315 Rev. C1 0 HIGH RANGE:500.0 Conc 5 0 0 .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 73 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 6.4.4.5. RNGE MODE AUTO: Configuring the M400E analyzer for Auto Range Mode AUTO range mode gives the analyzer to ability to output data via a LOW range (displayed on the front panel as RANGE1) and HIGH range (displayed on the front panel as RANGE2) on a single analog output. When the AUTO range mode is selected, the analyzer automatically switches back and forth between user selected LOW & HIGH ranges depending on the level of the O3 concentration. The unit will move from LOW range to HIGH range when the O3 concentration exceeds to 98% of the LOW range span limit. The unit will return from HIGH range back to LOW range once the O3 concentration falls below 75% of the LOW range span limit. To set the ranges press following keystroke sequence: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X MODE SET SETUP X.X RANGE MODE MENU UNIT EXIT RANGE MODE:SNGL SNGL DUAL AUTO The LOW and HIGH ranges have separate slopes and offsets for computing the O3 concentration. The two ranges must be independently calibrated. SETUP X.X ENTR EXIT RANGE MODE:SNGL SNGL DUAL AUTO SETUP X.X MODE SET SETUP X.X 0 0 EXIT ENTR EXIT RANGE MODE MENU UNIT EXIT LOW RANGE:50.0 Conc 0 5 0 .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting SETUP X.X 0 0 HIGH RANGE:200.0 Conc 2 0 0 .0 Toggled these keys to select the upper SPAN limit for the reporting range ENTR EXIT EXIT discards the new setting ENTR accepts the new setting NOTE Avoid accidentally setting the LOW range (RANGE1) of the instrument with a higher span limit than the HIGH range (RANGE2). This will cause the unit to stay in the low reporting range perpetually and defeat the function of the AUTO range mode. 74 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Basic Operation of the M400E Analyzer 6.4.4.6. SETUP RNGE UNIT: Setting the Reporting range Unit Type The M400E can display concentrations in ppb, ppm, ug/m3, mg/m3 units. Changing units affects all of the COM port values, and all of the display values for all reporting ranges. To change the units of measure press: NOTE Concentrations displayed in mg/m3 and ug/m3 use 0C, 760 mmHg for Standard Temperature and Pressure (STP). Consult your local regulations for the STP used by your agency. NOTE Once the Units of Measurement have been changed, the unit MUST be recalibrated, as the “expected span values” previously in effect will no longer be valid. Simply entering new expected span values without running the entire calibration routine is not sufficient. The following equations give approximate conversions between volume/volume units and weight/volume units: O3 ppb x 2.14 = O3 ug/m3 O3 ppm x 2.14 = O3 mg/m3 04315 Rev. C1 75 Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual USER NOTES: 76 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7. ADVANCED FEATURES OF THE M400E ANALYZER 7.1. USING USING THE DATA ACQUISITION SYSTEM (IDAS) The M400E analyzer contains a flexible and powerful, internal data acquisition system (iDAS) that enables the analyzer to store concentration and calibration data as well as a host of diagnostic parameters. The iDAS of the M400E can store up to about one million data points, which can, depending on individual configurations, cover days, weeks or months of valuable measurements. The data are stored in non-volatile memory and are retained even when the instrument is powered off. Data are stored in plain text format for easy retrieval and use in common data analysis programs (such as spreadsheet-type programs). The iDAS is designed to be flexible, users have full control over the type, length and reporting time of the data. The iDAS permits users to access stored data through the instrument’s front panel or its communication ports. The principal use of the iDAS is logging data for trend analysis and predictive diagnostics, which can assist in identifying possible problems before they affect the functionality of the analyzer. The secondary use is for data analysis, documentation and archival in electronic format. To support the iDAS functionality, Teledyne Instruments offers APICOM, a program that provides a visual interface for remote or local setup, configuration and data retrieval of the iDAS (see Section 7.1). Using APICOM, data can even be retrieved automatically to a remote computer for further processing. The APICOM manual, which is included with the program, contains a more detailed description of the iDAS structure and configuration, which is briefly described in this document. The M400E is configured with a basic iDAS configuration already enabled. The data channels included in this basic structure may be used as is or temporarily disabled for later or occasional use. Note iDAS operation is suspended whenever its configuration is edited using the analyzer’s the front panel and therefore data may be lost. To prevent such data loss, it is recommended to use the APICOM graphical user interface for iDAS changes. Please be aware that all stored data will be erased if the analyzer’s disk-on-chip or CPU board is replaced or if the configuration data stores there is reset. 7.1.1. IDAS STATUS The green SAMPLE LED on the instrument front panel, which indicates the analyzer status, also indicates certain aspects of the iDAS status: Table 7-1: Front Panel LED Status Indicators for iDAS LED STATE OFF BLINKING ON iDAS Status System is in calibration mode. Data logging can be enabled or disabled for this mode. Calibration data are typically stored at the end of calibration periods, concentration data are typically not sampled, diagnostic data should be collected. Instrument is in hold-off mode, a short period after the system exits calibrations. iDAS channels can be enabled or disabled for this period. Concentration data are typically disabled whereas diagnostic should be collected. Sampling normally. The iDAS can be disabled only by disabling or deleting its individual data channels. 04315 Rev. C1 77 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.1.2. IDAS STRUCTURE The iDAS is designed around the feature of a “record”. A record is a single data point. The type of date recorded in a record is defined by two properties: PARAMETER type that defines the kind of data to be stored (e.g. the average of O3 concentrations measured with three digits of precision). See Section 7.1.5.3. A TRIGGER event that defines when the record is made (e.g. timer; every time a calibration is performed, etc.). See Section 7.1.5.2. The specific PARAMETERS and TRIGGER events that describe an individual record are defined in a construct called a DATA CHANNEL (see Section 7.1.5). Each data channel related one or more parameters with a specific trigger event and various other operational characteristics related to the records being made (e.g. the channels name, number or records to be made, time period between records, whether or not the record is exported via the analyzer’s RS-232 port, etc.). 7.1.3. IDAS CHANNELS The key to the flexibility of the iDAS is its ability to store a large number of combinations of triggering events and data parameters in the form of data channels. Users may create up to 20 data channels and each channel can contain one or more parameters. For each channel, the following are selected: One triggering event is selected Up to 50 data parameters, which can be the shared between channels. Several properties that define the structure of the channel and allow the user to make operational decisions regarding the channel. Table 7-2: iDAS Data Channel Properties PROPERTY DEFAULT SETTING RANGE The name of the data channel. “NONE” Up to 6 letters or digits1. TRIGGERING EVENT The event that triggers the data channel to measure and store the datum ATIMER Any available event (see Appendix A-5). NUMBER AND LIST OF PARAMETERS A User-configurable list of data types to be recorded in any given channel. 1-DETMES Any available parameter (see Appendix A-5). The amount of time between each channel data point. 000:01:00 000:00:01 to 366:23:59 (Days:Hours:Minutes) 100 1 to 1 million, limited by available storage space. OFF OFF or ON ON OFF or ON OFF OFF or ON NAME REPORT PERIOD NUMBER OF RECORDS RS-232 REPORT CHANNEL ENABLED CAL HOLD OFF DESCRIPTION The number of reports that will be stored in the data file. Once the limit is exceeded, the oldest data is over-written. Enables the analyzer to automatically report channel values to the RS-232 ports. Enables or disables the channel. Allows a channel to be temporarily turned off without deleting it. Disables sampling of data parameters while instrument is in calibration mode2. 1 More with APICOM, but only the first six are displayed on the front panel). 2 When enabled records are not recorded until the DAS HOLD OFF period is passed after calibration mode. DAS HOLD OFF SET in the VARS menu (see Section 6.12.) 78 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.3.1. Default iDAS Channels A set of default Data Channels has been included in the analyzer’s software for logging O3 concentration and certain predictive diagnostic data. These default channels include but are not limited to: CONC: Samples O3 concentration at one minute intervals and stores an average every hour with a time and date stamp. Readings during calibration and calibration hold off are not included in the data. By default, the last 800 hourly averages are stored. O3REF: Logs the O3 reference value once a day with a time and date stamp. This data can be used to track lamp intensity and predict when lamp adjustment or replacement will be required. By default, the last 730 daily readings are stored. PNUMTC: Collects sample flow and sample pressure data at five-minute intervals and stores an average once a day with a time and date stamp. This data is useful for monitoring the condition of the pump and critical flow orifice (sample flow) and the sample filter (clogging indicated by a drop in sample pressure) over time to predict when maintenance will be required. The last 360 daily averages (about 1 year) are stored. O3GEN: Logs the O3 generator drive value once a day with a time and date stamp. This data can be used to track O3 generator lamp intensity and predict when lamp adjustment or replacement will be required. By default, the last 360 daily readings are stored. CALDAT: Logs new slope and offset every time a zero or span calibration is performed. This Data Channel also records the instrument readings just prior to performing a calibration. This information is useful for performing predictive diagnostics as part of a regular maintenance schedule (See Section 12.2). The CALDAT channel collects data based on events (e.g. a calibration operation) rather than a timed interval. This does not represent any specific length of time since it is dependent on how often calibrations are performed. These default data channels can be used as they are, or they can be customized from the front panel to fit a specific application. They can also be deleted to make room for custom user-programmed Data Channels. Appendix A-5 lists the firmware-specific iDAS configuration in plain-text format. This text file can either be loaded into APICOM and then modified and uploaded to the instrument or can be copied and pasted into a terminal program to be sent to the analyzer. NOTE Sending an iDAS configuration to the analyzer through its COM ports will replace the existing configuration and will delete all stored data. Back up any existing data and the iDAS configuration before uploading new settings. 04315 Rev. C1 79 Advanced FEATURES of the M400E analyzer Figure 7-1: 80 M400E Ozone Analyzer Operator’s Manual Default M400E iDAS Channels Setup 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.4. SETUP DAS VIEW: VIEWING IDAS CHANNELS AND INDIVIDUAL RECORDS iDAS data and settings can be viewed on the front panel through the following keystroke sequence. 04315 Rev. C1 81 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.1.5. SETUP DAS EDIT: ACCESSING THE IDAS EDIT MODE iDAS configuration is most conveniently done through the APICOM remote control program. The following list of key strokes shows how to edit using the front panel. SAMPLE CAL iDAS EDIT – Keypad Functions SETUP KEY SETUP X.X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT Main iDAS Menu SETUP X.X DATA ACQUISITION VIEW EDIT SETUP X.X 8 1 EXIT FUNCTION PREV Selects the previous data channel in the list NEXT Selects the next data channel in the list INS Inserts a new data channel into the list BEFORE the selected channel DEL Deletes the currently selected data channel EDIT Enters EDIT mode Exports the configuration of all data channels to the RS-232 interface Keys only appear when needed PRINT ENTER PASSWORD:818 8 ENTR EXIT EDIT Channel Menu SETUP X.X PREV MEXT 0) CONC: ATIMER 1, 800 INS DEL EDIT PRNT EXIT Enters EDIT mode for the selected channel When editing the data channels, the top line of the display indicates some of the configuration parameters. For example, the display line: 0) CONC1: ATIMER, 4, 800 translates to the following configuration: Channel No.: 0 NAME: CONC1 TRIGGER EVENT: ATIMER PARAMETERS: Four parameters are included in this channel EVENT: This channel is set up to store 800 records. To edit the name of a data channel, follow the above key sequence and then press: 82 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.5.1. Editing iDAS Data Channel Names To edit the name of an iDAS data channel, follow the instruction shown in Section 7.1.5 then press: Starting at the EDIT CHANNEL MENU SETUP X.X 0) CONC: ATIMER 1, 800 EDIT PRNT SETUP X.X EXIT NAME: CONC EDIT PRNT SETUP X.X C O EXIT NAME: CONC N C — — ENTR EXIT EXIT discards the new setting ENTR accepts the new setting Press each key repeatedly to cycle through the available character set: 0-9, A-Z, space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } < >\ | ; : , . / ? 04315 Rev. C1 83 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.1.5.2. Editing iDAS Triggering Events Triggering events define when and how the iDAS records a measurement of any given data channel. Triggering events are firmware-specific and a complete list of Triggers for this model analyzer can be found in Appendix A5. The most commonly used triggering events are: ATIMER: Sampling at regular intervals specified by an automatic timer. Most trending information is usually stored at such regular intervals, which can be instantaneous or averaged. EXITZR, EXITSP, and SLPCHG (exit zero, exit span, slope change): Sampling at the end of (irregularly occurring) calibrations or when the response slope changes. These triggering events create instantaneous data points, e.g., for the new slope and offset (concentration response) values at the end of a calibration. Zero and slope values are valuable to monitor response drift and to document when the instrument was calibrated. WARNINGS: Some data may be useful when stored if one of several warning messages appears such as WTEMPW (GFC wheel temperature warning). This is helpful for trouble-shooting by monitoring when a particular warning occurred. To edit the list of data parameters associated with a specific data channel, follow the instruction shown in Section 7.1.5 then press: NOTE A full list of iDAS Trigger Events can be found in Appendix A-5 of this manual 84 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.5.3. Editing iDAS Parameters Data parameters are types of data that may be measured and stored by the iDAS. For each Teledyne Instruments analyzer model, the list of available data parameters is different, fully defined and not customizable. Appendix A-5 lists firmware specific data parameters for the M400E. iDAS parameters include things like O3 concentration measurements, temperatures of the various heaters placed around the analyzer, pressures and flows of the pneumatic subsystem and other diagnostic measurements as well as calibration data such as slope and offset. Most data parameters have associated measurement units, such as mV, ppb, cm³/min, etc., although some parameters have no units. With the exception of concentration readings, none of these units of measure can be changed. To change the units of measure for concentration readings See Section 6.8.6. Note iDAS does not keep track of the units (i.e. PPM or PPB) of each concentration value and iDAS data files may contain concentrations in multiple units if the unit was changed during data acquisition. Each data parameter has user-configurable functions that define how the data are recorded: Table 7-3: iDAS Data Parameter Functions FUNCTION PARAMETER EFFECT Instrument-specific parameter name. INST: Records instantaneous reading. AVG: Records average reading during reporting interval. SAMPLE MODE MIN: Records minimum (instantaneous) reading during reporting interval. MAX: Records maximum (instantaneous) reading during reporting interval. SDEV: Records the standard deviation of the data points recorded during the reporting interval. PRECISION STORE NUM. SAMPLES Decimal precision of parameter value (0-4). OFF: Stores only the average (default). ON: Stores the average and the number of samples in each average for a parameter. This property is only useful when the AVG sample mode is used. Note that the number of samples is the same for all parameters in one channel and needs to be specified only for one of the parameters in that channel. Users can specify up to 50 parameters per data channel (the M400E provides about 40 parameters). However, the number of parameters and channels is ultimately limited by available memory. Data channels can be edited individually from the front panel without affecting other data channels. However, when editing a data channel, such as during adding, deleting or editing parameters, all data for that particular channel will be lost, because the iDAS can store only data of one format (number of parameter columns etc.) for any given channel. In addition, an iDAS configuration can only be uploaded remotely as an entire set of channels. Hence, remote update of the iDAS will always delete all current channels and stored data. 04315 Rev. C1 85 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual To modify, add or delete a parameter, follow the instruction shown in Section 7.1.5 then press: NOTE When the STORE NUM SAMPLES feature is turned on, the instrument will store how many sample readings were used to compute the AVG, MIN or MAX value but not the readings themselves. 86 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.5.4. Editing Sample Period and Report Period The iDAS defines two principal time periods by which sample readings are taken and permanently recorded: SAMPLE PERIOD: Determines how often iDAS temporarily records a sample reading of the parameter in volatile memory. The SAMPLE PERIOD is set to one minute by default and generally cannot be accessed from the standard iDAS front panel menu, but is available via the instruments communication ports by using APICOM or the analyzer’s standard serial data protocol. SAMPLE PERIOD is only used when the iDAS parameter’s sample mode is set for AVG, MIN or MAX. REPORT PERIOD: Sets how often the sample readings stored in volatile memory are processed, (e.g. average, minimum or maximum are calculated) and the results stored permanently in the instruments Disk-on-Chip as well as transmitted via the analyzer’s communication ports. The REPORT PERIOD may be set from the front panel. If the INST sample mode is selected the instrument stores and reports an instantaneous reading of the selected parameter at the end of the chosen report period. To define the REPORT PERIOD, follow the instruction shown in Section 7.1.5 then press: 04315 Rev. C1 87 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual The SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to the beginning and end of the appropriate interval of the instruments internal clock. If SAMPLE PERIOD were set for one minute the first reading would occur at the beginning of the next full minute according to the instrument’s internal clock. If the REPORT PERIOD were set for of one hour, the first report activity would occur at the beginning of the next full hour according to the instrument’s internal clock. EXAMPLE: Given the above settings, if iDAS were activated at 7:57:35 the first sample would occur at 7:58 and the first report would be calculated at 8:00 consisting of data points for 7:58. 7:59 and 8:00. During the next hour (from 8:01 to 9:00), the instrument will take a sample reading every minute and include 60 sample readings. NOTE In AVG, MIN or MAX sample modes (see Section 7.1.5.3), the settings for the SAMPLE PERIOD and the REPORT PERIOD determine the number of data points used each time the average, minimum or maximum is calculated, stored and reported to the COMM ports. The actual sample readings are not stored past the end of the of the chosen REPORT PERIOD. When the STORE NUM SAMPLES feature is turned on, the instrument will store how many sample readings were used to compute the AVG, MIN or MAX. 7.1.5.5. Report periods in Progress when Instrument Is Powered Off If the instrument is powered off in the middle of a REPORT PERIOD, the samples accumulated so far during that period are lost. Once the instrument is turned back on, the iDAS restarts taking samples and temporarily them in volatile memory as part of the REPORT PERIOD currently active at the time of restart. At the end of this REPORT PERIOD, only the sample readings taken since the instrument was turned back on will be included in any AVG, MIN or MAX calculation. Also, the STORE NUM SAMPLES feature will report the number of sample readings taken since the instrument was restarted. 88 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.5.6. Editing the Number of Records The number of data records in the iDAS is limited to about a cumulative one million data points in all channels (one megabyte of space on the disk-on-chip). However, the actual number of records is also limited by the total number of parameters and channels and other settings in the iDAS configuration. Every additional data channel, parameter, number of samples setting etc. will reduce the maximum amount of data points somewhat. In general, however, the maximum data capacity is divided amongst all channels (max: 20) and parameters (max: 50 per channel). The iDAS will check the amount of available data space and prevent the user from specifying too many records at any given point. If, for example, the iDAS memory space can accommodate 375 more data records, the ENTR key will disappear when trying to specify more than that number of records. This check for memory space may also make an upload of an iDAS configuration with APICOM or a terminal program fail, if the combined number of records would be exceeded. In this case, it is suggested to either try to determine what the maximum number of records available is using the front panel interface or use trial-and-error in designing the iDAS script or calculate the number of records using the DAS or APICOM manuals. To set the NUMBER OF RECORDS, follow the instruction shown in Section 7.1.5 then press: . 04315 Rev. C1 89 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.1.5.7. RS-232 Report Function The iDAS can automatically report data to the communications ports, where they can be captured with a terminal emulation program or simply viewed by the user using the APICOM software. To enable automatic COMM port reporting, follow the instruction shown in Section 7.1.5 then press: Starting at the EDIT CHANNEL MENU SETUP X.X Use the PREV and NEXT keys to scroll to the DATA CHANNEL to be edited PREV NEXT SETUP X.X EDIT PRNT EXIT Continue pressing until ... SETUP X.X EDIT PRNT SETUP X.X OFF Toggle these keys to turn the RS-232 REPORT feature ON/OFF 90 RS-232 REPORT: OFF EXIT RS-232 REPORT: OFF ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.5.8. Enabling / Disabling the HOLDOFF Feature The iDAS HOLDOFF feature prevents data collection during calibration operations. To enable or disable the HOLDOFF, follow the instruction shown in Section 7.1.5 then press: Starting at the EDIT CHANNEL MENU SETUP X.X Use the PREV and NEXT keys to scroll to the DATA CHANNEL to be edited PREV NEXT SETUP X.X EDIT PRNT EXIT Continue pressing until ... SETUP X.X EDIT PRNT SETUP X.X EXIT CAL.HOLD OFF: OFF OFF Toggle these keys to turn the HOLDOFF feature ON/OFF ENTR EXIT EXIT discards the new setting ENTR accepts the new setting HOLDOFF also prevents iDAS measurements from being made at certain times when the quality of the analyzer’s O3 measurements may be suspect (e.g. while the instrument is warming up). In this case, the length of time that the HOLDOFF feature is active is determined by the value of the internal variable (VARS), DAS_HOLDOFF. To set the length of the DAS_HOLDOFF period, see Section 7.2. 04315 Rev. C1 91 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.1.5.9. The Compact Report Feature When enabled, this option avoids unnecessary line breaks on all RS-232 reports. Instead of reporting each parameter in one channel on a separate line, up to five parameters are reported in one line. The COMPACT DATA REPORT generally cannot be accessed from the standard iDASfront panel menu, but is available via the instruments communication ports by using APICOM or the analyzer’s standard serial data protocol. 7.1.5.10. The Starting Date Feature This option allows the user to specify a starting date for any given channel in case the user wants to start data acquisition only after a certain time and date. If the STARTING DATE is in the past (the default condition), the iDAS ignores this setting and begins recording data as defined by the REPORT PERIOD setting. The STARTING DATE generally cannot be accessed from the standard iDAS front panel menu, but is available via the instruments communication ports by using APICOM or the analyzer’s standard serial data protocol. 7.1.6. DISABLING/ENABLING DATA CHANNELS Data channels can be temporarily disabled, which can reduce the read/write wear on the disk-on-chip. To disable a data channel, follow the instruction shown in Section 7.1.5 then press: Starting at the EDIT CHANNEL MENU SETUP X.X Use the PREV and NEXT keys to scroll to the DATA CHANNEL to be edited PREV MEXT SETUP X.X EDIT PRNT EXIT Continue pressing until ... SETUP X.X EDIT PRNT SETUP X.X ON Toggle these keys to enable or disable the CHANNEL 92 CHANNEL ENABLE:ON EXIT CHANNEL ENABLE:ON ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.1.7. REMOTE IDAS CONFIGURATION Editing channels, parameters and triggering events as described in this can be performed via the APICOM remote control program using the graphic interface shown below. Refer to Chapter 8 for details on remote access to the M400E analyzer. Figure 7-2: APICOMuser interface for configuring the iDAS. Once an iDAS configuration is edited (which can be done offline and without interrupting DAS data collection), it is conveniently uploaded to the instrument and can be stored on a computer for later review, alteration or documentation and archival. Refer to the APICOM manual for details on these procedures. The APICOM user manual (Teledyne Instruments part number 039450000) is included in the APICOM installation file, which can be downloaded at http://www.teledyne-api.com/software/apicom/. Although Teledyne Instruments recommends the use of APICOM, the iDAS can also be accessed and configured through a terminal emulation program such as HyperTerminal (Figure 6-6). However, all configuration commands must be created following a strict syntax or be pasted in from of a text file, which was edited offline and then uploaded through a specific transfer procedure. 04315 Rev. C1 93 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.2. SETUP MORE VARS: INTERNAL VARIABLES (VARS) The M400E has several-user adjustable software variables, which define certain operational parameters. Usually, these variables are automatically set by the instrument’s firmware, but can be manually re-defined using the VARS menu. The following table lists all variables that are available within the 818 password protected level. See Appendix A2 for a detailed listing of all of the M400E variables that are accessible through the remote interface. Table 7-4: Variable Names (VARS) NO. VARIABLE DESCRIPTION Changes the Internal Data Acquisition System (iDAS) HOLDOFF timer: 0 DAS_HOLD_OFF 1 CONC_PRECISION 2 No data is stored in the iDAS channels during situations when the software considers the data to be questionable such as during warm up of just after the instrument returns from one of its calibration mode to SAMPLE Mode. VARS DEFAULT VALUES ALLOWED VALUES May be set for intervals between 0.5 – 20 min 15 min. Allows the user to set the number of significant digits to the right of the decimal point display of concentration and stability values. AUTO, 1, 2, 3, 4 AUTO PHOTO_LAMP4 Allows adjustment of the temperature set point for the photometer UV lamp in the optical bench. 0 - 100C 58C O3_GEN_LAMP1 4 Allows adjustment of the temperature set point for the UV lamp in the O3 generator option.1 0 - 100C 48C 4 O3_GEN_LOW11 Allows adjustment of the O3 generator option for the low (mid) span calibration point on RANGE12 during 3-point calibration checks.1 0 – 1500 ppb 100 ppb 5 O3_GEN_LOW21 Allows adjustment of the O3 Generator Option for the low (mid) span calibration point on RANGE23 during 0– 1500 ppb 3-point calibration checks.1 100 ppb 3 , O3_SCRUB_SET1,4 6 7 CLOCK_ADJ Allows adjustment of the temperature set point for the heater attached to the metal wool scrubber option along with set points for both the High and Low alarm limits for the heater.1 Adjusts the speed of the analyzer’s clock. Choose the + sign if the clock is too slow, choose the - sign if the clock is too fast. 0 - 200C 110C -60 to +60 s/day 0 sec 1 Although, this variable may appear in the list even when the associated option is not installed. It is only effective when that option is installed and operating. 2 RANGE1 is the default range when the analyzer is set for SINGLE range mode and the LOW range when the unit is set for AUTO range mode. 3 RANGE2 HI range when the unit is set for AUTO range mode. 4 DO NOT ADJUST OR CHANGE this values unless instructed to by Teledyne Instruments’ customer service personnel. 94 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer To access and navigate the VARS menu, use the following key sequence: NOTE: There is a 2-second latency period between when a VARS value is changed and the new value is stored into the analyzer’s memory. DO NOT turn the analyzer off during this period or the new setting will be lost. 04315 Rev. C1 95 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.3. SETUP MORE DIAG :THE DIAGNOSTIC MENU A series of diagnostic tools is grouped together under the SETUPMOREDIAG menu. As these parameters are dependent on firmware revision, (see Appendix A). These tools can be used in a variety of troubleshooting and diagnostic procedures and are referred to in many places of the maintenance and trouble-shooting sections of this manual. The various operating modes available under the DIAG menu are: Table 7-5: Diagnostic Mode (DIAG) Functions DIAG SUBMENU SUBMENU FUNCTION Front Panel Mode Indicator MANUAL SECTION SIGNAL I/O Allows observation of all digital and analog signals in the instrument. Allows certain digital signals such as valves and heaters to be toggled ON and OFF. DIAG I/O 13.1.3 ANALOG OUTPUT When entered, the analyzer performs an analog output step test. This can be used to calibrate a chart recorder or to test the analog output accuracy. DIAG AOUT 13.7.7.1 ANALOG I/O CONFIGURATION The signal levels of the instruments analog outputs may be calibrated (either individually or as a group). Various electronic parameters such as signal span, and offset are available for viewing and configuration. DIAG AIO 7.4 O3 GENERATOR CALIBRATION1 The analyzer is performing an electric test. This test simulates IR detector signal in a known manner so that the proper functioning of the sync/demod board can be verified. DIAG OPTIC 9.6 DARK CALIBRATION The analyzer is performing a dark calibration procedure. This procedure measures and stores the inherent dc offset of the sync/demod board electronics. DIAG ELEC 9.5.1 FLOW CALIBRATION This function is used to calibrate the gas flow output signals of sample gas and ozone supply. These settings are retained when exiting DIAG. DIAG FCAL 9.5.2 Configures the A4 analog output channel. DIAG TCHN 7.4.6 TEST CHAN OUTPUT 1 Only appears if the IZS option is installed. 96 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer To access the various DIAG submenus, press the following keys: SAMPLE CAL SETUP PRIMARY SETUP MENU SETUP X.X CFG DAS RNGE PASS CLK MORE SECONDARY SETUP MENU SETUP X.X COMM VARS SETUP X.X 8 1 DIAG PREV NEXT Toggle these keys to scroll through the list of DIAG submenus DIAG EXIT ENTER PASSWORD:818 8 ENTR EXIT SIGNAL I/O ENTR EXIT ENTR Activates the selected DIAG submenu Figure 7-3: 04315 Rev. C1 EXIT Accessing the DIAG Submenus 97 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.4. USING THE MODEL 400E ANALYZER’S ANALOG OUTPUTS. The M400E analyzer comes equipped with three analog outputs. The first two outputs (A1 & A2) carry analog signals that represent the currently measured O3 output (see Section 6.4.4.2). The third output (A4) can be set by the user to carry the current signal level of any one of several operational parameters (see Table 7-10l). 7.4.1. ADJUSTING & CALIBRATING THE ANALOG OUTPUT SIGNALS The following lists the analog I/O functions that are available in the M400E analyzer. Table 7-6: DIAG - Analog I/O Functions SUB MENU AOUT CALIBRATED FUNCTION Initiates a calibration of the A1, A2 and A4 analog output channels that determines the slope and offset inherent in the circuitry of each output. These values are stored in the and applied to the output signals by the CPU automatically MANUAL SECTION 7.4.2 Sets the basic electronic configuration of the A1 output. There are four options: RANGE: Selects the signal type (voltage or current loop) and level of the output CONCOUT_11 A1 OFS: Allows them input of a DC offset to let the user manually adjust the output level AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this one channel only. Sets the basic electronic configuration of the A2 output. There are three options: 7.4 RANGE: Selects the signal type (voltage or current loop) and level of the output CONCOUT_21 A2 OFS: Allows them input of a DC offset to let the user manually adjust the output level AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this one channel only. Sets the basic electronic configuration of the A4 output. There are three options: RANGE: Selects the signal type (voltage or current loop) and level of the output TEST OUTPUT1 A4 OFS: Allows them input of a DC offset to let the user manually adjust the output level 7.4.6 AUTO CAL: Enables / Disables the AOUT CALIBRATION Feature CALIBRATED: Performs the same calibration as AOUT CALIBRATED, but on this one channel only. AIN CALIBRATED 1 Initiates a calibration of the A-to-D Converter circuit located on the Motherboard. 7.4.7 Changes to RANGE or REC_OFS require recalibration of this output. 98 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer To access the ANALOG I/O CONFIGURATION sub menu, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X 8 Toggle these keys to enter the correct PASSWORD EXIT DIAG EXIT ENTER PASSWORD:818 1 8 DIAG ENTR EXIT SIGNAL I/O NEXT ENTR EXIT Continue pressing NEXT until ... AIO Configuration Submenu DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO ENTR A OUTS CALIBRATED: NO CAL DIAG AIO 04315 Rev. C1 Adjusts the signal output for Analog Output A1 EXIT Adjusts the signal output for Analog Output A2 Selects the parameter top be output on the TEST channel and adjusts its signal output AIN CALIBRATED: NO CAL Figure 7-4: EXIT TEST_OUTPUT: 5V,OVR, NOCAL EDIT DIAG AIO EXIT CONC_OUT_2: 5V, OVR, NOCAL EDIT DIAG AIO EXIT CONC_OUT_1: 5V, OVR, NOCAL EDIT DIAG AIO EXIT EXIT Accessing the Analog I/O Configuration Submenus 99 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.4.2. CALIBRATION OF THE ANALOG OUTPUTS TEST CHANNEL calibration needs to be carried out on first startup of the analyzer (performed in the factory as part of the configuration process) or whenever re-calibration is required. The analog outputs can be calibrated automatically or adjusted manually. During automatic calibration, the analyzer tells the output circuitry to generate a zero mV signal and high-scale point signal (usually about 90% of chosen analog signal scale) then measures actual signal of the output. Any error at zero or high-scale is corrected with a slope and offset. Automatic calibration can be performed via the AOUTS CALIBRATION command, or by using the CAL button located inside TEST_CHANNEL submenu. By default, the analyzer is configured so that calibration of analog outputs can be initiated as a group with the AOUT CALIBRATION command or individually. 7.4.2.1. Enabling or Disabling the AutoCal for an Individual Analog Output To enable or disable the AutoCal feature for an individual analog output, press. 100 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.2.2. Automatic Calibration of the Analog Outputs To calibrate the outputs as a group with the AOUTS CALIBRATION command, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: NOTE Before performing this procedure, make sure that the AUTO CAL for each analog output (See Section 7.4.2.1) NOTE: Manual calibration should be used for any analog output set for a 0.1V output range or in cases where the outputs must be closely matched to the characteristics of the recording device. 04315 Rev. C1 101 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual To use the AUTO CAL feature to initiate an automatic calibration for an individual analog output, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: 102 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.2.3. Manual Calibration of the Analog Outputs configured for Voltage Ranges For highest accuracy, the voltages of the analog outputs can be manually calibrated. NOTE: The menu for manually adjusting the analog output signal level will only appear if the AUTO-CAL feature is turned off for the channel being adjusted (See Section 7.4.2.1). Calibration is performed with a voltmeter connected across the output terminals and by changing the actual output signal level using the front panel keys in 100, 10 or 1 count increments. See Figure 3-7 for pin assignments and diagram of the analog output connector. V +DC Figure 7-5: Gnd Setup for Calibrating An Table 7-7: Voltage Tolerances for the TEST CHANNEL Calibration 04315 Rev. C1 FULL SCALE ZERO TOLERANCE SPAN VOLTAGE SPAN TOLERANCE MINIMUM ADJUSTMENT (1 count) 0.1 VDC ±0.0005V 90 mV ±0.001V 0.02 mV 1 VDC ±0.001V 900 mV ±0.001V 0.24 mV 5 VDC ±0.002V 4500 mV ±0.003V 1.22 mV 10 VDC ±0.004V 4500 mV ±0.006V 2.44 mV 103 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual To adjust the signal levels of an analog output channel manually, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: From the AIO CONFIGURATION SUBMENU (See figure 7-4) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO SET> DISPLAYED AS CONC_OUT_1 CONC_OUT_2 TEST OUTPUT = CHANNEL = A1 = A2 = A4 ENTR EXIT AOUTS CALIBRATED: NO CAL EXIT Continue pressing SET> until you reach the output to be configured DIAG AIO CONC_OUT_2: 5V, CONC2, NOCAL EDIT DIAG AIO EXIT CONC_OUT_2: RANGE: 5V SET> EDIT EXIT Continue pressing SET> until ... DIAG AIO CONC_OUT_2: CALIBRATED:NO CAL DIAG AIO These keys increase / decrease the analog output signal level (not the value on the display) by 100, 10 or 1 counts. Continue adjustments until the voltage measured at the output of the analyzer and/or the input of the recording device matches the value in the upper right hand corner of the display (within the tolerances listed in Table 7-7 CONC_OUT_2: VOLT-Z: 0 mV U100 UP10 UP DIAG AIO These menu’s only appear if AUTO-CAL is turned OFF DOWN DN10 D100 ENTR EXIT CONC_OUT_2: CALIBRATED: YES CAL 104 DOWN DN10 D100 ENTR EXIT CONC_OUT_2: VOLT-S: 4500 mV U100 UP10 UP DIAG AIO EXIT EXIT 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.2.4. Manual Adjustment of Current Loop Output Span and Offset A current loop option may be purchased for the A1 and A2 Analog outputs of the analyzer. This option places circuitry in series with the output of the D-to A converter on the motherboard that changes the normal DC voltage output to a 0-20 milliamp signal. The outputs can be ordered scaled to any set of limits within that 0-20 mA range, however most current loop applications call for either 0-20 mA or 4-20mA range spans. All current loop outputs have a + 5% over range. Ranges whose lower limit is set above 1 mA also have a –5 under range. To switch an analog output from voltage to current loop, follow the instructions in Section 7.4.3 and select CURR from the list of options on the “Output Range” menu. Adjusting the signal zero and span levels of the current loop output is done by raising or lowering the voltage output of the D-to-A converter circuitry on the analyzer’s motherboard. This raises or lowers the signal level produced by the Current Loop Option circuitry. The software allows this adjustment to be made in 100, 10 or 1 count increments. Since the exact amount by which the current signal is changed per D-to-A count varies from output-to-output and instrument–to–instrument, you will need to measure the change in the signal levels with a separate, current meter placed in series with the output circuit. See Figure 3-7 for pin assignments and diagram of the analog output connector. Figure 7-6: Setup for Checking Current Output Signal Levels CAUTION General Safety Hazard DO NOT EXCEED 60 V PEAK VOLTAGE BETWEEN CURRENT LOOP OUTPUTS AND INSTRUMENT GROUND. 04315 Rev. C1 105 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual To adjust the zero and span signal levels of the current outputs, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: From the AIO CONFIGURATION SUBMENU (See figure 7-4) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO SET> DISPLAYED AS CONC_OUT_1 CONC_OUT_2 TEST OUTPUT = CHANNEL = A1 = A2 = A4 ENTR EXIT AOUTS CALIBRATED: NO CAL EXIT Continue pressing SET> until you reach the output to be configured DIAG AIO CONC_OUT_2: 5V, CONC2, NOCAL EDIT DIAG AIO EXIT CONC_OUT_2: RANGE: CURR SET> EDIT EXIT Continue pressing SET> until ... DIAG AIO CONC_OUT_2: CALIBRATED:NO CAL DIAG AIO These keys increase / decrease the analog output signal level (not the value on the display) by 100, 10 or 1 counts. Continue adjustments until the voltage measured at the output of the analyzer and/or the input of the recording device matches the value in the upper right hand corner of the display (within the tolerances listed in Table 7-7 CONC_OUT_2: CURR-Z: 0 mV U100 UP10 UP DIAG AIO These menu’s only appear if AUTO-CAL is turned OFF DOWN DN10 D100 ENTR EXIT CONC_OUT_2: CALIBRATED: YES CAL 106 DOWN DN10 D100 ENTR EXIT CONC_OUT_2: CURR-S: 5000 mV U100 UP10 UP DIAG AIO EXIT EXIT 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer An alternative method for setting up the Current Loop outputs is to connect a 250 ohm 1% resistor across the current loop output in lieu of the current meter (see Figure 3-7 for pin assignments and diagram of the analog output connector). Using a voltmeter connected across the resistor follow the procedure above but adjust the output for the following values: V +DC Gnd V OUT + Volt Meter V IN + 250 Ω Figure 7-7: V OUT - V IN - ANALYZER Recording Device Alternative Setup Using 250Ω Resistor for Checking Current Output Signal Levels Table 7-8: Current Loop Output Check % FS Voltage across Resistor for 2-20 mA Voltage across Resistor for 4-20 mA 0 0.5 VDC 1 VDC 100 5.0 5.0 04315 Rev. C1 107 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.4.3. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION In its standard configuration the analog outputs is set to output a 0 – 5 VDC signals. Several other output ranges are available (see Table 7-9). Each range has is usable from -5% to + 5% of the rated span. Table 7-9: Analog Output Voltage Range Min/Max RANGE NAME RANGE SPAN MINIMUM OUTPUT MAXIMUM OUTPUT 0.1V 0-100 mVDC -5 mVDC 105 mVDC 1V 0-1 VDC -0.05 VDC 1.05 VDC 5V 0-5 VDC -0.25 VDC 5.25 VDC 10V 0-10 VDC -0.5 VDC 10.5 VDC 0 mA 20 mA The default offset for all VDC ranges is 0 VDC. CURR 0-20 mA While these are the physical limits of the current loop modules, typical applications use 2-20 or 4-20 mA for the lower and upper limits. Please specify desired range when ordering this option. The default offset for all current ranges is 0 mA. To change the output type and range, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press, 108 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.4. TURNING AN ANALOG OUTPUT OVER-RANGE FEATURE ON/OFF In its default configuration, a ± 5% over-range is available on each of the M400E’s analog outputs. This overrange can be disabled if your recording device is sensitive to excess voltage or current. To turn the over-range feature on or off, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press 04315 Rev. C1 109 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual 7.4.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT Some analog signal recorders require that the zero signal is significantly different from the baseline of the recorder in order to record slightly negative readings from noise around the zero point. This can be achieved in the M400E by defining a zero offset, a small voltage (e.g., 10% of span). To add a zero offset to a specific analog output channel, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: 110 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4 The test functions available to be reported are: Table 7-10: Test Channels Functions available on the M400E’s Analog Output TEST CHANNEL NONE DESCRIPTION ZERO FULL SCALE TEST CHANNEL IS TURNED OFF PHOTO MEAS The raw output of the photometer during its measure cycle 0 mV 5000 mV* PHOTO REF The raw output of the photometer during its reference cycle 0 mV 5000 mV* O3 GEN REF The raw output of the O3 generator’s reference detector 0 mV 5000 mV* The pressure of gas in the photometer absorption tube 0 "Hg 40 "Hg-In-A SAMPLE PRESSURE SAMPLE FLOW The gas flow rate through the photometer 3 0 cm /min 1000 cm3/min SAMPLE TEMP The temperature of gas in the photometer absorption tube 0 C 70 C PHOTO LAMP TEMP The temperature of the photometer UV lamp 0 C 70 C O3 SCRUB TEMP The temperature of the optional Metal Wool Scrubber. 0 C 70 C O3 LAMP TEMP The temperature of the IZS Option’s O3 generator UV lamp 0 mV 5000 mV CHASSIS TEMP The temperature inside the M400E’s chassis (same as BOX TEMP) 0 C 70 C Once a function is selected, the instrument not only begins to output a signal on the analog output, but also adds TEST to the list of test functions viewable via the front panel display. 04315 Rev. C1 111 Advanced FEATURES of the M400E analyzer M400E Ozone Analyzer Operator’s Manual To activate the TEST Channel and select a function, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X 8 Toggle these keys to enter the correct PASSWORD EXIT DIAG EXIT ENTER PASSWORD:818 1 DIAG 8 ENTR EXIT SIGNAL I/O PREV NEXT ENTR EXIT Continue pressing NEXT until ... DIAG PREV NEXT DIAG PREV NEXT Toggle these keys to choose a mass flow controller TEST channel parameter DIAG PREV NEXT TEST CHAN OUTPUT ENTR EXIT TEST CHAN:NONE ENTR EXIT TEST CHANNEL:CHASSIS TEMP ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 112 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Advanced FEATURES of the M400E analyzer 7.4.7. AIN CALIBRATION This is the sub-menu to conduct a calibration of the M400E analyzer’s analog inputs. This calibration should only be necessary after major repair such as a replacement of CPU, motherboard or power supplies. To perform an analog input calibration, l, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4) then press: From the AIO CONFIGURATION SUBMENU (See Figure 7-4) DIAG ANALOG I/O CONFIGURATION PREV NEXT ENTR DIAG AIO AOUTS CALIBRATED: NO EXIT EXIT Continue pressing SET> until you reach the output to be configured DIAG AIO CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X ID Toggle these keys to cycle through the available Baud rates: 300 1200 4800 9600 19200 38400 57600 115200 EXIT COMMUNICATIONS MENU EXIT COM1 MODE:0 SET> EDIT SETUP X.X EDIT SETUP X.X EXIT COM1 BAUD RATE:19200 PREV NEXT SETUP X.X PREV NEXT ENTR EXIT COM1 BAUD RATE:19200 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 118 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.1.4. COMM PORT COMMUNICATION MODES Each of the analyzer’s serial ports can be configured to operate in a number of different modes, listed in Table 8-1. As modes are selected, the analyzer sums the mode ID numbers and displays this combined number on the front panel display. For example, if quiet mode (01), computer mode (02) and Multi-Drop-Enabled mode (32) are selected, the analyzer would display a combined MODE ID of 35. Table 8-1: COMM Port Communication Modes MODE1 ID 1 QUIET DESCRIPTION Quiet mode suppresses any feedback from the analyzer (such as warning messages) to the remote device and is typically used when the port is communicating with a computer program where such intermittent messages might cause communication problems. Such feedback is still available but a command must be issued to receive them. COMPUTER 2 Computer mode inhibits echoing of typed characters and is used when the port is communicating with a computer operated control program. SECURITY 4 When enabled, the serial port requires a password before it will respond. The only command that is active is the help screen (? CR). When turned on this mode switches the COM port settings from 2048 E, 7, 1 No parity; 8 data bits; 1 stop bit to Even parity; 7 data bits; 1 stop bit RS-485 1024 Configures the COM2 Port for RS-485 communication. RS-485 mode has precedence over multidrop mode if both are enabled. MULTIDROP PROTOCOL 32 Multidrop protocol allows a multi-instrument configuration on a single communications channel. Multidrop requires the use of instrument IDs. ENABLE MODEM 64 Enables to send a modem initialization string at power-up. Asserts certain lines in the RS-232 port to enable the modem to communicate. ERROR CHECKING2 128 Fixes certain types of parity errors at certain Hessen protocol installations. XON/XOFF HANDSHAKE2 256 Disables XON/XOFF data flow control also known as software handshaking. HARDWARE HANDSHAKE 8 HARDWARE FIFO2 512 COMMAND PROMPT 4096 Enables CTS/RTS style hardwired transmission handshaking. This style of data transmission handshaking is commonly used with modems or terminal emulation protocols as well as by Teledyne Instrument’s APICOM software. Disables the HARDWARE FIFO (First In – First Out), When FIFO is enabled it improves data transfer rate for that COM port. Enables a command prompt when in terminal mode. 1 Modes are listed in the order in which they appear in the SETUP MORE COMM COM[1 OR 2] MODE menu 2 The default setting for this feature is ON. Do not disable unless instructed to by Teledyne Instruments Customer Service personnel. Note Communication Modes for each COM port must be configured independently. 04315 Rev. C1 119 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual Press the following keys to select communication modes for a one of the COMM Ports, such as the following example where RS-485 mode is enabled: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X ID PREV EXIT COMMUNICATIONS MENU EXIT Combined Mode ID displayed here COM1 MODE:0 EXIT COM1 QUIET MODE:OFF NEXT OFF EXIT Continue pressing NEXT until ... SETUP X.X Activate / Deactivate the Selected mode by toggling the ON / OFF key DIAG SET> EDIT SETUP X.X Use the PREV and NEXT Keys to between the available modes SECONDARY SETUP MENU COM1 COM2 SETUP X.X CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X ID SECONDARY SETUP MENU DIAG EXIT COMMUNICATIONS MENU COM1 COM2 SETUP X.X EDIT EXIT Continue pressing until ... SETUP X.X TEST SETUP X.X TRANSMITTING TO COM1 SETUP X.X COM1: TEST PORT PREV NEXT OFF 04315 Rev. C1 ENTR EXIT EXIT 121 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.1.6. MACHINE ID Each type of Teledyne Instruments’ analyzer is configured with a default ID code. The default ID code for all M400E analyzers is 700. The ID number is only important if more than one analyzer is connected to the same communications channel such as when several analyzers are on the same Ethernet LAN (See Section 8.4); in a RS-232 multidrop chain (See Section 8.2.1) or operating over a RS-485 network (See Section 8.3). If two analyzers of the same model type are used on one channel, the ID codes of one or both of the instruments needs to be changed so To edit the instrument’s ID code, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X ID Toggle these keys to cycle through the available character set: 0-7 SECONDARY SETUP MENU DIAG EXIT COMMUNICATIONS MENU COM1 COM2 SETUP X.X 0 EXIT 4 EXIT MACHINE ID:400 ID 0 0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting The ID number is only important if more than one analyzer is connected to the same communications channel (e.g., a multi-drop setup). Different models of Teledyne Instruments’ analyzers have different default ID numbers, but if two analyzers of the same model type are used on one channel (for example, two M400E’s), the ID of one instrument needs to be changed. The ID can also be used for to identify any one of several analyzers attached to the same network but situated in different physical locations. 122 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.1.7. TERMINAL OPERATING MODES The M400E can be remotely configured, calibrated or queried for stored data through the serial ports. As terminals and computers use different communication schemes, the analyzer supports two communicate modes specifically designed to interface with these two types of devices. Computer mode is used when the analyzer is connected to a computer with a dedicated interface program. Interactive mode is used with a terminal emulation programs such as HyperTerminal or a “dumb” computer terminal. The commands that are used to operate the analyzer in this mode are listed in Table 8-2. 8.1.7.1. Help Commands in Terminal Mode Table 8-2: Terminal Mode Software Commands COMMAND Control-T Switches the analyzer to terminal mode (echo, edit). If mode flags 1 & 2 are OFF, the interface can be used in interactive mode with a terminal emulation program. Control-C Switches the analyzer to computer mode (no echo, no edit). CR (carriage return) BS (backspace) 04315 Rev. C1 Function A carriage return is required after each command line is typed into the terminal/computer. The command will not be sent to the analyzer to be executed until this is done. On personal computers, this is achieved by pressing the ENTER key. Erases one character to the left of the cursor location. ESC (escape) Erases the entire command line. ?[ID] CR This command prints a complete list of available commands along with the definitions of their functionality to the display device of the terminal or computer being used. The ID number of the analyzer is only necessary if multiple analyzers are on the same communications line, such as the multi-drop setup. Control-C Pauses the listing of commands. Control-P Restarts the listing of commands. 123 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.1.7.2. Command Syntax Commands are not case-sensitive and all arguments within one command (i.e. ID numbers, keywords, data values, etc.) must be separated with a space character. All Commands follow the syntax: X [ID] COMMAND Where X is the command type (one letter) that defines the type of command. Allowed designators are listed in Table 8-3 and Appendix A-6. [ID] is the machine identification number (Section8.1.6). Example: the Command “? 700” followed by a carriage return would print the list of available commands for the revision of software currently installed in the instrument assigned ID Number 700. COMMAND is the command designator: This string is the name of the command being issued (LIST, ABORT, NAME, EXIT, etc.). Some commands may have additional arguments that define how the command is to be executed. Press ? or refer to Appendix A-6 for a list of available command designators. is a carriage return. All commands must be terminated by a carriage return (usually achieved by pressing the ENTER key on a computer). Table 8-3: Teledyne Instruments Serial I/O Command Types COMMAND COMMAND TYPE C Calibration D Diagnostic L Logon T Test measurement V Variable W Warning 8.1.7.3. Data Types Data types consist of integers, hexadecimal integers, floating-point numbers, Boolean expressions and text strings. 124 Integer data are used to indicate integral quantities such as a number of records, a filter length, etc. They consist of an optional plus or minus sign, followed by one or more digits. For example, +1, -12, 123 are all valid integers. Hexadecimal integer data are used for the same purposes as integers. They consist of the two characters “0x,” followed by one or more hexadecimal digits (0-9, A-F, a-f), which is the ‘C’ programming language convention. No plus or minus sign is permitted. For example, 0x1, 0x12, 0x1234abcd are all valid hexadecimal integers. 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E Floating-point numbers are used to specify continuously variable values such as temperature set points, time intervals, warning limits, voltages, etc. They consist of an optional plus or minus sign, followed by zero or more digits, an optional decimal point and zero or more digits. (At least one digit must appear before or after the decimal point.) Scientific notation is not permitted. For example, +1.0, 1234.5678, 0.1, 1 are all valid floating-point numbers. Boolean expressions are used to specify the value of variables or I/O signals that may assume only two values. They are denoted by the keywords ON and OFF. Text strings are used to represent data that cannot be easily represented by other data types, such as data channel names, which may contain letters and numbers. They consist of a quotation mark, followed by one or more printable characters, including spaces, letters, numbers, and symbols, and a final quotation mark. For example, “a”, “1”, “123abc”, and “()[]<>” are all valid text strings. It is not possible to include a quotation mark character within a text string. Some commands allow you to access variables, messages, and other items. When using these commands, you must type the entire name of the item; you cannot abbreviate any names. 8.1.7.4. Status Reporting Reporting of status messages as an audit trail is one of the three principal uses for the RS-232 interface (the other two being the command line interface for controlling the instrument and the download of data in electronic format). You can effectively disable the reporting feature by setting the interface to quiet mode (Section 8.1.4, Table 8-1). Status reports include warning messages, calibration and diagnostic status messages. Refer to Appendix A-3 for a list of the possible messages, and this for information on controlling the instrument through the RS-232 interface. General Message Format All messages from the instrument (including those in response to a command line request) are in the format: X DDD:HH:MM [Id] MESSAGE Where: X is a command type designator, a single character indicating the message type, as shown in the Table 8-3. DDD:HH:MM is the time stamp, the date and time when the message was issued. It consists of the Day-of-year (DDD) as a number from 1 to 366, the hour of the day (HH) as a number from 00 to 23, and the minute (MM) as a number from 00 to 59. [ID] is the analyzer ID, a number with 1 to 4 digits. MESSAGE is the message content that may contain warning messages, test measurements, variable values, etc. is a carriage return / line feed pair, which terminates the message. The uniform nature of the output messages makes it easy for a host computer to parse them into an easy structure. Keep in mind that the front panel display does not give any information on the time a message was issued, hence it is useful to log such messages for trouble-shooting and reference purposes. Terminal emulation programs such as HyperTerminal can capture these messages to text files for later review. 04315 Rev. C1 125 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.1.7.5. COMM Port Password Security In order to provide security for remote access of the M400E, a LOGON feature can be enabled to require a password before the instrument will accept commands. This is done by turning on the SECURITY MODE (Mode 4, Section 8.1.4). Once the SECURITY MODE is enabled, the following items apply. A password is required before the port will respond or pass on commands. If the port is inactive for one hour, it will automatically logoff, which can also be achieved with the LOGOFF command. Three unsuccessful attempts to log on with an incorrect password will cause subsequent logins to be disabled for 1 hour, even if the correct password is used. If not logged on, the only active command is the '?' request for the help screen. The following messages will be returned at logon: LOGON SUCCESSFUL - Correct password given LOGON FAILED - Password not given or incorrect LOGOFF SUCCESSFUL - Connection terminated successfully To log on to the M400E analyzer with SECURITY MODE feature enabled, type: LOGON 940331 940331 is the default password. To change the default password, use the variable RS232_PASS issued as follows: V RS232_PASS=NNNNNN Where N is any numeral between 0 and 9. 126 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.2. REMOTE ACCESS BY MODEM The M400E can be connected to a modem for remote access. This requires a cable between the analyzer’s COM port and the modem, typically a DB-9F to DB-25M cable (available from Teledyne Instruments with part number WR0000024). Once the cable has been connected, check to make sure: The DTE-DCE is in the DCE position. The M400E COM port is set for a baud rate that is compatible with the modem, The Modem is designed to operate with an 8-bit word length with one stop bit. The MODEM ENABLE communication mode is turned ON (Mode 64, see Section 8.1.4). Once this is completed, the appropriate setup command line for your modem can be entered into the analyzer. The default setting for this feature is AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 This string can be altered to match your modem’s initialization and can be up to 100 characters long. To change this setting press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X.X EDIT EXIT SECONDARY SETUP MENU DIAG EXIT SETUP X.X COMMUNICATIONS MENU COM1 COM2 Continue pressing until ... EXIT keys move the cursor left and right along the text string The INS and CH> key inserts a new character before the cursor position 04315 Rev. C1 COM1 PORT INIT:AT Y0 &DO &H &I0 SET> EDIT EXIT COM1 PORT INIT:AT Y0 &DO &H &I0 INS DEL [A] ENTR EXIT EXIT discards the new setting ENTR accepts the new setting The DEL deletes character at the cursor position Toggle this key to cycle through the available character set: Alpha: A-Z (Upper and Lower Case); Special Characters: space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } < > | ; : , . / ? Numerals: 0-9 127 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual To initialize the modem press: 128 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.2.1. MULTIDROP RS-232 SET UP The RS-232 multidrop consists of a printed circuit assembly that plugs onto the CN3, CN4 and CN5 connectors of the CPU card and the cabling to connect it to the analyzer’s motherboard. This PCA includes all circuitry required to enable your analyzer for multidrop operation. It converts the instrument’s COM1 port to multidrop configuration allowing up to eight Teledyne Instruments’ E-Series analyzers or E-Series analyzers to be connected the same I/O port of the host computer. Because both of the DB9 connectors on the analyzer’s back panel are needed to construct the multidrop chain, COM2 is no longer available for separate RS-232 or RS-485 operation; however, with the addition of an Ethernet Option (option 63, See Section 5.7.3 and 8.4) the COM2 port is available for communication over a 10BaseT LAN. JP2 Rear Panel CPU Card (as seen from inside) Cable to Ethernet Card Multidrop PCA Cable to Motherboard Figure 8-3: Location of JP2 on RS232-Multidrop PCA (option 62) Each analyzer or analyzer in the multidrop chain must have: One Teledyne Instruments Option 62 installed. One 6’ straight-through, DB9 male DB9 Female cable (Teledyne Instruments P/N WR0000101) is required for each analyzer. To set up the network, for each instrument: 1. Turn the instrument on and change its MACHINE ID code to a unique 4-digit number. 2. Remove the top cover of the instrument and locate JP2 on the multidrop PCA (7-4) 3. Make sure that the jumpers are in place connection pins 9 10 and 11 12. 4. If the instrument is to be the last instrument on the chain, make sure a jumper is in place connecting pins 21 22. 5. If you are adding an instrument to the end of an already existing chain, do not forget to remove JP2, pins 21 22 on the multidrop PCA on the instrument that was previously the last instrument in the chain. 6. Close the instrument. 7. Using straight-through, DB9 male DB9 Female cables interconnect the host and the analyzers as shown in Figure 8-4. 04315 Rev. C1 129 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual NOTE: Teledyne Instruments recommends setting up the first link, between the Host and the first instrument and testing it before setting up the rest of the chain. KEY: Host Female DB9 RS-232 port Male DB9 CALIBRATOR CALIBRATOR TAPI Analyzer COM2 COM2 COM2 Last INSTRUMENT COM2 RS-232 RS-232 RS-232 RS-232 Make Sure Jumper between JP2 pins 21 22 is installed. Figure 8-4: 130 RS232-Multidrop PCA Host/Analyzer Interconnect Diagram 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.3. RS-485 CONFIGURATION OF COM2 As delivered from the factory, COM2 is configured for RS-232 communications. This port can be re-configured for operation as a non-isolated, half-duplex RS-485 port capable of supporting up to 32 instruments with a maximum distance between the host and the furthest instrument being 4000 feet. If you require full duplex or isolated operation, please contact Teledyne Instruments Customer Service. To reconfigure COM2 as an RS-285 port set switch 6 of SW1 to the ON position (see Figure 8-7). The RS-485 port can be configured with or without a 150 Ω termination resistor. To include the resistor, install jumper at position JP3 on the CPU board (see Figure 8-7). To configure COM2 as an unterminated RS-485 port leave JP3 open. CN4 JP3 COM2 – RS-232 CN3 COM1 – RS-232 CN5 COM2 – RS-485 SW1 Pin 6 Figure 8-5: 04315 Rev. C1 CPU card Locations of RS-232/485 Switches, Connectors and Jumpers 131 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual When COM2 is configured for RS-485 operation the port uses the same female DB-9 connector on the back of the instrument as when Com2 is configured for RS-232 operation, however, the pin assignments are different. Female DB-9 (COM2) (As seen from outside analyzer) RX/TXGND RX/TX+ 1 2 6 3 7 4 8 5 9 (RS-485) Figure 8-6: Back Panel connector Pin-Outs for COM2 in RS-485mode. The signal from this connector is routed from the motherboard via a wiring harness to a 6-pin connector on the CPU card, CN5. CN5 (Located on CPU card) RX/TXGND RX/TX+ 2 4 6 1 3 5 (As seen from inside analyzer) Figure 8-7: CPU connector Pin-Outs for COM2 in RS-485 mode. NOTE: The DCE/DTE switch has no effect on COM2. 132 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.4. REMOTE ACCESS VIA THE ETHERNET When equipped with the optional Ethernet interface, the analyzer can be connected to any standard 10BaseT Ethernet network via low-cost network hubs, switches or routers. The interface operates as a standard TCP/IP device on port 3000. This allows a remote computer to connect through the internet to the analyzer using APICOM, terminal emulators or other programs. The firmware on board the Ethernet card automatically sets the communication modes and baud rate (115,200 kBaud) for the COM2 port. Once the Ethernet option is installed and activated, the COM2 submenu is replaced by a new submenu, INET. This submenu is used to manage and configure the Ethernet interface with your LAN or Internet Server(s). The card has four LEDs that are visible on the rear panel of the analyzer, indicating its current operating status. Table 8-4: Ethernet Status Indicators LED FUNCTION LNK (green) ON when connection to the LAN is valid. ACT (yellow) Flickers on any activity on the LAN. TxD (green) Flickers when the RS-232 port is transmitting data. RxD (yellow) Flickers when the RS-232 port is receiving data. 8.4.1. ETHERNET CARD COM2 COMMUNICATION MODES AND BAUD RATE The firmware on board the Ethernet card automatically sets the communication modes for the COM2 port. The baud rate is also automatically set at 115 200 kBaud. 8.4.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP The Ethernet option for you M400E uses Dynamic Host Configuration Protocol (DHCP) to configure its interface with your LAN automatically. This requires your network servers also be running DHCP. The analyzer will do this the first time you turn the instrument on after it has been physically connected to your network. Once the instrument is connected and turned on, it will appear as an active device on your network without any extra set up steps or lengthy procedures. NOTE It is a good idea to check the INET settings the first time you power up your analyzer after it has been physically connected to the LAN/Internet to make sure that the DHCP has successfully downloaded the appropriate information from you network server(s). The Ethernet configuration properties are viewable via the analyzer’s front panel. 04315 Rev. C1 133 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual Table 8-5: LAN/Internet Configuration Properties PROPERTY DEFAULT STATE DESCRIPTION This displays whether the DHCP is turned ON or OFF. DHCP STATUS On Editable INSTRUMENT IP ADDRESS Configured by DHCP EDIT key disabled when DHCP is ON This string of four packets of 1 to 3 numbers each (e.g. 192.168.76.55.) is the address of the analyzer itself. GATEWAY IP ADDRESS Configured by DHCP EDIT key disabled when DHCP is ON A string of numbers very similar to the Instrument IP address (e.g. 192.168.76.1.) that is the address of the computer used by your LAN to access the Internet. SUBNET MASK TCP PORT HOST NAME 1 Configured by DHCP EDIT key disabled when DHCP is ON 3000 Editable, but DO NOT CHANGE M400E Editable Also, a string of four packets of 1 to 3 numbers each (e.g. 255.255.252.0) that defines that identifies the LAN to which the device is connected. All addressable devices and computers on a LAN must have the same subnet mask. Any transmissions sent devices with different subnet masks are assumed to be outside of the LAN and are routed through a different gateway computer onto the Internet. This number defines the terminal control port by which the instrument is addressed by terminal emulation software, such as Internet or Teledyne Instruments’ APICOM. The name by which your analyzer will appear when addressed from other computers on the LAN or via the Internet. While the default setting for all Teledyne Instruments M400E analyzers is “M400E”, the host name may be changed to fit customer needs. Do not change the setting for this property unless instructed to by Teledyne Instruments Customer Service personnel. NOTE If the gateway IP, instrument IP and the subnet mask are all zeroes (e.g. “0.0.0.0”), the DCHP was not successful in which case you may have to configure the analyzer’s Ethernet properties manually. See your network administrator. 134 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E To view the above properties listed in Table 8-5, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X ID ADDR 1 EXIT COMMUNICATIONS MENU INET SETUP X.X 8 EXIT EXIT ENTER PASSWORD:818 8 SETUP X.X ENTR EXIT DHCP:ON EDIT EDIT key is disabled when DHCP is ON SETUP X.X SETUP X.X SETUP X.X EXIT SUBNET MASK IP:0.0.0.0 DO NOT alter unless instructed to by Teledyne Instruments’ customer Service personnel SETUP X.X EXIT TCP PORT:3000 EDIT SETUP X.X EXIT HOSTNAME: TMS 9000 EDIT EXIT SETUP X.X INITIALIZING INET 0% INITIALIZATION process proceeds automatically SETUP X.X INITIALIZATION SUCCEEDED SETUP X.X ID ADDR 04315 Rev. C1 SETUP X.X INITIALIZATION FAILED COMMUNICATIONS MENU INET EXIT Contact your IT Network Administrator 135 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.4.2.1. Manually Configuring the Network IP Addresses There are several circumstances when you may need to configure the interface settings of the analyzer’s Ethernet card manually. The INET sub-menu may also be used to edit the Ethernet card’s configuration properties Your LAN is not running a DHCP software package, The DHCP software is unable to initialize the analyzer’s interface; You wish to program the interface with a specific set of IP addresses that may not be the ones automatically chosen by DHCP. Editing the Ethernet Interface properties is a two-step process. STEP 1: Turn DHCP OFF: While DHCP is turned ON, the ability to set the INSTRUMENT IP, GATEWAY IP and SUBNET MASK manually is disabled 136 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing: Internet Configuration Keypad Functions From Step 1 above) SETUP X.X DHCP: OFF SET> EDIT SETUP X.X EXIT FUNCTION [0] Press this key to cycle through the range of numerals and available characters (“0 – 9” & “ . ”) Moves the cursor one character left or right. DEL Deletes a character at the cursor location. ENTR Accepts the new setting and returns to the previous menu. EXIT Ignores the new setting and returns to the previous menu. Some keys only appear as needed. INST IP: 000.000.000.000 EDIT KEY EXIT SETUP X.X Cursor location is indicated by brackets INST IP: [0] 00.000.000 DEL [0] ENTR EXIT SETUP X.X GATEWAY IP: 000.000.000.000 EDIT EXIT SETUP X.X GATEWAY IP: [0] 00.000.000 DEL [?] ENTR EXIT SETUP X.X SUBNET MASK:255.255.255.0 EDIT EXIT SETUP X.X SUBNET MASK:[2]55.255.255.0 SETUP X.X TCP PORT 3000 EDIT ENTR EXIT The PORT number needs to remain at 3000. Do not change this setting unless instructed to by Teledyne Instruments’ Customer Service personnel. SETUP X.X SETUP X.X INITIALIZING INET 0% … INITIALIZING INET 100% INITIALIZATI0N SUCCEEDED SETUP X.X ID 04315 Rev. C1 DEL [?] EXIT INET SETUP X.X INITIALIZATION FAILED Contact your IT Network Administrator COMMUNICATIONS MENU COM1 EXIT 137 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.4.3. CHANGING THE ANALYZER’S HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network. The default name for all Teledyne Instruments M400E analyzers is M400E. To change this name (particularly if you have more than one M400E analyzer on your network), press. SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X ID ADDR EXIT DIAG EXIT SETUP X.X 8 ENTER PASSWORD:818 1 8 SETUP X.X ENTR EXIT DHCP:ON EDIT EXIT COMMUNICATIONS MENU INET EXIT Continue pressing SET> until ... SETUP X.X HOSTNAME: TMS 9000 EDIT KEY Moves the cursor one character to the left. CH> Moves the cursor one character to the right. INS Inserts a character before the cursor location. DEL [?] SETUP X.X FUNCTION EXIT HOSTNAME: TMS 9000 INS DEL [?] ENTR EXIT Deletes a character at the cursor location. Press this key to cycle through the range of numerals and characters available for insertion. 0-9, A-Z, space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } < >\ | ; : , . / ? ENTR Accepts the new setting and returns to the previous menu. EXIT Ignores the new setting and returns to the previous menu. Use these key to edit the HOSTNAME SETUP X.X HOSTNAME: TMS 9K–STACK 2 INS DEL [?] ENTR EXIT Some keys only appear as needed. SETUP X.X ENTR accepts the new setting EXIT ignores the new setting INITIALIZING INET 0% INITIALIZATION process proceeds automatically SETUP X.X INITIALIZATION SUCCEEDED SETUP X.X ID ADDR 138 SETUP X.X INITIALIZATION FAILED COMMUNICATIONS MENU INET EXIT Contact your IT Network Administrator 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.5. USING THE M400E WITH A HESSEN PROTOCOL NETWORK 8.5.1. GENERAL OVERVIEW OF HESSEN PROTOCOL The Hessen protocol is a multidrop protocol, in which several remote instruments are connected via a common communications channel to a host computer. The remote instruments are regarded as slaves of the host computer. The remote instruments are unaware that they are connected to a multidrop bus and never initiate Hessen protocol messages. They only respond to commands from the host computer and only when they receive a command containing their own unique ID number. The Hessen protocol is designed to accomplish two things: to obtain the status of remote instruments, including the concentrations of all the gases measured; and to place remote instruments into zero or span calibration or measure mode. API’s implementation supports both of these principal features. The Hessen protocol is not well defined, therefore while API’s application is completely compatible with the protocol itself, it may be different from implementations by other companies. The following subs describe the basics for setting up your instrument to operate over a Hessen Protocol network. For more detailed information as well as a list of host computer commands and examples of command and response message syntax, download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site: http://www.teledyne-api.com/manuals/index.asp . 8.5.2. HESSEN COMM PORT CONFIGURATION Hessen protocol requires the communication parameters of the M400E’s COMM ports to be set differently than the standard configuration as shown in the table below. Table 8-6: RS-232 Communication Parameters for Hessen Protocol PARAMETER STANDARD HESSEN Baud Rate 300 – 19200 1200 Data Bits 8 7 Stop Bits 1 2 Parity None Even Duplex Full Half To change the baud rate of the M400E’s COMM ports, See Section 8.1.3. To change the rest of the COMM port parameters. See Section 8.1 Note Make sure that the communication parameters of the host computer are also properly set. Also, the instrument software has a 200 ms. latency before it responds to commands issued by the host computer. This latency should present no problems, but you should be aware of it and not issue commands to the instrument too frequently. 04315 Rev. C1 139 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.5.3. ACTIVATING HESSEN PROTOCOL The first step in configuring the M400E to operate over a Hessen protocol network is to activate the Hessen mode for COMM ports and configure the communication parameters for the port(s) appropriately. Press; 140 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.5.4. SELECTING A HESSEN PROTOCOL TYPE Currently there are two versions of Hessen Protocol in use. The original implementation, referred to as TYPE 1, and a more recently released version, TYPE 2 that has more flexibility when operating with instruments that can measure more than one type of gas. For more specific information about the difference between TYPE 1and TYPE 2 download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site: http://www.teledyne-api.com/manuals/index.asp . To select a Hessen Protocol Type press: NOTE While Hessen Protocol Mode can be activated independently for COM1 and COM2, The TYPE selection affects both Ports. 04315 Rev. C1 141 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.5.5. SETTING THE HESSEN PROTOCOL RESPONSE MODE The Teledyne Instruments implementation of Hessen Protocol allows the user to choose one of several different modes of response for the analyzer. Table 8-7: Teledyne Instruments Hessen Protocol Response Modes MODE ID MODE DESCRIPTION CMD This is the Default Setting. Reponses from the instrument are encoded as the traditional command format. Style and format of responses depend on exact coding of the initiating command. BCC Responses from the instrument are always delimited with (at the beginning of the response, (at the end of the response followed by a 2 digit Block Check Code (checksum), regardless of the command encoding. TEXT Responses from the instrument are always delimited with at the beginning and the end of the string, regardless of the command encoding. To Select a Hessen response mode, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X ID DIAG EXIT COMMUNICATIONS MENU HESN COM1 COM2 SETUP X.X EDIT EXIT Continue pressing NEXT until ... SETUP X.X EDIT SETUP X.X BCC Use these keys to choose the Hessen Response type. 142 HESSEN RESPONSE MODE:CMD EXIT HESSEN VARIATION:TYPE1 TEXT CMD ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.5.6. HESSEN PROTOCOL GAS LIST ENTRIES 8.5.6.1. Gas List Entry Format and Definitions The M400E analyzer keeps a list of available gas types. Each entry in this list is of the following format. [GAS TYPE],[RANGE],[GAS ID],[REPORTED] WHERE: GAS TYPE = The type of gas to be reported (e.g O3, CO2, NOx, etc.). In the case of the M400E analyzer, there is only one gas type: O3. RANGE = The concentration range for this entry in the gas list. This feature permits the user to select which concentration range will be used for this gas list entry. The M400E analyzer has two ranges: RANGE1 (LOW) & RANGE2 (HIGH). 0123- The HESSEN protocol to use whatever range is currently active. The HESSEN protocol will always use RANGE1 for this gas list entry The HESSEN protocol will always use RANGE2 for this gas list entry Not applicable to the M400E analyzer. GAS ID = An identification number assigned to a specific gas. In the case of the M400E analyzer, there is only one gas O3, and its default GAS ID is 400. This ID number should not be modified. REPORT = States whether this list entry is to be reported or not reported when ever this gas type or instrument is polled by the HESSEN network. If the list entry is not to be reported this field will be blank. The M400E analyzer is a single gas instrument that measures O3. It’s default gas list consists of only one entry that reads: O3, 0, 400, REPORTED If you wish to have just the last concentration value stored for a specific range this list entry should be edited or additional entries should be added to the list. 04315 Rev. C1 143 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.5.6.2. Editing or Adding HESSEN Gas List Entries To add or edit an entry to the Hessen Gas List, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X ID EDIT EXIT Continue pressing NEXT until ... EDIT SETUP X.X O3, 0, 400, REPORTED PREV MEXT There is only one GAS TYPE available on the M400E: O3 SETUP X.X DEL EDIT PRNT EXIT GAS TYPE:03 0 ENTR EXIT 0 GAS ID:[ID Number] 0 ENTR EXIT SETUP X.X REPORTED:ON ON SETUP X.X PREV MEXT 144 EXIT discards the new setting ENTR accepts the new setting For new list entries this number will be displayed as 000. Toggle this key turn ON/OFF the REPORT attribute EXIT sets the Gas typ too NONE CONC RANGE:0 0 SETUP X.X Toggle these keys to set the GAS ID to 400. INS ENTR EXIT SETUP X.X Toggle this key to set the concentration range for the list entry EXIT ENTR EXIT O3, 0, 400, REPORTED INS DEL EDIT PRNT EXIT 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E 8.5.6.3. Deleting HESSEN Gas List Entries To delete an entry from the Hessen Gas list, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X SECONDARY SETUP MENU COMM VARS SETUP X.X ID EDIT EXIT Continue pressing NEXT until ... SETUP X.X EDIT SETUP X.X PREV MEXT SETUP X.X YES HESSEN GAS LIST EXIT O3, 0, 400, REPORTED INS DEL EDIT PRNT EXIT DELETE? NO DELETED 04315 Rev. C1 145 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.5.7. SETTING HESSEN PROTOCOL STATUS FLAGS Teledyne Instruments’ implementation of Hessen protocols includes a set of status bits that the instrument includes in responses to inform the host computer of its condition. Each bit can be assigned to one operational and warning message flag. The default settings for these bit/flags are: Table 8-8: Default Hessen Status Bit Assignments DEFAULT BIT ASSIGNMENT STATUS FLAG NAME WARNING FLAGS SAMPLE FLOW WARNING 0001 PHOTO REF WARNING 0002 SAMPLE PRESS WARN 0004 SAMPLE TEMP WARN 0008 1 0010 O3 GEN REF WARNING 1 0020 03 GEN LAMP WARNING 03 GEN TEMP WARN 1 2 0040 2 0040 PHOTO TEMP WARNING OPERATIONAL FLAGS In MANUAL Calibration Mode 0200 In ZERO Calibration Mode 0400 In SPAN Calibration Mode 0800 In LO SPAN Calibration Mode 0800 2 2 UNITS OF MEASURE FLAGS UGM 0000 MGM 2000 PPB 4000 PPM 6000 0080, 0100, 1000, 8000 SPARE/UNUSED BITS UNASSIGNED FLAGS (0000) LAMP STABIL WARN LAMP DRIVER WARN 3 O3 SCRUB TEMP WARN FRONT PANEL WARN BOX TEMP WARNING ANALOG CAL WARNING SYSTEM RESET CANNOT DYN ZERO RELAY BOARD WARNING CANNOT DYN SPAN REAR BOARD NOT DETECTED INVALID CONC Instrument is in MP CAL mode 1 2 Only applicable if the IZS option is installed It is possible to assign more than one flag to the same Hessen status bit. This allows the grouping of similar flags, such as all temperature warnings, under the same status bit. Be careful not to assign conflicting flags to the same bit as each status bit will be triggered if any of the assigned flags is active. 3 146 Only applicable if the optional metal wool scrubber is installed 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 357BRemote Operation Of The M400E To assign or reset the status flag bit assignments, press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X COMM VARS SETUP X.X ID SECONDARY SETUP MENU DIAG EXIT COMMUNICATIONS MENU SETUP X.X HESN COM1 COM2 SETUP X.X EDIT EXIT EDIT SETUP X.X EXIT O3 GEN REF WARNING:0010 PREV NEXT Continue pressing NEXT until ... EDIT PRNT EXIT Continue pressing NEXT until desired flag message is displayed SETUP X.X BOX TEMP WARNING:0010 PREV NEXT SETUP X.X The keys move the cursor brackets “[ ]” left and right along the bit string. DEL deletes the character currently inside the cursor brackets. EDIT PRNT EXIT BOX TEMP WARNING:[0]010 INS DEL [0] ENTR EXIT EXIT discards the new setting ENTR accepts the new setting INS Inserts a the character at the current location of the cursor brackets. Press the [?] key repeatedly to cycle through the available character set: 0-9 NOTE: Values of A-F can also be set but are meaningless. 8.5.8. INSTRUMENT ID CODE The M400E analyzer is programmed with a default ID code of 400. Each instrument on a Hessen Protocol network must have a unique ID code. If more than one M400E analyzer is on the Hessen network, you will have to change this code for all but one of the M400E analyzer’s on the Hessen network (see Section 8.1.6). 04315 Rev. C1 147 357BRemote Operation Of The M400E M400E Ozone Analyzer Operator’s Manual 8.6. APICOM REMOTE CONTROL PROGRAM APICOM is an easy-to-use, yet powerful interface program that allows the user to access and control any of Teledyne Instruments’ main line of ambient and stack-gas instruments from a remote connection through direct cable, modem or Ethernet. Running APICOM, a user can: Establish a link from a remote location to the M400E through direct cable connection via RS-232 modem or Ethernet. View the instrument’s front panel and remotely access all functions that could be accessed when standing in front of the instrument. Remotely edit system parameters and set points. Download, view, graph and save data for predictive diagnostics or data analysis. Check on system parameters for trouble-shooting and quality control. APICOM is very helpful for initial setup, data analysis, maintenance and trouble-shooting. Figure 8-8 shows examples of APICOM’s main interface, which emulates the look and functionality of the instruments actual front panel Figure 8-8: APICOM Remote Control Program Interface NOTE APICOM is included free of cost with the analyzer and the latest versions can also be downloaded for free at http://www.teledyne-api.com/software/apicom/. USER NOTES: 148 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9. M400E CALIBRATION PROCEDURES This section contains a variety of information regarding the various methods for calibrating a Model 400E Ozone Analyzer as well as other supporting information. For information on EPA protocol calibration, please refer to Chaoter 10. This section is organized as follows: SECTION 9.1 – BEFORE CALIBRATION This section contains general information you should know before about calibrating the analyzer. SECTION 9.2 – BASIC MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE M400E ANALYZER This section describes the procedure for checking the calibrating and calibrating the instrument with no zero/span valves installed or if installed, not operating. It requires that zero air and span gas is inlet through the SAMPLE port. Also included are instructions for selecting the reporting range to be calibrated when the M400E analyzer is set to operate in either the DUAL range or AUTO range modes. SECTION 9.3 – MANUAL CALIBRATION CHECK AND CALIBRATION WITH VALVE OPTIONS Installed This section describes: The procedure for checking the calibration of the instrument with zero/span valves or the izs option installed and operating but controlled manually through the keypad on the Front Panel of the instrument. The procedure for calibrating of the instrument with zero/span valves and operating but controlled manually through the keypad on the front panel of the instrument. Instructions on activating the zero/span valves via the control in contact closures of the analyzers external digital I/O. SECTION 9.4 – AUTOMATIC ZERO/SPAN Cal/Check (AutoCal) This section describes the procedure for using the AutoCal feature of the analyzer to check or calibrate the instrument. The AutoCal feature requires that either the zero/span valve option or the internal zero/span (IZS) option be installed and operating. SECTION 9.5 – O3 PHOTOMETER Electronic Calibration This section describes how to calibrate inherent electronic offsets that may be affecting the performance of the M400E analyzer’s internal photometer. SECTION 9.6 – CALIBRATION THE IZS Option O3 Generator This section describes how to check the performance of the O3 generator that is included in the IZS option (OPT – 51A; see Section 5.6.2) available for the M400E analyzer. NOTE Throughout this chapter are various diagrams showing pneumatic connections between the M400E and various other pieces of equipment such as calibrators and zero air sources. These diagrams are only intended to be schematic representations of these connections and do not reflect actual physical locations of equipment and fitting location or orientation. Contact your regional EPA or other appropriate governing agency for more detailed recommendations. 04315 Rev. C1 149 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.1. BEFORE CALIBRATION NOTE If any problems occur while performing the following calibration procedures, refer to Chapter 13 of this manual for troubleshooting tips. 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES Calibration of the Model 400E O3 Analyzer requires certain amount of equipment and supplies. These include, but are not limited to, the following: Zero-air source Ozone span gas source Gas lines - All gas lines should be PTFE (Teflon) or FEP A recording device such as a strip-chart recorder and/or data logger (optional) 9.1.2. ZERO AIR AND SPAN GAS To perform the following calibration you must have sources for zero air and span gas available. ZERO AIR is similar in chemical composition to the Earth’s atmosphere but scrubbed of all components that might affect the analyzers readings. For O3 measuring devices, zero air should be: Devoid of O3 and Mercury Vapor, and; Have a dew point of -20C. Devices that condition ambient air by drying and removing any pollutants, such as the Teledyne Instruments’ Model 701 Zero Air Module, are ideal for producing Zero Air. SPAN GAS is a gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range. It is recommended that the span gas used have a concentration equal to 80% of the full measurement range. EXAMPLE: If the application is to measure between 0 ppm and 500 ppb, an appropriate span gas would be 400 ppb. EXAMPLE: If the application is to measure between 0 ppb and 1000 ppb, an appropriate Span Gas would be 800 ppb. Because of the instability of O3, it is impractical, if not impossible, to produce stable concentrations of bottled, pressurized O3. Therefore, when varying concentrations of O3 is required for span calibrations they must be generated locally. We Recommend using a gas dilution calibrator with a built in O3 generator, such as a Teledyne Instruments’ Model 700E, as a source for O3 span gas. All equipment used to produce calibration gasses should be verified against EPA / NIST traceable standards (see Section 10.1.4). 150 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.2. BASIC MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE M400E ANALYZER ZERO/SPAN CALIBRATION CHECKS VS. ZERO/SPAN CALIBRATION Pressing the ENTR key during the following procedure resets the stored values for OFFSET and SLOPE and alters the instrument’s Calibration. If you wish to perform a ZERO /Span Calibration see Section 9.2.3. 9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION OF THE M400E ANALYZER. Connect the Sources of Zero Air and Span Gas as shown below. Figure 9-1: 04315 Rev. C1 Pneumatic connections for Manual Calibration Checks without Z/S Valve or IZS Options 151 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.2.2. PERFORMING A BASIC MANUAL CALIBRATION CHECK NOTE If the ZERO or SPAN keys are not displayed, the measurement made during is out of the allowable range allowed for a reliable calibration. See Chapter 13 for troubleshooting tips. 152 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION 9.2.3.1. Setting the expected O3 Span Gas concentration NOTE It is important to verify the PRECISE O3 Concentration Value of the SPAN gas independently. SAMPLE CAL SAMPLE ZERO CONC SAMPLE 0 O3= XXXX SETUP O3 SPAN CONC: 400.0 Conc 0 4 0 The O3 span concentration value automatically defaults to 400.0 Conc. 0 .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting Make sure that you input the ACTUAL concentration value of the SPAN Gas. To change this value to meet the actual concentration of the SPAN Gas, enter the number sequence by pressing the key under each digit until the expected value is set. 04315 Rev. C1 153 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.2.3.2. Zero/Span Point Calibration Procedure NOTE If the ZERO or SPAN keys are not displayed, the measurement made during is out of the allowable range allowed for a reliable calibration. See Chapter 13 for troubleshooting tips. 154 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.2.4. MANUAL CALIBRATION CHECKS AND CALIBRATIONS USING AUTO RANGE OR DUAL RANGE MODES If the analyzer is being operated in DUAL range mode or AUTO range mode, then the HIGH and LOW ranges must be independently checked. When the analyzer is in either DUAL or AUTO Range modes, the user must run a separate calibration procedure for each range. After pressing the CAL, CALZ or CALS keys, the user is prompted for the range that is to be calibrated as seen in the CALZ example below: SAMPLE CAL SAMPLE SETUP RANGE=500.0 PPB O3= XXXX TST> CAL buttons until ... SAMPLE CAL CALZ CALS SAMPLE Use these Keys to select the RANGE to be calibrated. LOW = RANGE1; HIGH = RANGE2 O3= XXXX RANGE TO CAL HIGH M-P CAL ENTR STABIL=XXXX PPB O3= XXXX ZERO EXIT O3= XXXX CONC EXIT Continue the Calibration operation as per the standard procedure NOTE Once this selection is made, the calibration procedure continues as described in Section 9.2. The other range may be calibrated by starting over from the main SAMPLE display. 04315 Rev. C1 155 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.3. MANUAL CALIBRATION CHECK AND CALIBRATION WITH VALVE OPTIONS INSTALLED 9.3.1. SETUP FOR CALIBRATION CHECKS AND CALIBRATION WITH VALVE OPTIONS INSTALLED. Enclosure Wall Connect the sources of zero air and span gas as shown in Figure 9-2 and Figure 9-3. 156 04315 Rev. C1 M400E Calibration Procedures Enclosure Wall M400E Ozone Analyzer Operator’s Manual Figure 9-2: Gas Line Connections for the M400E Analyzer with Zero/Span Valve Option (OPT-50A) Figure 9-3: 04315 Rev. C1 Gas Line Connections for the M400E Analyzer with IZS Options (OPT-51A) 157 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS INSTALLED Performing the calibration checks on M400E analyzer’s with the Valve option installed is similar to that described in Section 9.2, except that the ZERO And SPAN calibration operations are initiated directly and independently with dedicated keys (CALZ & CALS). 158 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.3.2. MANUAL CALIBRATION USING VALVE OPTIONS NOTE While the internal Zero Span Option is a convenient tool for performing Calibration Checks, its O3 generator is not stable enough to be used as a source of Zero Air or Span Gas for calibrating the instrument. Calibrations should ONLY be performed using external sources of Zero Air and Span Gas whose accuracy is traceable to EPA or NIST standards. Enclosure Wall On instruments with Z/S valve options, zero air and span gas is supplied to the analyzer through the zero gas and span gas inlets (see Figure 9-2 and the zero and cal operations are initiated directly and independently with dedicated keys (CALZ & CALS). 04315 Rev. C1 159 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.3.2.1. Setting the Expected O3 Span Gas Concentration with the Z/S Option Installed SAMPLE CAL CALZ CALS SAMPLE ZERO CONC SAMPLE 0 O3= XXXX SETUP O3 SPAN CONC: 400.0 Conc 0 4 0 The O3 span concentration value automatically defaults to 400.0 Conc. 0 .0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting Make sure that you input the ACTUAL concentration value of the SPAN Gas. To change this value to meet the actual concentration of the SPAN Gas, enter the number sequence by pressing the key under each digit until the expected value is set. 160 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.3.2.2. Zero/Span Point Calibration Procedure the Z/S Option Installed If the M400E analyzer is set for either the AUTO or DUAL range modes, read Section 9.2.4 before proceeding. SAMPLE CAL CALZ CALS Set the Display to show the STABIL test function. This function calculates the stability of the O3 measurement Toggle TST> button until ... SAMPLE CAL CALZ CALS SETUP Allow zero gas to enter the sample port at the rear of the analyzer. Wait until STABIL falls below 1.0 PPB. This may take several minutes. SAMPLE CAL CALZ CALS M-P CAL STABIL=XXXX PPB ZERO M-P CAL STABIL=XXXX PPB ENTR SETUP O3= XXXX CONC EXIT O3= XXXX CONC EXIT Allow span gas to enter the sample port at the rear of the analyzer. Press ENTR to changes the OFFSET & SLOPE values based on the zero point measurement. Press EXIT to leave the calibration unchanged and return to the previous menu. Wait until STABIL falls below 1.0 PPB. This may take several minutes. SAMPLE The SPAN key now appears during the transition from zero to span. You may see both keys. If either the ZERO or SPAN buttons fail to appear see Section 11 for troubleshooting tips. CAL CALZ CALS M-P CAL STABIL=XXXX PPB ZERO SPAN CONC M-P CAL STABIL=XXXX PPB ENTR M-P CAL CONC STABIL=XXXX PPB ENTR CONC O3= XXXX SETUP O3= XXXX EXIT O3= XXXX EXIT O3= XXXX EXIT Press ENTR to changes the OFFSET & SLOPE values based on the zero point measurement. Press EXIT to leave the calibration unchanged and return to the previous menu. EXIT at this point returns to the SAMPLE menu. NOTE If the ZERO or SPAN keys are not displayed, the measurement made during is out of the allowable range allowed for a reliable calibration. See Chapter 13 for troubleshooting tips. 04315 Rev. C1 161 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.3.2.3. Use of Zero/Span Valve with Remote Contact Closure Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN connector. Instructions for setup and use of these contacts are found in Section 3.3.4. When the contacts are closed for at least 5 seconds, the instrument switches into zero, low span or high span mode and the internal zero/span valves will be automatically switched to the appropriate configuration. The remote calibration contact closures may be activated in any order. It is recommended that contact closures remain closed for at least 10 minutes to establish a reliable reading. The instrument will stay in the selected mode for as long as the contacts remain closed. If contact closures are being used in conjunction with the analyzer’s AutoCal (see Section 9.4) feature and the AutoCal attribute “CALIBRATE” is enabled, the M400E will not re-calibrate the analyzer UNTIL when the contact is opened. At this point, the new calibration values will be recorded before the instrument returns to SAMPLE mode. If the AutoCal attribute “CALIBRATE” is disabled, the instrument will return to SAMPLE mode, leaving the instrument’s internal calibration variables unchanged. 9.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL) The AutoCal system allows unattended periodic operation of the ZERO/SPAN valve options by using the M400E’s internal time of day clock. AutoCal operates by executing SEQUENCES programmed by the user to initiate the various calibration modes of the analyzer and open and close valves appropriately. It is possible to program and run up to three separate sequences (SEQ1, SEQ2 and SEQ3). Each sequence can operate in one of three modes, or be disabled. Table 9-1: AUTOCAL Modes MODE NAME DISABLED ZERO Causes the Sequence to perform a Zero calibration/check. ZERO-LO Causes the Sequence to perform a Zero and Low (Midpoint) Span concentration calibration/check. ZERO-HI Causes the Sequence to perform a Zero and High Span concentration calibration/check. ZERO-LO-HI Causes the Sequence to perform a Zero, Low (Midpoint) Span and High Span concentration calibration/check. LO Causes the Sequence to perform a Low Span concentration calibration/check only. HI Causes the Sequence to perform a High Span concentration calibration/check only. LO-HI 162 ACTION Disables the Sequence. Causes the Sequence to perform a Low (Midpoint) Span and High Span concentration calibration/check but no Zero Point calibration/check. 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures For each mode, there are seven parameters that control operational details of the SEQUENCE. They are: Table 9-2: AutoCal Attribute Setup Parameters ATTRIBUTE NAME Timer Enabled ACTION Turns on the Sequence timer. Starting Date Sequence will operate after Starting Date. Starting Time Time of day sequence will run. Delta Days Number of days to skip between each Seq. execution. Delta Time Number of hours later each “Delta Days” Seq is to be run. Duration Number of minutes the sequence operates. Calibrate Enable to do a calibration – Disable to do a cal check only MUST be set to NO for instruments with IZS Options installed and functioning. The following example sets sequence #2 to do a zero-span calibration every other day starting at 1 Am on September 4, 2001, lasting 15 minutes, without calibration. This will start ½ hour later each iteration. Table 9-3: Example AutoCal Sequence MODE AND ATTRIBUTE VALUE Sequence 2 Mode ZERO-HI COMMENT Define Sequence #2 Select Zero and Span Mode Timer Enable ON Starting Date Sept. 4, 2001 Starting Time 01:00 Delta Days 2 Delta Time 00:30 Duration 15.0 Operate Span valve for 15 min Calibrate NO Do not calibrate at end of Sequence Enable the timer Start after Sept 4, 2001 First Span starts at 1:00AM Do Sequence #2 every other day Do Sequence #2 ½ hr later each day NOTES The programmed STARTING_TIME must be a minimum of 5 minutes later than the real time clock for setting real time clock (See Section 6.4.3). Avoid setting two or more sequences at the same time of the day. Any new sequence that is initiated whether from a timer, the COM ports or the contact closure inputs will override any sequence that is in progress. The CALIBRATE attribute must always be set to NO on analyzers with IZS Options installed and functioning. Calibrations should ONLY be performed using external sources of Zero Air and Span Gas whose accuracy is traceable to EPA or NIST standards 04315 Rev. C1 163 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.4.1. SETUP ACAL: PROGRAMMING AND AUTO CAL SEQUENCE To program the example sequence shown in Table 9-3, press: SAMPLE =XXX.X RANGE = 500.0 PPB O3 SETUP X.X CFG ACAL DAS RNGE PASS CLK MORE EXIT SETUP X.X SEQ 1) DISABLED NEXT MODE SETUP X.X EXIT SEQ 2) DISABLED PREV NEXT MODE SETUP X.X EXIT MODE: DISABLED NEXT SETUP X.X ENTR EXIT MODE: ZERO PREV NEXT SETUP X.X ENTR EXIT MODE: ZERO–LO PREV NEXT SETUP X.X ENTR EXIT MODE: ZERO–HI PREV NEXT SETUP X.X ENTR EXIT SEQ 2) ZERO–HI, 1:00:00 PREV NEXT MODE SET SETUP X.X EXIT TIMER ENABLE: ON SET> EDIT SETUP X.X EXIT STARTING DATE: 01–JAN–02 EDIT Toggle keys to set Day, Month & Year: SETUP X.X 0 4 EXIT STARTING DATE: 01–JAN–02 SEP 0 3 ENTR EXIT Format : DD-MON-YY CONTINUE NEXT PAGE With STARTING TIME 164 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures CONTINUED FROM PREVIOUS PAGE STARTING DATE Toggle keys to set Day, Month & Year: SETUP X.X 0 STARTING DATE: 01–JAN–02 4 SEP 0 3 ENTR EXIT Format : DD-MON-YY SETUP X.X STARTING DATE: 04–SEP–03 EDIT SETUP X.X EXIT STARTING TIME:00:00 EDIT Toggle keys to set time: Format : HH:MM This is a 24 hr clock . PM hours are 13 – 24. Example 2:15 PM = 14:15 SETUP X.X 1 EXIT STARTING TIME:00:00 4 :1 SETUP X.X 5 ENTR STARTING TIME:14:15 EDIT SETUP X.X EXIT DELTA DAYS: 1 EDIT Toggle keys to set number of days between procedures (1-367) SETUP X.X 0 0 EXIT DELTA DAYS: 1 2 SETUP X.X ENTR SETUP X.X EXIT DELTA TIME00:00 EDIT SETUP X.X 0 0 EXIT DELTA TIME: 00:00 :3 SETUP X.X EXIT DELTA DAYS:2 EDIT Toggle keys to set delay time for each iteration of the sequence: HH:MM (0 – 24:00) EXIT 0 ENTR EXIT DELTA TIEM:00:30 EDIT EXIT CONTINUE NEXT PAGE With DURATION TIME 04315 Rev. C1 165 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual CONTINUED FROM PREVIOUS PAGE DELTA TIME SETUP X.X DURATION:15.0 MINUTES EDIT Toggle keys to set duration for each iteration of the sequence: Set in Decimal minutes from 0.1 – 60.0 SETUP X.X 3 0 SETUP X.X EXIT DURATION 15.0MINUTES .0 ENTR DURATION:30.0 MINUTES EDIT SETUP X.X EXIT CALIBRATE: OFF EDIT Toggle key Between Off and ON SETUP X.X Display show: EXIT CALIBRATE: OFF ON SETUP X.X EXIT ENTR EXIT CALIBRATE: ON EDIT EXIT SEQ 2) ZERO–SPAN, 2:00:30 Sequence MODE Delta Time Delta Days SETUP X.X SEQ 2) ZERO–SPAN, 2:00:30 PREV NEXT MODE SET EXIT EXIT returns to the SETUP Menu NOTE If at any time an illegal entry is selected (Example: Delta Days > 367) the ENTR key will disappear from the display. 166 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.5. O3 PHOTOMETER ELECTRONIC CALIBRATION There are several electronic characteristics of the M400E analyzer’s photometer that may occasionally need checking or calibration: 9.5.1. PHOTOMETER DARK CALIBRATION The dark calibration test turns off the photometer UV lampand records any offset signal level of the UV detectorpreamp-voltage to frequency converter circuitry. This allows the instrument to compensate for any voltage levels inherent in the Photometer detection circuit that might affect the output of the detector circuitry and therefore the calculation of O3 concentration. To activate the dark calibration feature, press: 04315 Rev. C1 167 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual 9.5.2. O3 PHOTOMETER GAS FLOW CALIBRATION NOTE A separate flow meter is required for the procedure. To calibrate the flow of gas through the M400E analyzer’s optional photometer bench. 8. Turn OFF the M400E analyzer. 9. Attach the flow meter directly to the SAMPLE inlet port of the analyzer (see Figure 3-2). 10. Turn the analyzer ON. 11. Perform the following steps: 168 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual M400E Calibration Procedures 9.6. CALIBRATION THE IZS OPTION O3 GENERATOR The following procedure calibrates to output of the O3 generator that is included in the IZS calibration valve option ( OPT-51A). This function: Drives the IZS O3 Generator to output a series of O3 levels between zero and full scale; Measures the actual O3 output at each level, and; Records the generator lamp drive voltage and generator’s O3 output level in a lookup table. Whenever a certain O3 output level is requested, the instrument’s CPU uses the data in this table to interpolate the correct drive voltage for the desired O3 output. NOTE Because the instrument waits 5–7 minutes at each step for the O3 level to stabilize, this calibration operation often takes more than one hour to complete. To calibrate the O3 Generator press: SAMPLE CAL SETUP X.X SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUP X.X EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 EXIT ENTER PASSWORD:818 1 ENTR EXIT 8 DIAG SIGNAL I/O ENTR PREV NEXT EXIT Continue pressing NEXT until ... DIAG O3 GEN CALIBRATION PREV NEXT Analyzer returns to the previous menu when the calibration operation is complete DIAG O3GEN PREV NEXT EXIT O3 GEN CAL [X]% COMPLETE PREV NEXT DIAG O3GEN 04315 Rev. C1 ENTR EXIT Display tracks the % of test completes CANCELLED EXIT 169 M400E Calibration Procedures M400E Ozone Analyzer Operator’s Manual USER NOTES: 170 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10. EPA PROTOCOL CALIBRATION In order to insure that high quality, accurate measurement information is obtained at all times, the analyzer must be calibrated prior to use. A quality assurance program centered on this aspect and including attention to the built-in warning features of the analyzer, periodic inspection, regular zero/span checks and routine maintenance is paramount to achieving this. The US EPA strongly recommends that you obtain a copy of the publication Quality Assurance Handbook for Air Pollution Measurement Systems (abbreviated, Q.A. Handbook Volume II); USEPA Order Number: EPA454R98004; or NIST Order Number: PB99-129876. This manual can be purchased from: EPA Technology Transfer Network (http://www.epa.gov/ttn/amtic) National Technical Information Service (NTIS, http://www. ntis.gov/) A bibliography and references relating to O3 monitoring are listed in Section 10.6. 10.1.1. M400E CALIBRATION – GENERAL GUIDELINES Calibration is the process of adjusting the gain and offset of the M400A against some recognized standard. The reliability and usefulness of all data derived from any analyzer depends primarily upon its state of calibration. In this section, the term dynamic calibration is used to express a multipoint check against known standards and involves introducing gas samples of known concentration into the instrument in order to adjust the instrument to a predetermined sensitivity and to produce a calibration relationship. This relationship is derived from the instrumental response to successive samples of different known concentrations. As a minimum, three reference points and a zero point are recommended to define this relationship. The instrument(s) supplying the zero air and Span calibration gasses used must themselves be calibrated and that calibration must be traceable to an EPA/ NIST primary standard (see Section 8.1.4.) All monitoring instrument systems are subject to some drift and variation in internal parameters and cannot be expected to maintain accurate calibration over long periods of time. Therefore, it is necessary to check the calibration relationship on a predetermined schedule dynamically. Zero and span checks must be used to document that the data remains within control limits. These checks are also used in data reduction and validation. To ensure accurate measurements of the O3 levels, the analyzer must be calibrated at the time of installation and re-calibrated as necessary. (Section 12 of the Q.A. Manual.11) A general procedure for dynamically calibrating a O3 analyzer can be found in 40 CFR 50 Appendix C. Calibration can be done by either diluting high concentration O3 standards with zero air or using separate supplies of O3 at known concentration. Care must be exercised to ensure that the calibration system meets the guidelines outlined in the revised Appendix D, 40 CFR 50.1 Detailed calibration procedures are also discussed in the Technical Assistance Document (TAD).2 Dynamic multipoint calibration of the M400E must be conducted by using either the UV photometric calibration procedure or a certified transfer standard. The equipment (i.e. calibrator and UV photometer) that is needed to carry out the calibration is commercially available, or it can be assembled by the user. Calibrations should be carried out at the field-monitoring site. The Analyzer should be in operation for at least several hours (preferably overnight) before calibration. During the calibration, the M400E should be in the CAL mode, and therefore sample the test atmosphere through all components used during normal ambient sampling and through as much of the ambient air inlet system as is practicable. If the instrument will be used on more than one range, it should be calibrated separately on each applicable range. 04315 Rev. C1 171 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual Details of documentation, forms and procedures should be maintained with each analyzer and also in a central backup file as described in Section 12 of the Quality Assurance Handbook. Personnel, equipment and reference materials used in conducting audits must be independent from those normally used in calibrations and operations. Ozone audit devices must be referenced to a primary UV photometer or one of the Standard Reference Photometers maintained by NIST and the US EPA. 10.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES The measurement of O3 in ambient air requires a certain amount of basic sampling equipment and supplemental supplies. These include, but are not limited to, the following: Equivalent Method photometric O3 analyzer, such as the T-API Model 400E Strip chart recorder and/or data logging system Sampling lines Sampling manifold UV (ultraviolet) photometric calibration system Certified calibration transfer standards Zero-air source Ozone generation device ("calibrator") Spare parts and expendable supplies Record forms Independent audit system When purchasing these materials, a logbook should be maintained as a reference for future procurement needs and as a basis for future fiscal planning. Spare Parts and Expendable Supplies In addition to the basic equipment described in the Q.A. Handbook, it is necessary to maintain an inventory of spare parts and expendable supplies. Chapter 12 of this manual describes the parts that require periodic replacement and the frequency of replacement. Appendix B contains a list of spare parts and kits of expendables supplies. 10.1.3. CALIBRATION GAS AND ZERO AIR SOURCES Production of Zero Air Devices that condition ambient air by drying and removal of pollutants are available on the commercial market such as the API Model 701 zero air generator. Production of Span Gas Because of the instability of O3, the certification of O3 concentrations as Standard Reference Materials is impractical, if not impossible. Therefore, when O3 concentration standards are required, they must be generated and certified locally. We Recommend using a Gas Dilution Calibrator with a built in O3 generator, such as a TAPI Model 700E, as a source for O3 Span Gas. In ALL cases, the instrument(s) supplying the zero air and Span calibration gasses used must themselves be calibrated and that calibration must be traceable to an EPA/NIST primary standard. 172 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.1.4. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY Equipment used to produce calibration gasses should be verified against EPA/NIST traceable standards. Ozone is the only criteria pollutant for which standard concentrations for calibration cannot be directly traceable to an NIST-SRM (National Institute of Standards - Standard Reference Material). Such standards are classified into two basic groups: primary standards and transfer standards. A primary O3 standard is an O3 concentration standard that has been dynamically generated and assayed by UV photometry in accordance with the procedures prescribed by the U.S. Environmental Protection Agency (EPA) under Title 40 of the Code of Federal Regulations, Part 50, Appendix D (40 CFR Part 50). An O3 transfer standard is a transportable device or apparatus, which, together with associated operational procedures, is capable of accurately reproducing O3 concentration standards or producing accurate assays of O3 concentrations that are quantitatively related to a primary O3 standard. It is worth noting that the requirements for the repeatability and reliability of transfer standards are more stringent than are those for stationary, primary standards. A Standard Reference Photometer (SRP) has been developed as a primary O3 standard by the U.S. National Institute of Standards and Technology (NIST) and the EPA. It is a highly stable, highly precise, computercontrolled instrument for assaying O3 concentrations. NIST maintains one or more “master” SRP’s in lieu of a Standard Reference Materials (SRM) for ozone. A nationwide network of regionally located SRP’s enables State and local air monitoring agencies to compare their O3 standards with authoritative O3 standards maintained and operated under closely controlled conditions. Other SRPs are located in foreign countries. To maintain a uniform and consistent set of references, the US EPA maintains 9 Standard Reference Photometers (SRP) around the US. It is suggested that the regional office of the EPA be contacted for the location of a SRP nearby and that the standards be compared. This assures a uniform standard for ozone concentration is applied everywhere. Currently, the U.S. SRP Network consists of SRPs located at: EPA's National Exposure Research Laboratory (NERL), in Research Triangle Park, North Carolina EPA's Region I Environmental Services Division in Lexington, Massachusetts EPA's Region II Environmental Services Division in Edison, New Jersey EPA's Region IV Environmental Services Division in Athens, Georgia EPA's Region V Environmental Services Division in Chicago, Illinois EPA's Region VI Environmental Services Division in Houston, Texas EPA's Region VII Environmental Services Division in Athens, Georgia EPA's Region VIII Environmental Services Division in Denver, Colorado The State of California Air Resources Board (CARB) in Sacramento, California Commercial UV photometers meeting the requirements of a primary ozone standard as set forth in 40 CFR Part 50 are available and are currently being used by air monitoring agencies. Agencies have been encouraged to compare their primary O3 standards (and O3 transfer standards) as part of their routine quality assurance (QA) programs. Additionally, to provide a reference against which calibration standards for O3 must be compared, the U.S. EPA has prescribed a reference calibration procedure based on the principle of UV light absorption by ozone at a wavelength of 254 nm1. This procedure provides an authoritative standard for all O3 measurement. Ozone 04315 Rev. C1 173 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual transfer standards may also be used for calibration if they have been certified against the UV calibration procedure.3 10.1.5. CALIBRATION FREQUENCY A system of Level 1 and Level 2 zero/span checks is recommended (see Section 10.2). These checks must be conducted in accordance with the specific guidance given in Subsection 9.1 of Section 2.0.9 (Ref. 11). Level 1 zero and span checks should be conducted at least every two weeks. Level 2 checks should be conducted in between the Level 1 checks at a frequency determined by the user. Span concentrations for both levels should be between 70 and 90% of the reporting range. To ensure accurate measurements of the ambient O3 concentrations, calibrate the M400E at the time of installation, and recalibrate it: 1. Any time the instrument fails above regiment of Level 1 and Level 2 checks. 2. No later than 3 months after the most recent calibration or performance audit which indicated the M400E response to be acceptable; or 3. Following any one of the activities listed below: a) An interruption of more than a few days in M400E operation. b) Any repairs which might affect its calibration. c) Physical relocation of the M400E. d) Any other indication (including excessive zero or span drift) of possible significant inaccuracy of the unit. Following any of the activities listed in above, perform Level 1 zero and span checks to determine if a calibration is necessary. If the zero and span drifts do not exceed the calibration limits in Section 2.0.9 Q.A. Manual (Ref. 11) (or limits set by the local agency), a calibration need not be performed. 10.1.6. DATA RECORDING DEVICE Either a strip chart recorder, data acquisition system, digital data acquisition system should be used to record the data from the M400E RS-232 port or analog outputs. If analog readings are being used, the response of that system should be checked against a NIST referenced voltage source or meter. Data recording device should be capable of bi-polar operation so that negative readings can be recorded. Strip chart recorder should be at least 6” (15 cm) wide. 10.1.7. RECORD KEEPING Record keeping is a critical part of all quality assurance programs. Standard forms similar to those that appear in this manual should be developed for individual programs. Three things to consider in the development of record forms are: 1. Does the form serve a necessary function? 2. Is the documentation complete? 3. Will the forms be filed in such a manner that they can easily be retrieved when needed? 174 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.2. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS All monitoring instruments are subject to some drift and variation in internal parameters and cannot be expected to maintain accurate calibration over long periods of time the EPA requires a schedule of periodic checks of the analyzer’s calibration be implemented. Zero and span checks must be used to document that the data remains within required limits. These checks are also used in data reduction and system validation. A Level 1 Span check is used to document that the M400E is within control limits and must be conducted every 2 weeks. A Level 2 Span Check is to be conducted between the Level 1 Checks on a schedule to be determined by the user. LEVEL 1 ZERO AND SPAN CALIBRATION (Section 12 of Q.A. Handbook)11 A Level 1 zero and span calibration is a simplified, two-point analyzer calibration used when analyzer linearity does not need to be checked or verified. (Sometimes when no adjustments are made to the analyzer, the Level 1 calibration may be called a zero/span check, in which case it must not be confused with a Level 2 zero/span check.) Since most analyzers have a reliably linear or near-linear output response with concentration, they can be adequately calibrated with only two concentration standards (two-point concentration). Furthermore, one of the standards may be zero concentration, which is relatively easily obtained and need not be certified. Hence, only one certified concentration standard is needed for the twopoint (Level 1) zero and span calibration. Although lacking the advantages of the multipoint calibration, the two-point zero and span calibration--because of its simplicity--can be (and should be) carried out much more frequently. Also, two-point calibrations are easily automated. Frequency checks or updating of the calibration relationship with a two-point zero and span calibration improves the quality of the monitoring data by helping to keep the calibration relationship more closely matched to any changes (drifts) in the analyzer response. LEVEL 2 ZERO AND SPAN CHECK (Section 12 of Q.A. Handbook)11 A Level 2 zero and span check is an "unofficial" check of an analyzer's response. It may include dynamic checks made with uncertified test concentrations, artificial stimulation of the analyzer's detector, electronic or other types of checks of a portion of the analyzer, etc. Level 2 zero and span checks are not to be used as a basis for analyzer zero or span adjustments, calibration updates, or adjustment of ambient data. They are intended as quick, convenient checks to be used between zero and span calibrations to check for possible analyzer malfunction or calibration drift. Whenever a Level 2 zero or span check indicates a possible calibration problem, a Level 1 zero and span (or multipoint) calibration should be carried out before any corrective action is taken. If a Level 2 zero and span check is to be used in the quality control program, a "reference response" for the check should be obtained immediately following a zero and span (or multipoint) calibration while the analyzer's calibration is accurately known. Subsequent Level 2 check responses should then be compared to the most recent reference response to determine if a change in response has occurred. For automatic Level 2 zero and span checks, the first scheduled check following the calibration should be used for the reference response. It should be kept in mind that any Level 2 check that involves only part of the analyzer's system cannot provide information about the portions of the system not checked and therefore cannot be used as a verification of the overall analyzer calibration. 10.3. MULTIPOINT CALIBRATION 10.3.1. GENERAL INFORMATION The procedures for multipoint calibration of an O3 analyzer by UV photometry or a transfer standard have been specified in the Code of Federal Regulations1. To facilitate these procedures, operational and calculation data forms have been developed. These forms will aid in conducting calibrations and quality assurance checks. A detailed description of the calibration theory and procedures for UV photometry and transfer standards is in the Code of Federal Regulations1 and TAD.2, 3 04315 Rev. C1 175 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual In general, ambient monitors are always calibrated in situ without disturbing their normal sampling setup, except for transferring the sample inlet from the ambient sampling point to the calibration system. Calibration should be performed with a primary UV photometer or by a transfer standard (see Section 10.1.4). The user should be sure that all flow meters are calibrated under the conditions of use against a reliable standard such as a soap bubble meter or wet test meter. All volumetric flow rates should be corrected to 25°C and 760 mm Hg. A discussion of the calibration of flow meters is in Appendix 12 of Ref. 11. A newly installed M400E should be operated for several hours or preferably overnight before calibration to allow it to stabilize. A brand new M400E (fresh from the factory) may require several days of operation to fully stabilize. Allow the photometer or transfer standard to warm up and stabilize before use, particularly if stored or transported in cold weather. 10.3.2. MULTIPOINT CALIBRATION PROCEDURE Multipoint Calibration consist of performing a calibration of the instrument’s Zero Point and High Span Point, then checking its accuracy at various intermediate points between these two. The procedure for performing the Zero Point and High Span Point are identical to those described in Section 9.2.3. After the Zero and High Span points have been set, determine five approximately evenly spaced calibration points between the Zero and High Span Point. For each midpoint: ACTION: Allow Calibration Gas diluted to proper concentration for Midpoint N SAMPLE WAIT 10 MINUTES Or until the reading stabilizes and the SPAN button is displayed RANGE = 500.0 PPB < TST TST > CAL CALZ CALS ZERO CAL M RANGE = 500.0 PPB < TST TST > ZERO SPAN CONC O3 =XXX.X SETUP O3 =XXX.X EXIT Record the O3 reading as displayed on the instrument’s front panel Press EXIT to Return to the Main SAMPLE Display ACTION: Allow Calibration Gas diluted to proper concentration for Midpoint N+1 Plot the analyzer responses versus the corresponding calculated concentrations to obtain the calibration relationships. Determine the straight line of best fit (y = mx + b); determined by the method of least squares (e.g., see Appendix J of Volume I of the Q.A. Handbook6). After the best-fit line has been drawn, determine whether the analyzer response is linear. To be considered linear, no calibration point should differ from the best-fit line by more than 2% of full scale. 176 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.3.3. DYNAMIC MULTIPOINT CALIBRATION CHECK The EPA-prescribed calibration procedure is based on photometric assays of O3 concentrations in a dynamic flow system. It is based on the same principles that the M400E uses to measure ozone. The theory is covered in Chapter 11 of this manual. Since the accuracy of the calibration standards obtained by this calibration procedure depends entirely on the accuracy of the photometer, it is very important that the photometer is operating properly and accurately. The fact that the photometer makes a ratio measurement (I/Io) rather than an absolute measurement eases this task. The checks described in this section, if carried out carefully, will provide reasonable confidence that a photometer which has the required inherent capability is operating properly. Checks should be carried out frequently on a new calibrator, and a chronological record of the results should be kept. If the record of the photometer performance shows continued adequacy and reliability, the frequency of the checks can be reduced with no loss of confidence in the photometer. (The record, however, may indicate the need for continued frequent verification of the system condition.) Even where the record shows excellent stability, the checks should still be carried out monthly, as the possibility of malfunction is always present. A well-designed properly built photometer is a precision instrument, and once it is operating adequately, it is likely to continue to do so for some time, particularly if the photometer is stationary and is used intermittently under ideal laboratory conditions. If the photometer is commercially manufactured, it should include an operation/instruction manual. Study the manual thoroughly and follow its recommendations carefully and completely. 10.3.4. LINEARITY TEST Because the required photometric measurement is a ratio, a simple linearity check of the photometer is a good indication of accuracy. Linearity of commercially made photometers may be demonstrated by the manufacturer. The linearity test is conducted by first generating and assaying an ozone concentration near the upper range limit (80% of full scale is recommended) of the reporting range in use. Other data points can be created by adding zero air (Fd) to the flow of originally generated concentration (Fo) and pass the mixture through a mixing device to ensure a homogeneous concentration at the Inlet to the analyzer being calibrated. The First step of performing this linearity test is to determine the dilution ration of the various test points according to the following formula: Equation 10-1 Fo R= ( Fo + Fd ) For this test, the flow rates Fo and Fd must be accurately measured within ±2% of the true value. To help ensure accurate flow measurements, the two flowmeters should be of the same general type and one should be standardized against the other. The dilution ratio R is calculated as the flow of the original concentration (Fo) divided by the total flow (Fo + Fd). With stable, high resolution flowmeters and with careful technique, R should be accurate to within 1%. 04315 Rev. C1 177 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual When Fd has been adjusted and R has been calculated, assay the diluted concentration with the photometer and then compare the diluted assay (A2) with the original undiluted assay (A1) by calculating the percentage of linearity error (E) according to the following equation. Equation 10-2 E= A1 ( A2 / R ) × 100 A1 This linearity error must be <5% in magnitude and should be <3% for a well-performing system. NOTE The result is not the true linearity error because it includes possible instrument errors in the flow measurements. This test technique should only be used as an indicator If the linearity error is >5% or is greater than you expect it to be, check and verify the accuracy of the flow dilution carefully before assuming that the photometer is inaccurate. The test should be carried out several times at various dilution ratios, and an averaging technique should be used to determine the final result. If the linearity error is excessive and cannot be attributed to flow measurement inaccuracy, check the photometer system for: Dirty or contaminated cell, lines or manifold. Inadequate "conditioning" of the system. Leaking of two-way valve or other system components. Contaminated zero-air. Non-linear detectors in the photometer. Faulty electronics in the photometer. 178 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.3.5. O3 LOSS CORRECTION FACTOR In spite of scrupulous cleaning and preconditioning, some O3 may be lost on contact with the photometer cell walls and the gas-handling components. Any significant loss of O3 must be quantitatively determined and used to correct the output concentration assay. In any case, the O3 loss must not exceed 5%. To determine O3 loss: 1. Calibrate a stable ozone analyzer with the UV calibration system, assuming no losses. 2. Generate an O3 concentration, and measure it with the analyzer as close as possible to the actual inlet of the photometer cell. 3. Measure the concentration as close as possible to the outlet of the cell. 4. Repeat each measurement several times to get a reliable average. 5. Measure the concentration at the output manifold. The tests should be repeated at several different O3 concentrations. The percentage of O3 loss is calculated as, Equation 10-3 %O3 loss = Cm ( Ci + Co ) 2 × 100 Cm Where Ci = O3 concentration measured at cell inlet, ppm Co = O3 concentration measured at cell outlet, ppm, and Cm = O3 concentration measured at output manifold, ppm. For other configurations, the % O3 loss may have to be calculated differently. The ozone loss correction factor is calculated as: L = 1 - 0.01 × % O3 loss. 10.3.6. SPAN DRIFT CHECK The first level of data validation should accept or reject monitoring data based upon routine periodic analyzer checks. It is recommended that results from the Level 1 span checks be used as the first level of data validation. This means up to two weeks of monitoring data may be invalidated if the span drift for a Level 1 span check is 25%. For this reason, it may be desirable to perform Level 1 checks more often than the minimum recommended frequency of every 2 weeks. 10.4. AUDITING PROCEDURES An audit is an independent assessment of the accuracy of data. Independence is achieved by having the audit made by an operator other than the one conducting the routine field measurements and by using audit standards and equipment different from those routinely used in monitoring. The audit should be a true assessment of the measurement process under normal operations without any special preparation or adjustment of the system. Routine quality control checks (such as zero and span checks) conducted by the operator are necessary for obtaining and reporting good quality data, but they are not considered part of the auditing procedure. Three audits are recommended: two performance audits and a systems audit. These audits are summarized in 10.4.3 at the end of this section. See Appendix 15 of the Q.A. Handbook (Reference 11) for detailed procedures for a systems audit and for a performance audit, respectively. 04315 Rev. C1 179 M400E Ozone Analyzer Operator’s Manual OPERATING INSTRUCTIONS Proper implementation of an auditing program will serve a twofold purpose: (1) to ensure the integrity of the data and (2) to assess the data for accuracy. The technique for estimating the accuracy of the data is given in Section 2.0.8 of the QA Manual (Reference 11). 10.4.1. MULTIPOINT CALIBRATION AUDIT A performance audit consists of challenging the continuous analyzer with known concentrations of O3 within the measurement range of the analyzer. The difference between the known concentration and the analyzer response is obtained, and an estimate of the analyzer's accuracy is determined. Known concentrations of O3 must be generated by a stable O3 source and assayed by the primary UV photometric procedure or may be obtained using a certified O3 transfer standard. Procedures used to generate and assay O3 concentrations are the same as those described in Section 10.1.3. If during a regular field audit, the differences recorded for most analyzers are either negatively or positively biased, a check of the calibrator used in routine calibrations of the analyzers may be advisable. The test atmosphere must pass through all filters, scrubbers, conditioners, and other components used during normal ambient sampling and through as much of the ambient air inlet system as practical. Be sure the manifold includes a vent to assure that the M400E inlet is at atmospheric pressure. Audit Procedure: 1. Turn on the zero-air flow in the audit device. 2. After stabilization, record the analyzer zero. 3. Generate an up-scale audit point. 4. After stabilization, record the O3 analyzer response. 5. Assay the audit concentration using an audit UV photometer or certified transfer standard. 6. Repeat steps 4 and 5 for the two remaining up-scale audit points. If analyzer is operated on 0-1.0 ppm range, four up-scale audit points must be used. Results: Results of the audit will be used to estimate the accuracy of the ambient air quality data. Calculation of accuracy is described in Appendix 15 of the Q.A. Handbook (Reference 11). 10.4.2. DATA PROCESSING AUDIT Data processing audit involves reading a strip chart record, calculating an average, and transcribing or recording the results on the SAROAD form. The data processing audit should be performed by an individual other than the one who originally reduced the data. Initially, the audit should be performed 1 day out of every 2 weeks of data. For two 1-hour period within each day audited, make independent readings of the strip chart record and continue through the actual transcription of the data on the SAROAD form. The 2 hours selected during each day audited should be those for which either the trace is most dynamic (in terms of spikes) or the average concentration is high. The data processing audit is made by calculating the difference, Equation 10-4 d = [O3]R - [O3]A Where d = the difference between measured and audit values, ppm, [O3]R = the recorded analyzer response, ppm, and [O3]A = the data processing O3 concentration, ppm. If d exceeds 0.02 ppm, check all of the remaining data in the 2-week period. 180 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.4.3. SYSTEM AUDIT A system audit is an on-site inspection and review of the quality assurance activities used for the total measurement system (sample collection, sample analysis, data processing, etc.); it is a qualitative appraisal of system quality. Conduct the system audit at the startup of a new monitoring system and periodically (as appropriate) as significant changes in system operations occur. The recommended audit schedule depends on the purpose for which the monitoring data are being collected. For example, Appendix A, 40 CFR 588 requires that each analyzer in State and Local Air Monitoring Networks (SLAMS) be audited at least once a year. Each agency must audit 25% of the reference or equivalent analyzers each quarter. If an agency operates less than four reference or equivalent analyzers, it must randomly select analyzers for re-auditing so that one analyzer will be audited each calendar quarter and so that each analyzer will be audited at least once a year. Appendix B, 40 CFR 589 requires that each PSD (prevention of significant deterioration) reference or equivalent analyzer be audited at least once a sampling quarter. Results of these audits are used to estimate the accuracy of ambient air data. 10.4.4. ASSESSMENT OF MONITORING DATA FOR PRECISION AND ACCURACY A periodic check is used to assess the data for precision. A one-point precision check must be carried out at least once every 2 weeks on each analyzer at an O3 concentration between 0.08 and 0.10 ppm. The analyzer must be operated in its normal sampling mode, and the precision test gas must pass through all filters, scrubbers, conditioners, and other components used during normal ambient sampling. Those standards used for calibration or auditing may be used. Estimates of single instrument accuracy for ambient air quality measurements from continuous methods are calculated according to the procedure in Appendix 15 of the Q.A. Handbook (Reference 11). 10.5. SUMMARY OF QUALITY ASSURANCE CHECKS Essential to quality assurance are scheduled checks for verifying the operational status of the monitoring system. The operator should visit the site at least once each week. Every two weeks a Level 1 zero and span check must be made on the analyzer. Level 2 zero and span checks should be conducted at a frequency desired by the user. In addition, an independent precision check between 0.08 and 0.10 ppm may be required at least once every two weeks. 04315 Rev. C1 181 OPERATING INSTRUCTIONS M400E Ozone Analyzer Operator’s Manual Table 10-3 summarizes the quality assurance activities for routine operations. A discussion of each activity appears in the following sections. To provide for documentation and accountability of activities, a checklist should be compiled and then filled out by the field operator as each activity is completed. 182 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration Table 10-1: Daily Activity Matrix CHARACTERISTIC ACCEPTANCE LIMITS FREQUENCY AND METHOD OF MEASUREMENT ACTION IF REQUIREMENTS ARE NOT MET Shelter Temperature Mean temperature between 22C and 28C (72F and 82F), daily fluctuations not greater than 2C. Check thermograph chart daily for variations not greater than 2C (4F). Mark strip chart for the affected time period. Sample Introduction System No moisture, foreign material, leaks, obstructions; sample line connected to manifold. Weekly visual inspection. Adequate ink supply and chart paper. Legible ink traces. Repair/adjust temp control. Clean, repair or replace as needed. Replenish and chart paper supply Weekly visual inspection. Adjust recorder time to agree with clock note on chart. Weekly visual inspection. Adjust or repair as needed. Analyzer Operational Check Zero and span within tolerance limits as described in Subsec. 9.1.3 of Sec. 2.0.9 (Ref. 11). Level 1 zero and span every 2 weeks; Level 2 between Level 1 checks at frequency desired by user. Isolate source error, and repair. Precision Check Assess precision as described in Sec. 2.0.8 (Ref. 11). Every 2 weeks, Sec. 2.0.8 (Ref. 11). Calculate, report precision, Sec. 2.0.8 (Ref. 11). Recorder Correct settings of chart speed and range switches. Correct time. Flow and regulator indicators at proper settings. Analyzer Operational Settings Temperate indicators cycling or at proper levels. Analyzer in sample mode. Zero/span controls locked. After corrective action, recalibrate analyzer. Table 10-2: Activity Matrix for Audit Procedure AUDIT ACCEPTANCE LIMITS FREQUENCY AND METHOD OF MEASUREMENT ACTION IF REQUIREMENTS ARE NOT MET Multipoint calibration audit The difference between the measured and the audit values as a measure of accuracy (Sec. 2.0.8 of Ref. 11). At least once a quarter (Sec. 2.0.8 of Ref. 11) Re-calibrate the analyzer. Data processing audit Adhere to stepwise procedure for data reduction (Sec. 8.4); no difference exceeding 0.02 ppm. Perform independent check on a sample of recorded data, e.g., 1 day out of every 2 weeks of data, 2 hours for each day. Check all remaining data if one or more audit checks exceeds 0.02 ppm. Method described in this section of the Handbook. At the startup of a new monitoring system, and periodically as appropriate; observation and checklist. Initiate improved methods and/or training programs. Systems audit 04315 Rev. C1 183 M400E Ozone Analyzer Operator’s Manual OPERATING INSTRUCTIONS Table 10-3: Activity Matrix for Data Reduction, Validation and Reporting ACTIVITY ACCEPTANCE LIMITS FREQUENCY AND METHOD OF MEASUREMENT ACTION IF REQUIREMENTS ARE NOT MET Data reduction Stepwise procedure, Sec. 2.7.4 Ref. 11. Follow the method for each strip chart. Review the reduction procedure. Span drift check Level 1 span drift check <25%, Sec. 2.7.3 Ref 11. Check at least every 2 weeks; Sec. 2.7.3, Ref. 11. Invalidate data; take corrective action; increase frequency of Level 1 checks until data is acceptable. Strip chart edit No sign of malfunction. Visually check each strip chart. Void data for time interval for which malfunction is detected. Data reporting Data transcribed to SAROAD hourly data form; Ref. 10. Visually check. Review the data transcribing procedure. Table 10-4: Activity Matrix for Calibration Procedures CALIBRATION ACTIVITIES ACCEPTANCE LIMITS FREQUENCY AND METHOD OF MEASUREMENT ACTION IF REQUIREMENTS ARE NOT MET Zero-air Zero-air, free of contaminants (Sec. 2.0.7 Ref. 11.). Compare the new Zeroair against Source known to be free of contaminants. Take corrective action with generation system as appropriate. Calibrator Meet all requirement for UV photometer as specified in 2 Sec. 2.7.2 QA Manual, TAD 1 and the Fed. Reg. or approve Transfer Standard Sec. 2.7.1, Q.A. Manual and 3 TAD . Re-certify transfer Standard against Primary UV Photometer at least Twice each quarter. Return to supplier, or take corrective action with system as appropriate. According to Calibration procedure (Sec. 2.7.2 Q.A... Manual Ref 11) and Federal Register; data recorded. Calibrate at least Once, quarterly; Anytime an audit Indicates discrepancy; After maintenance that May affect the Calibration (Subsec 2.1) Federal Register1. Repeat the calibration. Multipoint 184 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration 10.6. REFERENCES 1. Calibration of Ozone Reference Methods, Code of Federal Regulations, Title 40, Part 50, Appendix D. 2. Technical Assistance Document for the Calibration of Ambient Ozone Monitors, EPA publication available from EPA, Department E (MD-77), Research Triangle Park, N.C. 27711. EPA-600/4-79-057, September 1979. 3. Transfer Standards for Calibration of Ambient Air Monitoring Analyzers for Ozone, EPA publication available from EPA, Department E (MD-77), Research Triangle Park, N.C. 27711. EPA-600/4-79-056, September 1979. 4. Ambient Air Quality Surveillance, Code of Federal Regulations, Title 40, Part 58. 5. U.S. Environmental Protection Agency. Evaluation of Ozone Calibration Procedures. EPA-600/S4-80050, February 1981. 6. Quality Assurance Handbook for Air Pollution Measurement Systems. Vol. I. EPA-600/9-76-005. March 1976. 7. Field Operations Guide for Automatic Air Monitoring Equipment, U.S. Environmental Protection Agency, Office of Air Programs; October 1972. Publication No. APTD-0736, PB 202-249, and PB 204-650. 8. Appendix A - Quality Assurance Requirements for State and Local Air Monitoring Stations (SLAMS), Code of Federal Regulations, Title 40, Part 58. 9. Appendix B - Quality Assurance Requirements for Prevention of Significant Deterioration (PSD) Air Monitoring, Code of Federal Regulations, Title 40, Part 50, Appendix D. 10. Aeros Manual Series Volume II: Aeros User's Manual. EPA-450/2-76-029, OAQPS No. 1.2-039. December 1976. 11. Quality Assurance Handbook for Air Pollution Measurement Systems, Volume II, (abbreviated Q.A. Handbook Volume II) National Technical Information Service (NTIS). Phone (703) 487-4650 part number PB 273-518 or the USEPA Center for Environmental Research Information (513) 569-7562 part number EPA 600/4/77/027A. USER NOTES: 04315 Rev. C1 185 Technical information M400E Ozone Analyzer Operator’s Manual SECTION III – TECHNICAL INFORMATION 186 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 346BEPA Protocol Calibration USER NOTES: 04315 Rev. C1 187 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11. THEORY OF OPERATION The Model 400E ozone analyzer is a microprocessor-controlled analyzer that determines the concentration of Ozone (O3) in a sample gas drawn through the instrument. It requires that sample and calibration gasses be supplied at ambient atmospheric pressure in order to establish a stable gas flow through the absorption tube where the gas’ ability to absorb ultraviolet (UV) radiation of a certain wavelength (in this case 254 nm) is measured. Calibration of the instrument is performed in software and does not require physical adjustments to the instrument. During calibration, the microprocessor measures the current state of the UV Sensor output and various other physical parameters of the instrument and stores them in memory. The microprocessor uses these calibration values, the UV absorption measurements made on the Sample Gas in the absorption tube along with data regarding the current temperature and pressure of the gas to calculate a final O3 concentration. This concentration value and the original information from which it was calculated are stored in one of the unit’s Internal Data Acquisition System (iDAS - see Sections 7.1) as well as reported to the user via a Front Panel Display or a variety of digital and analog signal outputs. 11.1. MEASUREMENT METHOD 11.1.1. CALCULATING O3 CONCENTRATION The basic principle by which the Model 400E Ozone Analyzer works is called Beer’s Law (also referred to as the Beer-Lambert equation). It defines the how light of a specific wavelength is absorbed by a particular gas molecule over a certain distance at a given temperature and pressure. The mathematical relationship between these three parameters for gasses at standard temperature and pressure (STP) is: -LC I=IO e Equation 11-1 at STP Where: Io I L C is the intensity of the light if there was no absorption. is the intensity with absorption. is the absorption path, or the distance the light travels as it is being absorbed. is the concentration of the absorbing gas. In the case of the Model 400E, Ozone (O3). is the absorption coefficient that tells how well O3 absorbs light at the specific wavelength of interest. To solve this equation for C, the concentration of the absorbing Gas (in this case O3), the application of a little algebra is required to rearrange the equation as follows: Equation 11-2 04315 Rev. C1 189 Theory of Operation M400E Ozone Analyzer Operator’s Manual Unfortunately, both ambient temperature and pressure influence the density of the sample gas and therefore the number of ozone molecules present in the absorption tube thus changing the amount of light absorbed. In order to account for this effect the following addition is made to the equation: Equation 11-3 Where: T = sample temperature in Kelvin P = sample pressure in inches of mercury Finally, to convert the result into parts per billion (PPB), the following change is made: Equation 11-4 In a nutshell the Model 400E Ozone Analyzer: Measures each of the above variables: sample temperature; sample pressure; the intensity of the UV light beam with and without O3 present, Inserts known values for the length of the absorption path and the absorption coefficient, and Calculates the concentration of O3 present in the sample gas. 190 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.1.2. THE PHOTOMETER UV ABSORPTION PATH In the most basic terms, the photometer of the Model 400E 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 O3 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 42 cm) that the light 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 similar window at the other end of 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 assembly 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 O3 in the absorption tube. Window Window UV Detector ABSORPTION TUBE UV Source Sample Gas IN Sample Gas OUT Absorption Path Length = 42 cm Figure 11-1: 04315 Rev. C1 O3 Absorption Path 191 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.1.3. THE REFERENCE / MEASUREMENT CYCLE In order to solve the Beer-Lambert equation (see Section 10.1.2) it is necessary to know the intensity of the light passing through the absorption path both when O3 is present and when it is not. The Model 400E accomplishes this be alternately sending the sample gas directly to the absorption tube and passing it through a chemical Scrubber that removes any O3 present. SAMPLE GAS INLET Reference Path O3 Scrubber Measure Path Measure/ Reference Valve SPAN GAS INLET DRY AIR INLET EXHAUST GAS OUTLET Flow / Pressure Sensor PCA PUMP Sample Gas Flow Control Figure 11-2: SAMPLE PRESSURE SENSOR ABSORPTION TUBE ZERO AIR INLET O3 FLOW SENSOR Reference / Measurement Gas Cycle The Measurement / Reference Cycle consists of: TIME INDEX 0 seconds STATUS Measure/Reference Valve Opens to the Measure Path. 0 – 2 seconds Wait Period. Ensures that the Absorption tube has been adequately flushed of any previously present gasses. 2 – 3 seconds Analyzer measures the average UV light intensity of O3 bearing Sample Gas (I) during this period. 3 seconds Measure/Reference Valve Opens to the Reference Path. 3 – 5 seconds Wait Period. Ensures that the Absorption tube has been adequately flushed of O3 b3earing gas. 5 – 6 seconds Analyzer measures the average UV light intensity of Non-O3 bearing Sample Gas (I0) during this period. CYCLE REPEAT EVERY 6 SECONDS 192 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.1.4. INTERFERENT REJECTION The detection of O3 is subject to interference from a number of sources including, SO2, NO2, NO, H2O, aromatic hydrocarbons such as meta-xylene and mercury vapor. The Model 400E’s basic method or operation successfully rejects interference from most of these Interferents. The O3 scrubber located on the reference path (see Figure 11-2) is specifically designed ONLY to remove O3 from the sample gas. Thus, the variation in intensities of the UV light detected during the instrument’s measurement phase versus the reference phase is ONLY due to the presence or absence of O3. Thus, the effect of interferents on the detected UV light intensity is ignored by the instrument. Even if the concentration of interfering gases were to fluctuate so wildly as to be significantly different during consecutive reference and measurement phases, this would only cause the O3 concentration reported by the instrument to become noisy. The average of such noisy readings would still be a relatively accurate representation of the O3 concentration in the sample gas. Interference from SO2, NO2, NO and H2O are very effectively rejected by the model 400E. The two types of Interferents that may cause problems for the Model 400E are aromatic hydrocarbons and mercury vapor. AROMATIC HYDROCARBONS While the instrument effectively rejected interference from meta-xylene, it should be noted that there are a very large number of volatile aromatic hydrocarbons that could potentially interfere with ozone detection. This is particularly true of hydrocarbons with higher molecular weights. If the Model 400A is installed in an environment where high aromatic hydrocarbon concentrations are suspected, specific tests should be conducted to reveal the amount of interference these compounds may be causing. MERCURY VAPOR mercury vapor absorbs radiation in the 254nm wavelength so efficiently that its presence, even in small amounts, will reduce the intensity of UV light to almost zero during both the Measurement and Reference Phases rendering the analyzer useless for detecting O3. If the Model 400E is installed in an environment where the presence of mercury vapor is suspected, specific steps MUST be taken to remove the mercury vapor from the sample gas before it enters the analyzer. 04315 Rev. C1 193 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.2. PNEUMATIC OPERATION NOTE It is important that the sample airflow system is both leak tight and not pressurized over ambient pressure. Regular leak checks should be performed on the analyzer as described in the maintenance schedule, Table 12-2. Procedures for correctly performing leak checks can be found in Section 12.3.4. 11.2.1. SAMPLE GAS AIR FLOW The flow of sample gas through the M400E analyzer is produced by an internal pump that draws a small vacuum on the downstream side of a critical flow orifice thereby creating a controlled airflow through the analyzers absorption tube and other components. This requires the analyzer gas inlets be at or near ambient pressure usually managed by placing a vent line on the incoming gas line (see Figure 3-10, Figure 3-11 and Figure 5-5). By placing the pump down stream from the sample chamber, several problems are avoided. First, the pumping process heats and compresses the sample air complicating the measurement process. Additionally, certain physical parts of the pump itself are made of materials that might chemically react with the sample gas. Finally, in certain applications where the concentration of the target gas might be high enough to be hazardous, maintaining a negative gas pressure relative to ambient means that should a minor leak occur, no sample gas would be pumped into the atmosphere surrounding analyzer. Figure 11-3: M400E Pneumatic Diagram – Basic Unit Note For illustrations of the gas flow path for the M400E analyzer with the various calibration valve options installed, see Figures Figure 3-6 and Figure 5-3. 194 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.2.2. FLOW RATE CONTROL To maintain a constant flow rate of the sample gas through the instrument, the Model 400E uses a special flow control assembly located downstream from the absorption tube and in the exhaust gas line just before the pump (see Figure 10-7). This assembly consists of: A critical flow orifice. Two o-rings: Located just before and after the critical flow orifice, the o-rings seal the gap between the walls of assembly housing and the critical flow orifice. A spring: Applies mechanical force needed to form the seal between the o-rings, the critical flow orifice and the assembly housing. Figure 11-4: Flow Control Assembly & Critical Flow Orifice 11.2.2.1. Critical Flow Orifice The most important component of the flow control assemblies is the critical flow orifice. Critical flow orifices are a remarkably simple way to regulate stable gas flow rates. They operate without moving parts by taking advantage of the laws of fluid dynamics. By restricting the flow of gas though the orifice, a pressure differential is created. This pressure differential combined with the action of the analyzer’s pump draws the gas through the orifice. As the pressure on the downstream side of the orifice (the pump side) continues to drop, the speed that the gas flows though the orifice continues to rise. Once the ratio of upstream pressure to downstream pressure is greater than 2:1, the velocity of the gas through the orifice reaches the speed of sound. As long as that ratio stays at least 2:1 the gas flow rate is unaffected by any fluctuations, surges, or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice. The actual flow rate of gas through the orifice (volume of gas per unit of time), depends on the size and shape of the aperture in the orifice. The larger the hole, the more gas molecules (moving at the speed of sound) pass through the orifice. With a nominal pressure of 10 in-Hg-A in the sample/reaction cell, the necessary ratio of reaction cell pressure to pump vacuum pressure of 2:1 is exceeded and accommodating a wide range of variability in atmospheric pressure and accounting for pump degradation. This extends the useful life of the pump. Once the pump degrades to the point where the sample and vacuum pressures is less than 2:1, a critical flow rate can no longer be maintained. 04315 Rev. C1 195 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.2.3. PARTICULATE FILTER The Model 400E Ozone Analyzer comes equipped with a 47 mm diameter Teflon particulate filter with a 5micron pore size. The filter is accessible through the front panel, which folds down to allow access, and should be changed according to the suggested maintenance schedule described in Table 12-2. 11.2.4. PNEUMATIC SENSORS 11.2.4.1. Sample Pressure Sensor An absolute value pressure transducer plumbed to the outlet of the sample chamber is used to measure sample pressure. The output of the sensor is used to compensate the concentration measurement for changes in air pressure. This sensor is mounted to a printed circuit board next to the internal pump (see Figure 3-4). 11.2.4.2. Sample Flow Sensor A thermal-mass flow sensor is used to measure the sample flow through the analyzer. The sensor is located in down stream from the absorption tube but upstream from the critical flow orifice. This sensor is mounted to the same printed circuit board as the pressure sensor (see Figure 3-4). 196 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3. ELECTRONIC OPERATION 11.3.1. OVERVIEW Status Outputs 1-8 Analog Outputs TEST CHANNEL OUTPUT Aout 4 Control Outputs 1–6 Serial I/O Ports COM 1 Optional Multidrop Card Aout 3 O3 Concentration RANGE2 Aout 2 O3 Concentration RANGE1 Aout 1 COM 2 Analog Outputs (D/A) Optional Ethernet Card External Digital I/O RS-232 or RS-485 Power Up Circuit Gas Flow Sensor Sensor Inputs Gas Pressure Sensor A/D Converter O3 Generator Lamp Supply Thermistor Interface Photometer Sample Gas Temperature CPU Status LED PC 104 Bus Disk on Chip MOTHERBOARD I2C Bus ZERO Valve RELAY PCA Photometer UV Lamp Temperature SPAN Valve 2 IC Status LED IZS Sample/Cal Valve (Optional) Measure/ Reference Valve IZS Option O3 Generator’s UV Lamp Temperature Photometer Detector Preamp PC 104 CPU Card Flash Chip Box Temperature IZS O3 Generator (optional) O3 Generator UV Reference Lamp Detector RS-232 Photometer Lamp Heater Absorption tube Photometer Detector PHOTOMETER Photometer Lamp Power Supply Keyboard & Display Optional Metal Wool Scrubber Thermocouple Sensor Figure 11-5: Optional IZS O3 Generator Lamp Heater INTERNAL PUMP M400E Electronic Block Diagram At its heart, the analyzer is a microcomputer (CPU) that controls various internal processes, interprets data, makes calculations, and reports results using specialized firmware developed by T-API. It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices via a separate printed circuit assembly called the motherboard. The motherboard collects data, performs signal conditioning duties and routs incoming and outgoing signals between the CPU and the analyzers other major components. 04315 Rev. C1 197 Theory of Operation M400E Ozone Analyzer Operator’s Manual An analog signal is generated by an optical bench that includes the Photometer UV Lamp, the Absorption Tube assembly and the UV Detector and Preamp. This signal constantly cycles between a voltage level corresponding to concentration of O3 in the measure gas and the one corresponding to the lack of O3 in the reference gas. This signal is transformed converted into digital data by a unipolar, analog-to-digital converter, located on the motherboard. A variety of sensors report other critical operational parameters, again through the signal processing capabilities of the motherboard. This data is used to calculate O3 concentration and as trigger events for certain warning messages and control commands issued by the CPU. They are stored in memory by the CPU and in most cases can be viewed but the user via the front panel display. The CPU communicates with the user and the outside world in a variety of manners: Through the analyzer’s keyboard and vacuum florescent display over a clocked, digital, serial I/O bus (using a protocol called I2C); RS 232 & RS485 Serial I/O channels; Various DCV and DCA analog outputs and; Several sets of Digital I/O channels. Finally, the CPU issues commands via a series of relays and switches (also over the I2C bus) located on a separate printed circuit assembly, called the relay PCA, to control the function of key electromechanical devices such as heaters and valves. 11.3.2. CPU The Model 400E’s CPU is a, low power (5 VDC, 0.8A max), high performance, 386-based microcomputer running MS-DOS. Its operation and assembly conform to the PC/104 Specification version 2.3 for embedded PC and PC/AT applications. It has 2 MB of DRAM on board and operates at 40MHz over an internal 32-bit data and address bus. Chip to chip data handling is performed by two 4-channel DMA devices over data busses of either 8-bit or 16-bit configuration. The CPU supports both RS-232 and RS-485 Serial I/O. The CPU includes two types of non-volatile data storage. DISK ON CHIP: While technically an EEPROM, the Disk-on-Chip (DOC), this device appears to the CPU as, behaves as and performs the same function in the system as an 8MB disk drive. It is used to store the operating system for the computer, the T-API Firmware, and most of the operational data generated by the analyzer’s Internal Data Acquisition System (iDAS - see Section 7.1). FLASH CHIP: Another, smaller EEPROM used to store critical calibration and configuration data. Segregating this data on a separate, less heavily accessed chip significantly decreases the chance of this key data being corrupted. 11.3.3. MOTHERBOARD This printed Circuit assembly provides a multitude of functions including, A/D conversion, digital input/output, PC-104 to I2C translation, temperature sensor signal processing and is a pass through for the RS-232 and RS485 signals. 11.3.3.1. A to D Conversion Analog signals, such as the voltages received from the analyzers various sensors, are converted into digital signals that the CPU can understand and manipulate by the analog to digital converter (A/D). Under the control of the CPU, this functional block selects a particular signal input and then coverts the selected voltage into a digital word. 198 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation The A/D consists of a voltage-to-frequency (V-F) converter, a programmable logic device (PLD), three multiplexers, several amplifiers and some other associated devices. The V-F converter produces a frequency proportional to its input voltage. The PLD counts the output of the V-F during a specified time, and sends the result of that count, in the form of a binary number, to the CPU. The A/D can be configured for several different input modes and ranges but in the M400E is used in uni-polar mode with a +5V full scale. The converter includes a 1% over and under-range. This allows signals from – 0.05V to +5.05V to be fully converted. For calibration purposes, two reference voltages are supplied to the A/D converter: Reference ground and +4.096 VDC. During calibration, the device measures these two voltages, outputs their digital equivalent to the CPU. The CPU uses these values to compute the converter’s offset and slope and uses these factors for subsequent conversions. See Section 7.4.7 for instructions on performing this calibration. 11.3.3.2. Sensor Inputs The key analog sensor signals are coupled to the A/D through the master multiplexer from two connectors on the motherboard. 100K terminating resistors on each of the inputs prevent cross talk from appearing on the sensor signals. O3 DETECTOR OUTPUT: This is the primary signal used in the computation of the O3 concentration. GAS PRESSURE SENSOR: This sensor measures the gas pressure in the sample chamber upstream of the critical flow orifice (see Figure 3-5). The sample pressure is used by the CPU to calculate O3 Concentration. GAS FLOW SENSOR: This sensor measures the flow rate of the sample gas through the instrument. This information is used as a diagnostic tool for determining gas flow problems 11.3.3.3. Thermistor Interface This circuit provides excitation, termination and signal selection for several negative-coefficient, thermistor temperature sensors located inside the analyzer. They are: SAMPLE TEMPERATURE SENSOR: The source of this signal is a thermistor attached to the absorption tube inside the optical bench assembly. It measures the temperature of the sample gas in the chamber. This data is used to during the calculation of the O3 concentration value. UV LAMP TEMPERATURE SENSOR: This thermistor, attached to the UV lamp in the optical bench reports the current temperature of the Lamp to the CPU as part of the lamp heater control loop. IZS LAMP TEMPERATURE SENSOR: This thermistor attached to the UV lamp of the O3 generator in the IZS option reports the current temperature of that lamp to the CPU as part of control loop that keeps the lamp constant temperature. BOX TEMPERATURE SENSOR: A thermistor is attached to the motherboard. It measures the analyzer’s inside temperature. This information is stored by the CPU and can be viewed by the user for troubleshooting purposes via the front panel display. (See Section 13.1.2). 04315 Rev. C1 199 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.3.4. Analog Outputs The analyzer comes equipped with four Analog Outputs: A1, A2, A4 and a fourth that is a spare. A1 AND A2 OUTPUTS: The first two, A1 and A2 are normally set up to operate in parallel so that the same data can be sent to two different recording devices. While the names imply that one should be used for sending data to a chart recorder and the other for interfacing with a data logger, either can be used for both applications. Both of these channels output a signal that is proportional to the O3 concentration of the Sample Gas. The A1 and A2 outputs can be slaved together or set up to operated independently. A variety of scaling factors are available, See Section 6.4.4 for information on setting the range type and scaling factors for these output channels. TEST OUTPUT: The third analog output, labeled A4 is special. It can be set by the user (see Section 7.4.6) to carry the current signal level of any one of the parameters accessible through the TEST menu of the unit’s software. In its standard configuration, the Analyzer comes with all four of these channels set up to output a DC voltage. However, 4-20mA current loop drivers can be purchased for the first two of these outputs, A1 and A2. OUTPUT LOOP-BACK: All three of the functioning analog outputs are connected back to the A/D converter through a Loop-back circuit. This permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures (see Section 7.4.1). 11.3.3.5. External Digital I/O This External Digital I/O performs two functions. STATUS OUTPUTS: Logic-Level voltages are output through an optically isolated 8-pin connector located on the rear panel of the analyzer. These outputs convey good/bad and on/off information about certain analyzer conditions. They can be used to interface with certain types of programmable devices CONTROL INPUTS: By connecting these digital inputs to an external source such as a PLC or Data logger Zero and Span calibrations can be remotely initiated. 11.3.3.6. I2C Data Bus I2C is a two-wire, clocked, digital serial I/O bus that is used widely in commercial and consumer electronic systems. A transceiver on the Motherboard converts data and control signals from the PC-104 bus to I2C. The data is then fed to the Keyboard/Display Interface and finally onto the relay PCA. An I2C data bus is used to communicate data and commands between the CPU and the Keyboard/Display Interface, the relay PCA and the power supply for the Photometer UV Lamp. On instruments with IZS Options, the power supply for the O3 Generator UV Lamp is also controlled by via the I2C bus. Interface circuits on the Keyboard/Display interface and relay PCA convert the I2C data to parallel inputs and outputs. An additional, interrupt line from the Keyboard to the Motherboard allows the CPU to recognize and service key presses on the keyboard. 11.3.3.7. Power Up Circuit This circuit monitors the +5V power supply during start-up and sets the Analog outputs, External Digital I/O ports, and I2C circuitry to specific values until the CPU boots and the instrument software can establish control. 11.3.4. RELAY PCA 200 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation The CPU issues commands via a series of relays and switches located on a separate printed circuit assembly, called the relay PCA, to control the function of key electromechanical devices such as heaters and valves. The relay PCA receives instructions in the form of digital signals over the I2C bus, interprets these digital instructions and activates its various switches and relays appropriately. The relay PCA is located in the right-rear quadrant of the analyzer and is mounted vertically on the backside of the same bracket as the instrument’s DC power supplies. Thermocouple Signal Output Status LED’s (D2 through D16) Watchdog Status LED (D1) (JP5) Thermocouple Configuration Jumpers DC Power Supply Test Points I2C Connector (J15) TC1 Input (J16) TC2 Input Power Connection for DC Heaters (JP7) Pump AC Configuration Jumper Valve Control Drivers Pump Power Output Valve Control Connector AC Power IN AC Relay (Only present if optional. DC Power Distribution Connectors Metal Wool Scrubber installed) Figure 11-6: 04315 Rev. C1 Relay PCA Layout (P/N 04523-0100) 201 Theory of Operation M400E Ozone Analyzer Operator’s Manual The most commonly used version of the Relay PCA installed in the M400E analyzer does not include the AC relays used in instruments where there are AC powered components requiring control. A plastic insulating safety shield covers the empty AC Relay sockets. CAUTION Electrical Shock Hazard NEVER REMOVE THIS SAFETY SHIELD WHILE THE INSTRUMENT IS PLUGGED IN AND TURNED ON. THE CONTACTS OF THE AC RELAY SOCKETS BENEATH THE SHIELD CARRY HIGH AC VOLTAGES EVEN WHEN NO RELAYS ARE PRESENT AC Relay Safety Shield Figure 11-7: Relay PCA P/N 045230100 with Safety Shield In Place On instruments where the optional Metal Wool Scrubber is installed, the relay PCA includes a solid state AC relay (see Figure 11-6). A retainer plate is installed over the relay to keep them securely seated in their sockets. Retainer Mounting Screws AC Relay Retainer Plate Figure 11-8: 202 Relay PCA P/N 045230200 with AC Relay Retainer in Place 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.4.1. Status LED’s Eight LED’s are located on the Analyzer’s relay PCA to show the current status on the various control functions performed by the relay PCA (see Figure 11-9). They are: Table 11-1: Relay PCA Status LED’s LED Color Function D1 RED Watchdog Circuit D21 YELLOW Metal Wool Scrubber Heater D7 GREEN Zero/Span Gas Valve1 D8 GREEN Measure/Ref Valve D9 GREEN Sample/Cal Gas 2 Valve D3 – D6 D10-D14 1 2 D15 YELLOW D16 YELLOW Photometer UV Lamp Heater IZS O3 Generator UV Lamp Heater Status When Lit Status When Unlit Cycles On/Off Every 3 Seconds under direct control of the analyzer’s CPU. HEATING NOT HEATING SPARE Valve Open to SPAN GAS FLOW Valve Open to REFERENCE gas path Valve Open to CAL GAS FLOW SPARE Valve Open to MEASURE gas path HEATING NOT HEATING HEATING NOT HEATING Valve Open to ZERO GAS FLOW Valve Open to SAMPLE GAS FLOW Only present when the Z/S valve option is installed. Only present when either the Z/S valve option or the IZS valve option is present. D9 (Green) – Optional Sample/Cal Valve D8 (Green) – Photometer Meas/Ref Valve D7 (Green) Optional Zero/Span Valve D2 (Yellow) Optional Metal Wool Scrubber Heater D6 (Green ) – GPT Valve D15 (Yellow) - Photometer Lamp Heater D16 (Yellow) – IZS O3 Generator Lamp Heater D1 (RED) Watchdog Indicator Figure 11-9: Status LED Locations – Relay PCA 11.3.4.2. Watchdog Circuitry Special circuitry on the relay PCA watches the status of LED D1. Should this LED ever stay ON or OFF for 30 seconds, the Watchdog Circuit will automatically shut off all valves as well as turn off the UV Source (s) and all heaters. The Sample Pump will still be running. 04315 Rev. C1 203 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.4.3. Valve Control The valve that switches the gas stream to and from the analyzer’s O3 scrubber during the measure/reference cycle (see Section 11.1.3) is operated by an electronic switch located on the relay PCA. This switch, under CPU control, supplies the +12VDC needed to activate each valve’s solenoid. Similar valves also controlled by the relay PCA are included in the following optional components: On instruments with the ZERO/SPAN valve option (OPT- 50A) there are two additional valves: The ZERO/SPAN valve selects which calibration gas inlet (the ZERO gas inlet or the SPAN Gas Inlet) is the source of gas when the analyzer is in one of its calibration modes (see Figure 5-3). The SAMPLE/CAL valve selects either the sample inlet when the analyzer is in SAMPLE mode or the calibration gas stream when the analyzer is in one of its calibration modes (see Figure 5-3). On instruments with the IZS valve option (OPT- 51A) one additional valves (the SAMPLE/CAL valve) selects either the sample inlet when the analyzer is in SAMPLE mode or the dry air inlet when the analyzer is in one of its calibration modes (see Figure 3-6). 11.3.4.4. Heater Control In the base version of the Model 400E photometric analyzer, there is only one DC heater operated by the relay PCA. It is attached to the Photometer UV Lamp housing and maintains the temperature of the UV Lamp at a constant 58ºC. Additional DC heater also controlled by the relay PCA, are included in the following optional components: On instruments with Zero/Span valve option (OPT-50A) the metal wool scrubber option (OPT- 68) there is a DC heater embedded in the scrubber maintains it at a constant 110ºC. On instruments with the IZS valve option (OPT- 51A) there is a DC heater attached to the IZS O3 generator UV Lamp that maintains it at a constant 48ºC Thermistor(s) – Photometer Lamp Temperature and Optional IZS O3 Generator Lamp Temperature) MOTHER BOARD A/D Converter (V/F) RELAY PCA Preamplifiers and Signal Conditioning THERMOCOUPLE CONFIGURATION JUMPER (JP5) Themocouple(s) (used on Optional Metal Wool Scrubber) CPU Cold Junction Compensation DC Control Logic Solid State AC Relays DC HEATERS (UV LAMP Heaters) AC HEATER (optional Metal Wool Scrubber) Figure 11-10: Heater Control Loop Block Diagram. 204 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.4.5. Thermocouple Inputs and Configuration Jumper (JP5) In its base configuration, the M400E analyzer does not include any thermocouple sensors, however in instruments where the optional metal wool scrubber (OPT-68) is installed one thermocouple is used to sense the temperature of the scrubber. By default, this single thermocouple input is plugged into the TC1 input (J15) on the relay PCA. TC2 (J16) is currently not used. Table 11-2: Thermocouple Configuration Jumper (JP5) Pin-Outs TC INPUT TC1 JUMPER PAIR DESCRIPTION 1 – 11 Gain Selector 2 – 12 Output Scale Selector 3 – 13 Type J Compensation 4 – 14 Type K Compensation 5 – 15 Termination Selector FUNCTION Selects preamp gain factor for J or K TC OUT = K TC gain factor; IN = J TC gain factor Selects preamp gain factor for J or K TC OUT = 10 mV / °C; IN = 5 mV / °C When present, sets Cold Junction Compensation for J type Thermocouple When present, sets Cold Junction Compensation for K type Thermocouple Selects between Isolated and grounded TC IN = Isolate TC; OUT = Grounded TC NOT USED TC2 Termination Selector 5 – 15 Type J Compensation 4 – 14 Type J Compensation 3 – 13 Output Scale Selector 2 – 12 Input Gain Selector 1 – 11 TC2 Not Used TC1 Figure 11-11: Thermocouple Configuration Jumper (JP5) Pin-Outs Table 11-3: Thermocouple Settings for Optional Metal Wool Scrubber 04315 Rev. C1 TC TYPE TERMINATION TYPE K ISOLATED OUTPUT SCALE TYPE 10mV / °C JUMPER BETWEE N PINS JUMPER COLOR 4 – 14 5 – 15 PURPLE 205 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.5. POWER SUPPLY/CIRCUIT BREAKER The analyzer operates on 100 VAC, 115 VAC or 230 VAC power at either 50 Hz or 60Hz. Individual instruments are set up at the factory to accept any combination of these five attributes. Power enters the analyzer through a standard IEC 320 power receptacle located on the rear panel of the instrument. From there it is routed through the ON/OFF Switch located in the lower right corner of the Front Panel. AC Line power is stepped down and converted to DC power by two DC Power Supplies. One supplies +12 VDC, for various valves and valve options, while a second supply provides +5 VDC and 15 VDC for logic and analog circuitry as well as the power supplies for the Photometer and IZS UV Lamps. All AC and DC Voltages are distributed via the relay PCA. Figure 11-12: Power Distribution Block Diagram 11.3.5.1. Power Switch/Circuit Breaker A 6.75 Amp circuit breaker is built into the ON/OFF Switch. CAUTION Should the AC power circuit breaker trip, investigate and correct the condition causing this situation before turning the analyzer back on. 206 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.6. AC POWER CONFIGURATION The M400E analyzer’s digital components will operate with any of the specified power regimes. As long as instrument is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display. Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. However, some of the analyzer’s non-digital components, such as the pump and the AC powered heater for the optional metal wool scrubber (OPT-68) must be properly configured for the type of power being supplied to the instrument. Configuration of the power circuits is set using several jumper sets located on the instruments relay PCA. RELAY PCA JP6 Heater for the optional Metal Wool Scrubber (OPT-68) JP7 Pump Configuration Figure 11-13: Location of AC power Configuration Jumpers 04315 Rev. C1 207 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.6.1. AC configuration – Internal Pump (JP7) Table 11-4: AC Power Configuration for Internal Pumps (JP7) LINE POWER LINE FREQUENCY 60 HZ WHITE 110VAC 115 VAC 50 HZ1 220VAC 240 VAC 1 FUNCTION JUMPER BETWEEN PINS Connects pump pin 3 to 110 / 115 VAC power line 2 to 7 Connects pump pin 3 to 110 / 115 VAC power line 3 to 8 Connects pump pins 2 & 4 to Neutral 4 to 9 Connects pump pin 3 to 110 / 115 VAC power line 2 to 7 Connects pump pin 3 to 110 / 115 VAC power line 3 to 8 Connects pump pins 2 & 4 to Neutral 4 to 9 Connects pump pins 3 and 4 together 1 to 6 Connects pump pin 1 to 220 / 240VAC power line 3 to 8 Connects pump pins 3 and 4 together 1 to 6 Connects pump pin 1 to 220 / 240VAC power line 3 to 8 JUMPER COLOR BLACK 60 HZ BROWN 50 HZ1 BLUE A jumper between pins 5 and 10 may be present on the jumper plug assembly, but is only functional on the M300E and has no function on the Models M100E, M200E or M400E. 110 VAC /115 VAC 220 VAC /240 VAC 1 6 1 6 2 7 2 7 3 8 3 8 4 9 4 9 5 10 5 10 Present on 50 Hz version of jumper set, but not functional for the M400E Figure 11-14: Pump AC Power Jumpers (JP7) 208 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.6.2. AC Configuration – Heaters for Option Packages (JP6) The optional metal wool scrubber (OPT-68) includes an AC heater that maintain the scrubber at an optimum operating temperature. Jumper set JP6 is used to connect the heaters associated with those options to AC power. Since these heaters work with either 110/155 VAC or 220/240 VAC, there is only one jumper configuration. Table 11-5: Power Configuration for Optional Metal Wool Scrubber Heater (JP6) JUMPER COLOR RED HEATER(S) Metal Wool Scrubber Heater 10 12 11 6 5 4 JUMPER BETWEEN PINS FUNCTION 1 to 8 Common 2 to 7 Neutral to Load 9 3 8 7 2 1 Figure 11-15: Typical Jumper Set (JP2) Set Up of Optional Metal Wool Scrubber Heater 04315 Rev. C1 209 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.7. PHOTOMETER LAYOUT AND OPERATION The Photometer is where the absorption of UV light by ozone is measured and converted into a voltage. It consists of several sub-assemblies: A mercury-vapor UV lamp. This lamp is coated in a material that optically screens the UV radiation output to remove the O3 producing 185nm radiation. Only light at 254nm is emitted. An AC power supply to supply the current for starting and maintaining the plasma arc of the mercury vapor lamp. A thermistor and DC heater attached to the UV lamp to maintain the lamp at an optimum operating temperature. 42 cm long quartz absorption tube. A thermistor attached to the quartz tube for measuring sample gas temperature. Gas inlet and outlet mounting blocks that rout sample gas into and out of the photometer. The vacuum diode, UV detector that converts UV light to a DC current. A preamplifier assembly, which convert the Detector’s current output into a DC Voltage then amplifies it to a level readable by the A to D converter circuitry of the instrument’s motherboard UV Detector Absorption Tube UV Lamp Power Transformer Power Connector from +15 VDC power supply UV Detector Preamp PCA Sample Gas Inlet UV Lamp Power Supply Sample Gas Thermistor UV Lamp Thermistor (UV Lamp Heater Behind Thermistor) Sample Gas Outlet UV Lamp (200 VAC @ 30 kHz) UV Lamp Heater Control PCA Figure 11-16: O3 Photometer Layout – Top Cover Removed 210 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.7.1. Photometer Electronic Operation Sensor Inputs Absorption tube Figure 11-17: O3 Photometer Electronic Block Diagram Like the O3 photometer and its subcomponents act as peripheral devices operated by the CPU via the motherboard. Communications to and from the CPU are handled by the motherboard. Outgoing commands for the various devices such as the photometer pump, the UV lamp power supply the U\V Lamp heater are issued via the I2C bus to circuitry on the relay PCA which turns them ON/OFF. The CPU also issues commands over the I2C bus that cause the relay PCA to cycle the measure/reference valve back and forth. Incoming date the UV light detector is amplified locally then converted to digital information by the motherboard. Output from the photometers temperature sensors is also amplified and converted to digital data by the motherboard. The O3 concentration of the sample gas is computed by the CPU using this data (along with gas pressure and flow data received from the M400E’s pressure sensors. 04315 Rev. C1 211 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.3.7.2. O3 Photometer UV Lamp Power Supply The photometer’s UV lamp requires a high voltage AC supply voltage to create and maintain its mercury vapor plasma arc. This AC voltage is produced by a variable transformer, the primary of which is supplied by the output of a DC regulator (powered by the instrument’s +15 VDC supply). A circuit made up of a control IC and several FET’s, turns the transformer on and off converting it into a 30kHz square wave. The DC regulator is controlled by a drive voltage supplied by an amplifier that adjusts its output based on the difference between the rectified current output of the lamp and a constant voltage resulting from a D-to-A converted “set-point” signal sent by the CPU via the I2C bus. If the rectified current output by the lamp is lower than the CPU set point voltage, the amplifier drives the regulator output voltage higher. If the current output is higher than the set point voltage, the amplifier decreases the regulator output voltage. At start up, when there is no mercury vapor arc and therefore no current being output by the lamp, the amplifier continues to drive the regulator output (and therefore the transformer output) higher and higher until the mercury is vaporized and the plasma arc is created (about 800 VAC). Once the arc is created, current begins to flow and the error amplifier reduces the regulator/transformer output to a steady 200 VAC. . Figure 11-18: O3 Photometer UV Lamp Power Supply Block Diagram 212 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.3.7.3. Photometer Temperature In order to operate at peak efficiency the UV lamp of the M400E’s O3 photometer is maintained at a constant 58ºC. This is intentionally set at a temperature higher than the ambient temperature of the M400E’s operating environment to make sure that local changes in temperature do not affect the UV Lamp. If the lamp temperature falls below 56ºC or rises above 61ºC a warning is issued by the analyzers CPU. This temperature is controlled as described in the section on the relay PCA (Section 11.3.4.4). The following TEST functions report these temperatures and are viewable from the instrument’s front panel: PHOTO_LAMP - The temperature of the UV Lamp reported in ºC. SAMPLE _TEMP - The temperature of the Sample gas in the absorption tube reported in ºC. 11.3.7.4. Photometer Gas Pressure and Flow Rate The sensors mounted to a printed circuit board next to the internal pump (see Figure 3-4) measure the absolute pressure and the flow rate of gas inside the photometer’s absorption tube. This information is used by the CPU to calculate the O3 concentration of the sample gas (See Equation 11-3). Both of these measurements are made downstream from the absorption tube but upstream of the pump. A critical flow orifice located between the flow sensor and the pump maintains the gas flow through the photometer at 800 cm3/min. The following TEST functions are viewable from the instrument’s front panel: SAMPL_FL- The flow rate of gas through the photometer measured in LPM. PRES – The pressure of the gas inside the absorption tube. This pressure is reported in inches of mercury-absolute (in-Hg-A), i.e. referenced to a vacuum (zero absolute pressure). This is not the same as PSIG. NOTE The M400E displays all pressures in inches of mercury-absolute (in-Hg-A). Absolute pressure is the reading referenced to a vacuum or zero absolute pressure. This method was chosen so that ambiguities of pressure relative to ambient pressure can be avoided. For example, if the vacuum reading is 25" Hg relative to room pressure at sea level the absolute pressure would be 5" Hg. If the same absolute pressure was observed at 5000 ft altitude where the atmospheric pressure was 5" lower, the relative pressure would drop to 20" Hg, however the absolute pressure would remain the same 5" Hg-A. 04315 Rev. C1 213 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.4. INTERFACE The analyzer has several ways to communicate the outside world. Users can input data and receive information directly via the front panel keypad and display. Direct communication with the CPU is also available by way of the analyzers RS232 & RS485 I/O ports. The analyzer can also send and receive different kinds of information via its external digital i/o connectors and the three analog outputs located on the rear panel. COMM A Male RS–232 ONLY RS-232 or RS–485 COMM B Female ETHERNET OPTION Control Inputs: 1–6 Status Outputs: 1–8 A1 A2 CPU Mother Board PC/104 BUS Analog Outputs KEYBOARD Optional 4-20 mA I2C BUS A3 I2C BUS A4ST RELAY BOARD FRONT PANEL DISPLAY Figure 11-19: Interface Block Diagram 11.4.1. FRONT PANEL The Front panel of the analyzer is hinged at the bottom and may be opened to gain access to various components mounted on the panel itself or located near the front of the instrument (such as the Particulate Filter). Two fasteners located in the upper right and left corners of the panel lock it shut. KEY DEFINITIONS FASTENER CONCENTRATION FIELD STATUS LED’s FASTENER MESSAGE FIELD MODE FIELD SAMPLE A RANGE = 50 PPM CO = 40.0 SAMPLE CAL CAL SETUP FAULT POWER GAS FILTER CORRELATION ANALYZER - MODEL 300E ON / OFF SWITCH KEYBOARD Figure 11-20: Front Panel 214 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.4.1.1. Front Panel Display The main display of the analyzer is a Vacuum Florescent Display with two lines of 40 text characters each. Information is organized in the following manner: MODE FIELD: The far left portion of the top line of text displays the name of the operation mode in which the analyzer is currently operating for more information on operation modes see Section 6.1. MESSAGE FIELD: The center portion of the top line of text displays a variety of informational messages. Warning messages are displayed here, as are responses by the analyzer to queries for operation data about the instrument. During interactive tasks, such as instrument calibration or certain diagnostic procedures, the instrument’s response messages are also displayed here. CONCENTRATION FIELD: The far right portion of the top line of text displays the concentration of the sample gas currently being measured by the analyzer. The number reported here is the actual concentration of the Sample Gas reported in whatever units the user selects. This number remains unaffected, regardless of how the ranges of the instrument’s analog outputs are configured. KEY DEFINITION FIELD: The Bottom line of text displays is reserved for defining the function of the row of keys just below the display. These definitions change depending on which part of the software menu tree is currently being displayed. 11.4.1.2. Keypad The row of eight keys just below the Vacuum Florescent Display are the main method by which the user interacts with the analyzer. These keys are context sensitive and are dynamically re-defined as the user moves around in the software menu structure. 11.4.1.3. Front Panel States LED’s There are three status LED’s located in the upper right corner of the Model 400E’s Front Pane. They are: Table 11-6: Front Panel Status LED’s NAME COLOR STATE Off SAMPLE Green Yellow On Blinking Unit is operating in SAMPLE mode front panel display being updated, iDAS Hold-Off mode is ON, iDAS disabled On Blinking FAULT 04315 Rev. C1 Red Unit is not operating in SAMPle mode, iDAS is disabled. Unit is operating in SAMPLe mode, front panel display being updated, iDAS data being stored. Off CAL DEFINITION Off Blinking AUTOCAL disabled AUTOCAL enabled Unit is in calibration mode No warnings exist Warnings exist 215 Theory of Operation M400E Ozone Analyzer Operator’s Manual 11.5. SOFTWARE OPERATION The Model 400E Ozone Analyzer is at its heart a high performance, 386-based microcomputer running MSDOS. Inside the DOS shell, special software developed by Teledyne Instruments interprets user commands vie the various interfaces, performs procedures and tasks, stores data in the CPU’s various memory devices and calculates the concentration of the sample gas. DOS Shell API FIRMWARE Analyzer Operations Memory Handling Calibration Procedures Configuration Procedures Autonomic Systems Diagnostic Routines IDAS Records Calibration Data System Status Data PC/104 BUS ANALYZER HARDWARE Interface Handling Sensor input Data Display Messages Keypad Analog Output Data RS232 & RS485 External Digital I/O Measurement Algorithm PC/104 BUS Figure 11-21: Basic Software Operation 11.5.1. ADAPTIVE FILTER The Model 400E software processes sample Gas Measurement and Reference data through a built-in adaptive filter built into the software. Unlike other analyzers that average the output signal over a fixed time period, the Model 400E averages over a set number of samples, where a new sample is calculated approximately every 3 seconds -this is technique is known as boxcar averaging. During operation, the software automatically switches between two different length filters based on the conditions at hand. During conditions of constant or nearly constant concentration, the software, by default, computes an average of the last 32 samples, or approximately 96 seconds. This provides the calculation portion of the software with smooth stable readings. If a rapid change in concentration is detected, the filter length is changed to average the last 6 samples, approximately 18 seconds of data, to allow the analyzer to respond more quickly. If necessary, these boxcar lengths can be changed between 1 and 1000 samples but with corresponding tradeoffs in rise time and signal-to-noise ratio (contact customer service for more information). Two conditions must be simultaneously met to switch to the short filter. First, the instantaneous concentration must exceed the average in the long filter by a fixed amount. Second, the instantaneous concentration must exceed the average in the long filter by a portion, or percentage, of the average in the long filter. 216 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Theory of Operation 11.5.2. CALIBRATION - SLOPE AND OFFSET Calibration of the analyzer is performed exclusively in software. During instrument calibration, (see Chapters 9 and 10) the user enters expected values for zero and span via the front panel keypad and commands the instrument to make readings of calibrated sample gases for both levels. The readings taken are adjusted, linearized and compared to the expected values. With this information, the software computes values for instrument slope and offset and stores these values in memory for use in calculating the O3 Concentration of the sample gas. The instrument slope and offset values recorded during the last calibration can be viewed by pressing the following keystroke sequence: SAMPLE RANGE = 500.0 PPB < TST TST > CAL SAMPLE SETUP TIME = 16:23:34 < TST TST > CAL SAMPLE < TST TST > CAL < TST TST > CAL O3 =XXX.X SETUP OFFSET = 0.000 SAMPLE O3 =XXX.X O3 =XXX.X SETUP SLOPE = 1.000 O3 =XXX.X SETUP USER NOTES: 04315 Rev. C1 217 Theory of Operation M400E Ozone Analyzer Operator’s Manual USER NOTES: 218 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures 12. MAINTENANCE SCHEDULE & PROCEDURES For the most part, the M400E analyzer is maintenance free, there are, however, a minimal number of simple procedures that when performed regularly will ensure that the M400E photometer continues to operate accurately and reliably over its lifetime. Repairs and troubleshooting are covered in Chapter13 of this manual. 12.1. PREDICTING FAILURES USING THE TEST FUNCTIONS Predictive diagnostic functions including failure warnings and alarms built into the analyzer’s firmware allow the user to determine when repairs are necessary without performing painstaking preventative maintenance procedures. The Test Functions can also be used to predict failures by looking at how their values change over time. Initially it may be useful to compare the state of these Test Functions to the values recorded on the printed record of the final calibration performed on your instrument at the factory, P/N 04314. The following table can be used as a basis for taking action as these values change with time. The internal data acquisition system (Idas) is a convenient way to record and track these changes. Use APICOM to download and review this data from a remote location. Table 12-1: Predictive Uses for Test Functions FUNCTION MODE BEHAVIOR STABIL ZERO CAL Increasing O3 REF SAMPLE Decreasing O3 DRIVE CALS Increasing Increasing > 1” PRES SAMPLE Decreasing > 1” SAMP FL SAMPLE SLOPE SPAN CAL Decreasing Increasing Decreasing Increasing OFFSET ZERO CAL Decreasing 04315 Rev. C1 INTERPRETATION Pneumatic leaks – instrument & sample system Malfunctioning UV lamp (Bench) UV lamp ageing Mercury contamination Ageing IZS UV lamp (only if reference detector option is installed) Pneumatic Leak between sample inlet and optical bench Dirty particulate filter Pneumatic obstruction between sample inlet and optical bench Obstruction in sampling manifold Pump diaphragm deteriorating Sample flow orifice plugged/obstructed Pneumatic obstruction between sample inlet and optical bench Obstruction in sampling manifold Pneumatics becoming contaminated/dirty Dirty particulate filter Pneumatic leaks – instrument & sample system Contaminated calibration gas Obstructed/leaking Meas/Ref Valve Pneumatic leaks – instrument & sample system Contaminated zero calibration gas Obstructed Meas/Ref Valve Pneumatic leaks – instrument & sample system 219 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual 12.2. MAINTENANCE SCHEDULE Table 12-2 shows a typical maintenance schedule for the M400E. Please note that in certain environments (i.e. dusty, very high ambient pollutant levels) some maintenance procedures may need to be performed more often than shown. NOTE A span and zero calibration check (see CAL CHECK REQ’D Column of Table 9-1) must be performed following some of the maintenance procedures listed below. To perform a CHECK of the instrument’s Zero or Span Calibration follow the same steps as described in Section 9.3 DO NOT PRESS THE ENTR KEY at the end of each operation. Pressing the ENTR key resets the stored values for OFFSET and SLOPE and alters the instruments Calibration. Alternately, use the Auto cal feature described in Section9.4 with the with the CALIBRATE ATTRIBUTE SET TO OFF. CAUTION Electrical Shock Hazard RISK OF ELECTRICAL SHOCK. DISCONNECT POWER BEFORE PERFORMING ANY OF THE FOLLOWING OPERATIONS THAT REQUIRE ENTRY INTO THE INTERIOR OF THE ANALYZER. CAUTION Qualified Personnel THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY. 220 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures Table 12-2: M400E Maintenance Schedule DATE PERFORMED CAL CHECK REQ’D.1 MANUAL SECTION ITEM ACTION FREQ Particulate Filter Replace Weekly or as needed Yes 12.3.1 Verify Test Functions Record and analyze Weekly or after any Maintenance or Repair No 13.1.2 Pump Diaphragm Replace As Needed Yes -- O3 Scrubber Replace Annually Yes 13.10.2 IZS Zero Air Scrubber Replace Annually No 13.10.3 Absorption Tube Inspect --Clean Annually --As Needed Yes 12.3.6 Perform Flow Check Check Flow Every 6 Months No 12.3.5 Perform Leak Check Perform Leak Check Annually or after any Maintenance or Repair Yes 12.3.4 Pneumatic lines Examine and clean As needed Yes if cleaned -- 04315 Rev. C1 221 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual USER NOTES: 222 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures 12.3. MAINTENANCE PROCEDURES The following procedures are to be performed periodically as part of the standard maintenance of the Model 400E. 12.3.1. REPLACING THE SAMPLE PARTICULATE FILTER The particulate filter should be inspected often for signs of plugging or contamination. We recommend that when you change the filter; handle it and the wetted surfaces of the filter housing as little as possible. Do not touch any part of the housing, filter element, PTFE retaining ring, glass cover and the o-ring with your bare hands. T-API recommends using PTFE coated tweezers or similar handling to avoid contamination of the sample filter assembly. To change the filter: 1. Turn OFF the analyzer to prevent drawing debris into the instrument. 2. Open the M400E’s hinged front panel and unscrew the knurled retaining ring on the filter assembly. Figure 12-1 Replacing the Particulate Filter 3. Carefully remove the retaining ring, PTFE o-ring, glass filter cover and filter element. 4. Replace the filter, being careful that the element is fully seated and centered in the bottom of the holder. 5. Re-install the PTFE o-ring with the notches up; the glass cover, then screw on the retaining ring and hand tighten. Inspect the seal between the edge of filter and the o-ring to assure a proper seal. 6. Re-start the Analyzer. 04315 Rev. C1 223 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual 12.3.2. REBUILDING THE SAMPLE PUMP The diaphragm in the sample pump periodically wears out and must be replaced. A sample rebuild kit is available – see Appendix B of this manual for the part number of the pump rebuild kit. Instructions and diagrams are included with the kit. Always perform a flow and leak check after rebuilding the sample pump. 12.3.3. REPLACING THE IZS OPTION ZERO AIR SCRUBBER 1. Turn off the analyzer. 2. Remove the cover from the analyzer. 3. Disconnect the white nylon ¼”-1/8” fitting from the Zero Air Scrubber (See Figure 12-2). 4. Remove the old scrubber by disconnecting the 9/16” fitting at the top of the O3 generator tower, then removing the scrubber. 5. Install the new scrubber by reversing these instructions. IZS Zero Air Scrubber Figure 12-2 224 Replacing the IZS Zero Air Scrubber 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures 12.3.4. PERFORMING LEAK CHECKS Leaks are the most common cause of analyzer malfunction; Section 12.3.4.1 presents a simple leak check procedure. Section 12.3.4.2 details a more thorough procedure. 12.3.4.1. Vacuum Leak Check and Pump Check This method is easy and fast. It detects, but does not locate most leaks; it also verifies that the sample pump is in good condition. 1. Turn the analyzer ON, and allow enough time for flows to stabilize. 2. Cap the sample inlet port. 3. After 2 minutes, when the pressures have stabilized, note the SAMP FL and PRES test function readings on the front panel. 4. If SAMP FL < 10 CC/M then the analyzer is free of any large leaks. 5. If PRES < 10 IN-HG-A then the sample pump diaphragm is in good condition. 12.3.4.2. Pressure Leak Check If you cannot locate the leak by the above procedure, obtain a leak checker similar to the T-API part number 01960, which contains a small pump, shut-off valve and pressure gauge. Alternatively, a tank of pressurized gas, with the two-stage regulator adjusted to ≤ 15 psi; a shutoff valve and pressure gauge may be used. CAUTION General Safety Hazard Once the fittings have been wetted with soap solution, DO NOT apply / re-apply vacuum, as this will cause soap solution to be drawn into the instrument, contaminating it. DO NOT exceed 15 psi pressure. 1. Turn OFF power to the instrument. 2. Install a leak checker or tank of gas as described above on the sample inlet at the rear panel. 3. Install a cap on the exhaust fitting on the rear panel. 4. Remove the instrument cover and locate the sample pump. Disconnect the two fittings on the sample pump and install a union fitting in place of the pump. The analyzer cannot be leak checked with the pump in line due to internal leakage that normally occurs in the pump. 5. Pressurize the instrument with the leak checker, allowing enough time to pressurize the instrument through the critical flow orifice fully. Check each fitting with soap bubble solution, looking for bubbles. Once the fittings have been wetted with soap solution, do not re-apply vacuum, as it will draw soap solution into the instrument and contaminate it. Do not exceed 15 psi pressure. 6. If the instrument has one of the zero and span valve options, the normally closed ports on each valve should also be separately checked. Connect the leak checker to the normally closed ports and check with soap bubble solution. 7. If the analyzer is equipped with an IZS option, connect the leak checker to the dry air inlet and check with soap bubble solution. 8. Once the leak has been located and repaired, the leak-down rate should be < 1 in-Hg (0.4 psi) in 5 minutes after the pressure is shut off. 04315 Rev. C1 225 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual 12.3.5. PERFORMING A SAMPLE FLOW CHECK NOTE Always use a separate calibrated flow meter capable of measuring flows in the 0 – 1000 cc/min range to measure the gas flow rate though the analyzer. DO NOT use the built in flow measurement viewable from the Front Panel of the instrument. This measurement is only for detecting major flow interruptions such as clogged or plugged gas lines. See Figure 3-2, Figure 3-3 and Figure 5-4 for sample port location. 1. Turn off power. 2. Attach the flow meter to the sample inlet port on the rear panel. Ensure that the inlet to the Flow Meter is at atmospheric pressure. 3. Turn on instrument power. 4. Sample flow should be 800 cc/min 10%. Low flows indicate blockage somewhere in the pneumatic pathway. High flows indicate leaks downstream of the Flow Control Assembly. Once an accurate measurement has been recorded by the method described above, adjust the analyzer’s internal flow sensors by following the procedure described in Section9.5.2. 226 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures 12.3.6. MAINTENANCE OF THE PHOTOMETER ABSORPTION TUBE 12.3.6.1. Cleaning or Replacing the Absorption Tube NOTE: Although this procedure should never be needed as long as the user is careful to supply the photometer with clean, dry and particulate free zero air only, it is included here for those rare occasions when cleaning or replacing the absorption tube may be required. 1. Make sure the analyzer is warmed-up and has been running for at least 15 minutes before proceeding. 2. Remove the center cover from analyzer the optical bench 3. Locate the optical bench (see Figure 3-4). 4. Remove the top cover of the optical bench. 5. Unclip the sample thermistor from the tube. 6. Loosen the two screws on the round tube retainers at either end of the tube. 7. Using both hands, carefully rotate the tube to free it. 8. Slide the tube towards the lamp housing. The front of the tube can now be slid past the detector block and out of the instrument. CAUTION General Safety Hazard Do not cause the tube to bind against the metal housings. The tube may break and cause serious injury. 9. Clean the tube with soapy water by running a swab from end-to-end. Rinse with isopropyl alcohol then de-ionized water 10. Air dry the tube. 11. Check the cleaning job by looking down the bore of the tube. It should be free from dirt and lint. 12. Inspect the o-rings that seal the ends of the optical tube (these o-rings may stay seated in the manifolds when the tube is removed.) If there is any noticeable damage to these o-rings, they should be replaced. 13. Re-assemble the tube into the lamp housing and perform an AUTO LEAK CHECK on the instrument. NOTE: Before re-tightening the retainer screws, gently push the tube all the way towards the front of the optical bench when it is re-assembled. This will ensure that the tube is assembled with the forward end against the stop inside the detector manifold. 04315 Rev. C1 227 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual 12.3.6.2. UV Lamp Adjustment This procedure details the steps for adjustment of the UV source lamp in the optical bench assembly. This procedure should be done whenever the test function O3 REF value drops below 3000 mV. 1. Make sure the analyzer is warmed-up and has been running for at least 15 minutes before proceeding. 2. Remove the cover from the analyzer. 3. Locate the UV DETECTOR GAIN ADJUST POT on the photometer assembly (see Figure 12-3). 4. Perform the following procedure: 5. Replace the cover on the analyzer. 228 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Figure 12-3: Maintenance Schedule & Procedures Optical Bench – Lamp Adjustment/ Installation 12.3.6.3. UV Lamp Replacement This procedure details the steps for replacement of the UV source lamp in the optical bench assembly. This procedure should be done whenever the lamp can no longer be adjusted as described in Section 12.3.6.2. 1. Turn the analyzer off. 2. Remove the cover from the analyzer. 3. Locate the Optical Bench Assembly (see Figure 3-4). 4. Locate the UV lamp at the front of the optical bench assembly (see Figure 11-16) 5. Unplug the lamp cable from the power supply connector on the side of the optical bench. 6. Slightly loosen (do not remove) the UV lamp setscrew and pull the lamp from its housing. 7. Install a new lamp in the housing, pushing it all the way in. Leave the UV lamp setscrew loose for now. 8. Turn the analyzer back on and allow it to warm up for at least 15 minutes. 9. Turn the UV detector gain adjustment pot (See Section 12.3.6.2) clockwise to its minimum value. The pot should click softly when the limit is reached. 10. Perform the UV Lamp Adjustment procedure described in Section 12.3.6.2 with the following exceptions: e) Slowly rotate the lamp in its housing (up to ¼ turn in either direction) until a MINIMUM value is observed. Make sure the lamp is pushed all the way into the housing while performing this rotation. If the PHOTO_DET will not drop below 5000 mV while performing this rotation, contact T-API Customer Service for assistance. f) Once a lamp position is found that corresponds to a minimum observed value for PHOTO_DET, tighten the lamp setscrew at the approximate minimum value observed. g) Adjust PHOTO_DET within the range of 4400 – 4600 mV. 11. Replace the cover on the analyzer. NOTE The UV lamp contains mercury (Hg), which is considered hazardous waste. The lamp should be disposed of in accordance with local regulations regarding waste containing mercury. 04315 Rev. C1 229 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual 12.3.7. ADJUSTMENT OR REPLACEMENT OF OPTIONAL IZS OZONE GENERATOR UV LAMP This procedure details the steps for replacement and initial adjustment of the UV lamp of the O3 generator included in the IZS option (OPT-51A). If you are adjusting an existing lamp, skip to Step 8. 1. Turn off the analyzer. 2. Remove the cover from the analyzer. 3. Locate the O3 generator (see Figure 3-4). UV Lamp Set Screws Lamp O-ring O3 Generator Body Figure 12-4: O3 Generator Temperature Thermistor and DC Heater Locations 4. Remove the two setscrews on the top of the O3 generator and gently pull out the old lamp. 5. Inspect the o-ring beneath the nut and replace if damaged. 6. Install the new lamp in O3 generator housing. Do not fully tighten the setscrews. The lamp should be able to be rotated in the assembly by grasping the lamp cable. 7. Turn on analyzer and allow it to stabilize for at least 20 minutes. 8. Locate the potentiometer used to adjust the O3 generator UV output. O3 Generator Body Adjustment Pot O3 Generator Reference Detector PCA Figure 12-5: 230 Location of O3 Generator Reference Detector Adjustment Pot 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Maintenance Schedule & Procedures 9. perform the following procedure: 10. Tighten the two setscrews. 11. Replace the analyzer’s cover 12. Perform a check (See Section 12.3.4). 13. Perform an Ozone generator calibration (see Section 9.6) 04315 Rev. C1 231 Maintenance Schedule & Procedures M400E Ozone Analyzer Operator’s Manual USER NOTES: 232 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13. GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER This section contains a variety of methods for identifying the source of performance problems with the analyzer. Also included in this section are procedures that are used in repairing the instrument. NOTE Qualified Personnel The operations outlined in this chapter must be performed by qualified maintenance personnel only. CAUTION General Safety Hazard Risk of electrical shock. Some operations need to be carried out with the instrument open and running. Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to the analyzer. Do not drop tools into the analyzer or leave those after your procedures. Do not shorten or touch electric connections with metallic tools while operating inside the analyzer. Use common sense when operating inside a running analyzer. 13.1. GENERAL TROUBLESHOOTING The M400E Photometric Ozone Analyzer has been designed so that problems can be rapidly detected, evaluated and repaired. During operation, it continuously performs diagnostic tests and provides the ability to evaluate its key operating parameters without disturbing monitoring operations. A systematic approach to troubleshooting will generally consist of the following five steps: 1. Note any WARNING MESSAGES and take corrective action as necessary. 2. Examine the values of all TEST FUNCTIONS and compare them to factory values. Note any major deviations from the factory values and take corrective action. 3. Use the internal electronic status LEDs to determine whether the electronic communication channels are operating properly. Verify that the DC power supplies are operating properly by checking the voltage test points on the relay PCA. Note that the analyzer’s DC power wiring is color-coded and these colors match the color of the corresponding test points on the relay PCA. 4. SUSPECT A LEAK FIRST! Customer service data indicate that the majority of all problems are eventually traced to leaks in the internal pneumatics of the analyzer or the diluent gas and source gases delivery systems. Check for gas flow problems such as clogged or blocked internal/external gas lines, damaged seals, punctured gas lines, a damaged / malfunctioning pumps, etc. 04315 Rev. C1 233 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 5. Follow the procedures defined in Section 3.5.4 to confirm that the analyzer’s vital functions are working (power supplies, CPU, relay PCA, keyboard, PMT cooler, etc.). See Figure 3-1 or the general layout of components and sub-assemblies in the analyzer. See the wiring interconnect diagram and interconnect list in Appendix D. 13.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES The most common and/or serious instrument failures will result in a warning message being displayed on the front panel. Table 13-1 lists warning messages, along with their meaning and recommended corrective action. It should be noted that if more than two or three warning messages occur at the same time, it is often an indication that some fundamental sub-system (power supply, relay PCA, motherboard) has failed rather than indication of the specific failures referenced by the warnings. In this case, it is recommended that proper operation of power supplies (See Section 13.7.2), the relay PCA (See Section13.7.5), and the motherboard (See Section13.7.7) be confirmed before addressing the specific warning messages. The M400E will alert the user that a Warning Message is active by displaying the keypad label MSG on the Front Panel. In this case, the Front panel display will look something like the following: STANDBY TEST SYSTEM RESET CAL MSG CLR SETUP The analyzer will also alert the user via the Serial I/O COM port(s) and cause the FAULT LED on the front panel to blink. To view or clear the various warning messages press: SAMPLE Suppresses the warning messages TEST SAMPLE TEST SAMPLE TEST SYSTEM Once the last warning has been cleared, the ACT CAL function returns will be displayed in the analyzer’s main MESSAGE FIELD. 234 SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET CAL MSG CLR SETUP SYSTEM RESET TEST STANDBY TEST MSG returns the active warnings to the message field. Press CLR to clear the current message. If more than one warning is active, the next message will take its place. CLR SETUP RANGE=500.0 PPB CAL MSG SETUP NOTE: If a warning message persists after several attempts to clear it, the message may indicate a real problem and not an artifact of the warm-up period 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer Table 13-1: Front Panel Warning Messages WARNING PHOTO TEMP WARNING FAULT CONDITION The optical bench temperature lamp temp is 51C. POSSIBLE CAUSES Bench lamp heater Bench lamp temperature sensor Relay controlling the bench heater Entire Relay Board 2 I C Bus “Hot” Lamp Box Temperature typically runs ~7C warmer than ambient temperature. Poor/blocked ventilation to the analyzer Stopped Exhaust-Fan Ambient Temperature outside of specified range BOX TEMP WARNING Box Temp is < 5C or > 48C. CANNOT DYN SPAN Dynamic Span operation failed. Measured concentration value is too high or low Concentration Slope value to high or too low CANNOT DYN ZERO Dynamic Zero operation failed. Measured concentration value is too high Concentration Offset value to high CONFIG INITIALIZED Configuration and Calibration data reset to original Factory state. Failed Disk on Chip User erased data DATA INITIALIZED Data Storage in iDAS was erased. Failed Disk-on-Chip. User cleared data. FRONT PANEL WARN The CPU is unable to Communicate with the Front Panel Display /Keyboard LAMP STABIL WARN Reference value is unstable. REAR BOARD NOT DET RELAY BOARD WARN SAMPLE FLOW WARN Motherboard not detected on power up. The CPU cannot communicate with the Relay Board. Sample flow rate is < 500 cc/min or > 1000 cc/min. Sample Pressure is <15 in-Hg or > 35 in-Hg SAMPLE PRES WARN SAMPLE TEMP WARN Normally 29.92 in-Hg at sea level decreasing at 1 in-Hg per 1000 ft of altitude (with no flow – pump disconnected). Sample temperature is < 10C or > 50C. WARNING only appears on Serial I/O COM Port(s) Front Panel Display will be frozen, blank or will not respond. Failed Keyboard 2 I C Bus failure Loose Connector/Wiring Faulty UV source lamp Noisy UV detector Faulty UV lamp power supply THIS WARNING only appears on Serial I/O COM Port(s) Front Panel Display will be frozen, blank or will not respond. Failure of Motherboard 2 I C Bus failure Failed Relay Board Loose connectors/wiring Failed Sample Pump Blocked Sample Inlet/Gas Line Dirty Particulate Filter Leak downstream of Critical Flow Orifice Failed Flow Sensor If Sample Pressure is < 15 in-HG: Blocked Particulate Filter Blocked Sample Inlet/Gas Line Failed Pressure Senor/circuitry If Sample Pressure is > 35 in-HG: Bad Pressure Sensor/circuitry Ambient Temperature outside of specified range Failed Sample Temperature Sensor Relay controlling the Bench Heater Failed Relay Board 2 I C Bus (table continued) 04315 Rev. C1 235 General Troubleshooting & Repair of the M400E Analyzer Table 13-1: Front Panel Warning Messages WARNING FAULT CONDITION PHOTO REF WARNING Occurs when Ref is <2500 mVDC or >4950 mVDC. O3 GEN TEMP WARNING SYSTEM RESET M400E Ozone Analyzer Operator’s Manual IZS Ozone Generator Temp is outside of control range of 48C 3C. The computer has rebooted. POSSIBLE CAUSES UV Lamp UV Photo-Detector Preamp No IZS option installed, instrument improperly configured O3 generator heater O3 generator temperature sensor Relay controlling the O3 generator heater Entire Relay Board 2 I C Bus This message occurs at power on. If it is confirmed that power has not been interrupted: Failed +5 VDC power Fatal Error caused software to restart Loose connector/wiring NOTE A failure of the analyzer’s CPU or Motherboard can result in any or ALL of the following messages. 13.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS Besides being useful as predictive diagnostic tools, the test functions viewable from the analyzers front panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzers Theory of Operation (see Chapter 11). The acceptable ranges for these test functions are listed in the “Nominal Range” column of the analyzer Final Test and Validation Data Sheet shipped with the instrument. Values outside these acceptable ranges indicate a failure of one or more of the analyzer’s subsystems. Functions whose values are still within acceptable ranges but have significantly changed from the measurement recorded on the factory data sheet may also indicate a failure. A worksheet has been provided in Appendix C to assist in recording the value of these test functions. NOTE A value of “XXXX” displayed for any of these TEST functions indicates an OUT OF RANGE reading. NOTE Sample Pressure measurements are represented in terms of ABSOLUTE pressure because this is the least ambiguous method reporting gas pressure. Absolute atmospheric pressure is about 29.92 in-Hg-A at sea level. It decreases about 1 in-Hg per 1000 ft gain in altitude. A variety of factors such as air conditioning systems, passing storms, and air temperature, can also cause changes in the absolute atmospheric pressure. 236 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer Table 13-2: Test Functions - Indicated Failures TEST FUNCTION TIME RANGE STABIL DIAGNOSTIC RELEVANCE AND CAUSES OF FAULT CONDITIONS. Time of Day clock is too fast or slow. To adjust see Section 6.4.3. Battery in clock chip on CPU board may be dead. Incorrectly, configured Measurement Range(s) could cause response problems with a Data logger or Chart Recorder attached to one of the Analog Output. If the Range selected is too small, the recording device will over range. If the Range is too big, the device will show minimal or no apparent change in readings. Indicates noise level of instrument or stability of the O3 concentration of Sample Gas. If the value displayed is too high the UV Source has become brighter. Adjust the variable gain potentiometer on the UV Preamp Board in the optical bench. If the value displayed is too low: < 100mV – Bad UV lamp or UV lamp power supply. < 2000mV – Lamp output has dropped, adjust UV Preamp Board or replace lamp. O3 MEAS & O3 REF If the value displayed is constantly changing: Bad UV lamp. Defective UV lamp power supply. Failed I2C Bus. If the O3 Ref value changes by more than 10mV between zero and span gas: Defective/leaking switching valve. PRES SAMPLE FL See Table 12-1 for SAMPLE PRES WARN. Check for Gas Flow problems. See Section 13.4 SAMPLE TEMP Temperatures outside of the specified range or oscillating temperatures are cause for concern. PHOTO LAMP Bench temp control improves instrument noise, stability and drift. Temperatures outside of the specified range or oscillating temperatures are cause for concern. See Table 12-1 for PHOTO TEMP WARNING. BOX TEMP O3 GEN TEMP If the Box Temperature is out of range, check fan in the Power Supply Module. Areas to the side and rear of instrument should allow adequate ventilation. See Table 12-1 for BOX TEMP WARNING. If the O3 Generator Temperature is out of range, check O3 Generator heater and temperature sensor. See Table 12-1 for O3 GEN TEMP WARNING. Values outside range indicate: SLOPE OFFSET Contamination of the Zero Air or Span Gas supply. Instrument is miss-calibrated. Blocked Gas Flow. Faulty Sample Pressure Sensor (P1) or circuitry. Bad/incorrect Span Gas concentration. Values outside range indicate: Contamination of the Zero Air supply. 13.1.3. DIAG SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O FUNCTION 04315 Rev. C1 237 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual The signal I/O diagnostic mode allows access to the digital and analog I/O in the analyzer. Some of the digital signals can be controlled through the keyboard. These signals, combined with a thorough understanding of the instruments Theory of Operation (found in Chapter 11), are useful for troubleshooting in three ways: The technician can view the raw, unprocessed signal level of the analyzer’s critical inputs and outputs. Many of the components and functions that are normally under algorithmic control of the CPU can be manually exercised. The technician can directly control the signal level Analog and Digital Output signals. This allows the technician to observe systematically the effect of directly controlling these signals on the operation of the analyzer. Figure 13-1 is an example of how to use the Signal I/O menu to view the raw voltage of an input signal or to control the state of an output voltage or control signal. Figure 13-1: Example of Signal I/O Function NOTE Any I/O signals changed while in the signal I/O menu will remain in effect ONLY until signal I/O menu is exited. The Analyzer regains control of these signals upon exit. See Appendix A-4 for a complete list of the parameters available for review under this menu. 238 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.2. USING THE ANALOG OUTPUT TEST CHANNEL The signals available for output over the M400E’s analog output channel can also be used as diagnostic tools. See Section 7.4 for instruction on activating the analog output and selecting a function. Table 13-3: Test Channel Outputs as Diagnostic Tools TEST CHANNEL PHOTO MEAS DESCRIPTION The raw output of the photometer during its measure cycle ZERO 0 mV FULL SCALE 5000 mV CAUSES OF EXTREMELY HIGH / LOW READINGS If the value displayed is: - >5000 mV: The UV source has become brighter; adjust the UV Detector Gain potentiometer. - < 100mV – Bad UV lamp or UV lamp power supply. - < 2000mV – Lamp output has dropped, adjust UV Preamp Board or replace lamp. If the value displayed is constantly changing: - Bad UV lamp. - Defective UV lamp power supply. 2 - Failed I C Bus. PHOTO REF The raw output of the photometer during its reference cycle 0 mV 5000 mV O3 GEN REF The raw output of the O3 generator’s reference detector 0 mV 5000 mV SAMPLE PRESSURE The pressure of gas in the photometer absorption tube 0 "Hg 40 "Hg-In-A Check for Gas Flow problems. SAMPLE FLOW The gas flow rate through the photometer 0 cm3/min 1000 cc/m Check for Gas Flow problems. SAMPLE TEMP The temperature of gas in the photometer absorption tube 0 C 70 C If the PHOTO REFERENCE value changes by more than 10mV between zero and span gas: - Defective/leaking M/R switching valve. Possible failure of: - O3 generator UV Lamp - O3 generator reference detector - O3 generator lamp power supply 2 - I C bus Possible causes of faults are the same as SAMPLE TEMP from Table 13-2 Possible failure of: - Bench lamp heater - Bench lamp temperature sensor - Relay controlling the bench heater - Entire Relay PCA 2 - I C Bus - Hot” Lamp Possible failure of: - Scrubber heater or temperature sensor - Bad or loose wiring TC input connector on relay PCA - Incorrectly configured TC input (e.g. J-type instead of Ktype) - AC Relay controlling the scrubber heater - Entire Relay PCA 2 - I C Bus PHOTO LAMP TEMP The temperature of the photometer UV lamp 0 C 70 C O3 SCRUB TEMP The temperature of the optional Metal Wool Scrubber. 0 C 70 C O3 LAMP TEMP The temperature of the IZS Option’s O3 generator UV lamp 0 mV 5000 mV Same as PHOTO TEMP WARNING from Table 13-1 CHASSIS TEMP The temperature inside the M400E’s chassis (same as BOX TEMP) 0 C 70 C Possible causes of faults are the same as BOX TEMP WARNING from Table 13-1 04315 Rev. C1 239 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.3. USING THE INTERNAL ELECTRONIC STATUS LEDS Several LEDs are located inside the instrument to assist in determining if the analyzers CPU, I2C bus and Relay PCA are functioning properly. 13.3.1. CPU STATUS INDICATOR DS5, a red LED, that is located on upper portion of the motherboard, just to the right of the CPU board, flashes when the CPU is running the main program loop. After power-up, approximately 30 – 60 seconds, DS5 should flash on and off. If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted, contact customer service because it may be possible to recover operation of the analyzer. If after 30 – 60 seconds, neither DS5 is flashing nor have any characters been written to the front panel display then the CPU is bad and must be replaced. Mother Board P/N 04069 CPU Status LED Figure 13-2: CPU Status Indicator 13.3.2. RELAY PCA STATUS LED S There are sixteen LEDs located on the Relay PCA. Some are not used on this model. 13.3.2.1. I2C Bus Watchdog Status LEDs The most important is D1 (see, which indicates the health of the I2C bus. Table 13-4: Relay PCA Watchdog LED Failure Indications LED Function Fault Status Indicated Failure(s) Failed/Halted CPU D1 (Red) I2C bus Health (Watchdog Circuit) Continuously ON or Continuously OFF Faulty Motherboard, Keyboard or Relay PCA Faulty Connectors/Wiring between Motherboard, Keyboard or Relay PCA Failed/Faulty +5 VDC Power Supply (PS1) If D1 is blinking, then the other LEDs can be used in conjunction with DIAG Menu Signal I/O to identify hardware failures of the relays and switches on the Relay. 240 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.3.2.2. O3 Option Status LED s D9 (Green) – Optional Sample/Cal Valve D8 (Green) – Photometer Meas/Ref Valve D7 (Green) Optional Zero/Span Valve D2 (Yellow) Optional Metal Wool Scrubber Heater D6 (Green ) – GPT Valve D15 (Yellow) - Photometer Lamp Heater D16 (Yellow) – IZS O3 Generator Lamp Heater D1 (RED) Watchdog Indicator Figure 13-3: Relay PCA Status LEDS Used for Troubleshooting Table 13-5: Relay PCA Status LED Failure Indications LED FUNCTION SIGNAL I/O PARAMETER ACTIVATED BY VIEW RESULT D21 Yellow Metal Wool Scrubber Heater1 O3_SCRUB_HEATER O3 SCRUB D7 Green Zero/Span Gas Valve3 SPAN_VALVE N/A D8 Green Measure/Ref Valve PHOTO_REF_VALVE N/A D9 Green Sample/Cal Gas Valve2 CAL_VALVE N/A D15 Yellow Photometer UV Lamp Heater _PHOTO_LAMP_HEATER PHOTO_LAMP D162 Green IZS O3 Generator UV Lamp Heater O3_GEN_HEATER O3 GEN TEMP 1 Only applies on analyzers with metal wool scrubber installed. 2 Only applies on analyzers with IZS options installed. 3 Only apllies to instruments with calibrtn valve options installed. 04315 Rev. C1 DIAGNOSTIC TECHNIQUE Voltage displayed should change. If not: Failed Heater Faulty Temperature Sensor Failed AC Relay Faulty Connectors/Wiring Valve should audibly change states. If not: Failed Valve Failed Relay Drive IC on Relay PCA Failed Relay PCA Faulty +12 VDC Supply (PS2) Faulty Connectors/Wiring Voltage displayed should change. If not: Failed Heater Faulty Temperature Sensor Failed AC Relay Faulty Connectors/Wiring 241 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.4. GAS FLOW PROBLEMS In general, flow problems can be divided into three categories: Flow is too high Flow is greater than zero, but is too low, and/or unstable Flow is zero (no flow) When troubleshooting flow problems, it is a good idea to first confirm that the actual flow and not the analyzer’s flow detection hardware and software are in error. Use an independent flow meter to perform a flow check as described in Section 12.3.5. 13.4.1. TYPICAL FLOW PROBLEMS 13.4.1.1. Flow is Zero The unit displays a SAMPLE FLOW warning message on the front panel display or the SAMPLE FLOW Test Function reports a zero or very low flow rate. Confirm that the sample pump is operating (turning). If not, use an AC Voltmeter to make sure that power is being supplied to the pump. If AC power is being supplied to the pump, but it is not turning, replace the pump. If the pump is operating but the unit reports no gas flow, perform a flow check as described in Section 12.3.5. If no independent flow meter is available: 1. Disconnect the gas lines from both the sample inlet and the exhaust outlet on the rear panel of the instrument. 2. Make sure that the unit is in basic SAMPLE Mode. 3. Place a finger over an exhaust outlet on the rear panel of the instrument. 4. If gas is flowing through the analyzer, you will feel pulses of air being expelled from the exhaust outlet. If gas flows through the instrument when it is disconnected from its sources of zero air, span gas or sample gas, the flow problem is most likely not internal to the analyzer. Check to make sure that: All calibrators/generators are turned on and working correctly. Valves, regulators and gas lines are not clogged or dirty. 13.4.1.2. Low Flow Check if the pump diaphragm is in good condition. If not, rebuild the pump (all Teledyne Instruments for instructions). Check the spare parts list for information of pump rebuild kits. Check for leaks as described in Section 12.3.4. Repair the leaking fitting, line or valve and re-check. Check for the sample filter and the orifice filter for dirt. Replace filters (see Sections12.3.1 and 13.10.1 respectively). Check for partially plugged pneumatic lines, orifices or valves. Clean or replace them. The critical orifice should be replaced if it becomes plugged. If an IZS option is installed in the instrument, press CALZ and CALS. If the flow increases then suspect a bad sample/cal valve. 242 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.4.1.3. High Flow The most common cause of high flow is a leak in the sample flow control assembly or between there and the pump. If no leaks or loose connections are found in the fittings or the gas line between the orifice and the pump, rebuild the sample flow control assembly as described in Section 13.10.1 . 13.4.1.4. Actual Flow Does Not Match Displayed Flow If the actual flow measured does not match the displayed flow, but is within the limits of 720-880 cc/min, adjust the calibration of the flow measurement as described in Section 13.10.1. 13.4.1.5. Sample Pump The sample pump should start immediately after the front panel power switch is turned ON. If it does not, refer to Section 13.7.1. 13.5. CALIBRATION PROBLEMS 13.5.1. MIS-CALIBRATED There are several symptoms that can be caused by the analyzer being mis-calibrated. This condition is indicated by out of range SLOPEs and OFFSETs as displayed through the test functions and is frequently caused by the following: Contaminated span gas. This can cause a large error in the slope and a small error in the offset. Span gas contaminated with a major interferent such as Mercury Vapor, will cause the analyzer to be calibrated to the wrong value. Also could be caused if the span gas concentration entered into the analyzer during the calibration procedure is not the precise concentration value of the gas used. Dilution calibrator not set up correctly or is malfunctioning. This will also cause the slope, but not the zero to be incorrect. Again, the analyzer is being calibrated to the wrong value. Too many analyzers on the manifold. This can cause either a slope or offset error because ambient gas with its pollutants will dilute the zero or span gas. Contaminated zero gas. This can cause either a positive or negative offset and will indirectly affect the slope. If contaminated with O3 it will cause a positive offset. 13.5.2. NON-REPEATABLE ZERO AND SPAN As stated earlier, leaks both in the M400E and in the external system are a common source of unstable and nonrepeatable readings. Check for leaks in the pneumatic systems as described in Section 12.3.5. Don’t forget to consider pneumatic components in the gas delivery system outside the M400E. Such as: A change in zero air source such as ambient air leaking into zero air line, or; A change in the span gas concentration due to zero air or ambient air leaking into the span gas line. Once the instrument passes a leak check, do a flow check (see Section 12.3.5) to make sure adequate sample is being delivered to the optical bench assembly. 04315 Rev. C1 243 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual Confirm the sample pressure, sample temperature, and sample flow readings are correct and have steady readings. Verify that the sample filter element is clean and does not need to be replaced. 13.5.3. INABILITY TO SPAN – NO SPAN KEY (CALS) Confirm that theO3span gas source is accurate. This can be done by inter-comparing the source with another calibrated monitor, or having theO3source verified by an independent traceable photometer. Check for leaks in the pneumatic systems as described in Section 12.3.4. Make sure that the expected span gas concentration entered into the instrument during calibration is not too different from expected span value. Check to make sure that there is no ambient air or zero air leaking into span gas line. 13.5.4. INABILITY TO ZERO – NO ZERO KEY (CALZ) Confirm that there is a good source of zero air. If the IZS option is installed, compare the zero reading from the IZS zero air source to the calibration zero air source. Check for leaks in the pneumatic systems as described in Section 12.3.4. Check to make sure that there is no ambient air leaking into zero air line. 13.6. OTHER PERFORMANCE PROBLEMS Dynamic problems (i.e. problems that only manifest themselves when the analyzer is monitoring sample gas) can be the most difficult and time consuming to isolate and resolve. The following section provides an itemized list of the most common dynamic problems with recommended troubleshooting checks and corrective actions. 13.6.1. TEMPERATURE PROBLEMS Individual control loops are used to maintain the set point of the UV Lamp, IZS Ozone Generator (Optional) and Metal Wool Scrubber (Optional) temperatures. If any of these temperatures are out of range or are poorly controlled, the M400E will perform poorly. 13.6.1.1. Box Temperature The box temperature sensor is mounted to the Motherboard and cannot be disconnected to check its resistance. Rather check the BOX TEMP signal using the SIGNAL I/O function under the DIAG Menu (see Section 13.1.2). This parameter will vary with ambient temperature, but at ~30oC (6-7 above room temperature) the signal should be ~1450 mV. 13.6.1.2. Sample Temperature The Sample Temperature should read approximately 5.0C higher than the box temperature. 244 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.6.1.3. UV Lamp Temperature There are three possible causes for the UV Lamp temperature to have failed. The UV Lamp heater has failed. Check the resistance between pins 5 and 6 on the six-pin connector adjacent to the UV Lamp on the Optical Bench. It should be approximately 30 Ohms. Assuming that the I2C bus is working and that there is no other failure with the Relay board, the FET Driver on the Relay Board may have failed. Using the PHOTO_LAMP_HEATER parameter under the SIGNAL I/O function of the DIAG menu, as described above, turn on and off the UV Lamp Heater (D15 on the relay board should illuminate as the heater is turned on). Check the DC voltage present between pin 1 and 2 on J13 of the Relay Board. If the FET Driver has failed there will be no change in the voltage across pins 1 and 2. If the FET Driver Q2 checks out OK, the thermistor temperature sensor in the lamp assembly may have failed. Unplug the connector to the UV Lamp Heater/Thermistor PCB, and measure the resistance of the thermistor between pins 5 and 6 of the 6 pin connector. The resistance near the 58oC set point is ~8.1k ohms. 13.6.1.4. IZS Ozone Generator Temperature (Optional) There are three possible causes for the Ozone Generator temperature to have failed. TheO3Gen heater has failed. Check the resistance between pins 5 and 6 on the six-pin connector adjacent to the UV Lamp on theO3Generator. It should be approximately 5 Ohms. Assuming that the I2C bus is working and that there is no other failure with the Relay board, the FET Driver on the Relay Board (see 13.7.5) may have failed. Using the O3_GEN_HEATER parameter under the SIGNAL I/O function of the DIAG menu, as described above, turn on and off the UV Lamp Heater. Check the DC voltage present between pin 1 and 2 on J14 of the Relay Board. If the FET Driver has failed there should be no change in the voltage across pins 1 and 2. If the FET Driver checks out OK, the thermistor temperature sensor in the lamp assembly may have failed. Unplug the connector to the Ozone Generator Heater/Thermistor PCB, and measure the resistance of the thermistor between pins 5 and 6 of the 6 pin connector. 04315 Rev. C1 245 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.7. SUBSYSTEM CHECKOUT 13.7.1. AC MAIN POWER The M400E analyzer’s electronic systems will operate with any of the specified power regimes. As long as system is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display. Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. If they do not, check the circuit breaker built into the ON/OFF switch on the instruments front panel The analyzer is correctly configured for the AC mains voltage in use if: The Sample Pump is running. If incorrect power is suspected, check that the correct voltage and frequency is present at the line input on the rear panel. Verify that the pump power configuration plug is properly wired (see Section 11.3.6.1) If the unit is set for 230 VAC and is plugged into 115 VAC or 100 VAC the sample pump will not start. If the unit is set for 115 or 100 VAC and is plugged into a 230 VAC circuit, the circuit breaker built into the ON/OFF Switch on the front panel will trip to the OFF position immediately after power is switched on. CAUTION Electrical Shock Hazard Should the AC power circuit breaker trip, investigate and correct the condition causing this situation before turning the analyzer back on. 13.7.2. DC POWER SUPPLY If you have determined that the analyzer’s AC mains power is working, but the unit is still not operating properly, there may be a problem with one of the instrument’s switching power supplies. The supplies can have two faults, namely no DC output, and noisy output. To assist tracing DC Power Supply problems, the wiring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the relay PCA follow a standard color-coding scheme as defined in the following table. Table 13-6: DC Power Test Point and Wiring Color Codes 246 NAME TEST POINT# COLOR DEFINITION DGND 1 Black Digital ground +5V 2 Red AGND 3 Green +15V 4 Blue -15V 5 Yellow +12R 6 Purple +12V 7 Orange Analog ground 12 V return (ground) line 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer TP1 TP2 TP3 TP4 TP5 TP6 TP7 DGND +5V AGND +15V -15V +12R 12V Figure 13-4: Location of DC Power Test Points on Relay PCA A voltmeter should be used to verify that the DC voltages are correct per the values in the table below, and an oscilloscope, in AC mode, with band limiting turned on, can be used to evaluate if the supplies are producing excessive noise (> 100 mV p-p). Table 13-7: DC Power Supply Acceptable Levels VOLTAGE POWER SUPPLY CHECK RELAY BOARD TEST POINTS FROM TO Test Point Test Point MIN V MAX V NAME # NAME # PS1 +5 DGND 1 +5 2 +4.80 +5.25 PS1 +15 AGND 3 +15 4 +13.5 +16.0 PS1 -15 AGND 3 -15V 5 -14.0 -16.0 PS1 AGND AGND 3 DGND 1 -0.05 +0.05 PS1 Chassis DGND 1 Chassis N/A -0.05 +0.05 PS2 +12 +12V Ret 6 +12V 7 +11.8 +12.5 PS2 DGND +12V Ret 6 DGND 1 -0.05 +0.05 13.7.3. I2C BUS Operation of the I2C bus can be verified by observing the behavior of D1 on the relay PCA & D2 on the valve driver PCA in conjunction with the performance of the front panel display. Assuming that the DC power supplies are operating properly the I2C bus is operating properly if: If D1 on the relay PCA and is flashing, or Pressing a key on the front panel results in a change to the display. There is a problem with the I2C bus if D1 on the relay PCA is ON/OFF constantly and pressing a key on the front panel DOES NOT results in a change to the display. If the keyboard interface is working but either the Watchdog LED is not flashing, the problem may be a wiring issue between the board and the motherboard 04315 Rev. C1 247 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.7.4. KEYBOARD/DISPLAY INTERFACE The front panel keyboard, display and Keyboard Display Interface PCA can be verified by observing the operation of the display when power is applied to the instrument and when a key is pressed on the front panel. Assuming that there are no wiring problems and that the DC power supplies are operating properly: The vacuum fluorescent display is good if on power-up a “-“ character is visible on the upper left hand corner of the display. If there is no “-“ character on the display at power-up and D1 on the Relay PCA or D2 on the valve driver PCA is flashing then the Keyboard/Display Interface PCA is bad. The CPU Status LED, DS5, is flashing, but there is no “-“ character on the display at power-up If the analyzer starts operation with a normal display but pressing a key on the front panel does not change the display, then there are three possible problems. 1. One or more of the keys is bad, 2. The interrupt signal between the Keyboard Display interface and the motherboard is broken, or 3. The Keyboard Display Interface PCA is bad. 13.7.5. RELAY PCA The Relay PCA can be most easily checked by observing the condition of the status LEDs on the Relay PCA (see Section 13.3.2), and using the SIGNAL I/O submenu under the DIAG menu (see Section 13.1.3) to toggle each LED ON or OFF. If D1 on the Relay PCA is flashing and the status indicator for the output in question (Heater power, Valve Drive, etc.) toggles properly using the Signal I/O function, then the associated control device on the Relay PCA is bad. Several of the control devices are in sockets and can be easily replaced. The table below lists the control device associated with a particular function. Table 13-8: Relay PCA Control Devices 248 FUNCTION CONTROL DEVICE IN SOCKET UV Lamp Heater Q2 No Optional IZSO3Gen Heater Q3 No Optional Metal Wool Scrubber K1 Yes All Valves U5 Yes 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.7.6. PHOTOMETER PRESSURE /FLOW SENSOR ASSEMBLY This assembly is only present in analyzers with O3 generator and/or photometer options installed. The pressure/flow sensor PCA, located at the rear of the instrument between the photometer and the pump (see Figure 3-4) can be checked with a Voltmeter. The following procedure assumes that the wiring is intact and that the motherboard as well as the power supplies are operating properly: BASIC PCA OPERATION: Measure the voltage across C1 it should be 5 VDC ± 0.25 VDC. If not then the board is bad Measure the voltage between TP2 and TP1 C1 it should be 10 VDC ± 0.25 VDC. If not then the board is bad. PHOTOMETER PRESSURE SENSOR: 1. Measure the pressure on the inlet side of S1 with an external pressure meter. 2. Measure the voltage across TP4 and TP1. The expected value for this signal should be: EXAMPLE: If the measured pressure is 20 Hg-in-A, the expected voltage level between TP4 and TP1 would be between 2870 mVDC and 3510 mVDC. EXAMPLE: If the measured pressure is 25 Hg-in-A, the expected voltage level between TP4 and TP1 would be between 3533 mVDC and 4318 mVDC. If this voltage is out of range, then either pressure transducer S1 is bad, the board is bad or there is a pneumatic failure preventing the pressure transducer from sensing the absorption cell pressure properly. PHOTOMETER FLOW SENSOR Measure the voltage across TP3 and TP1. With proper flow (800 cc3/min through the photometer), this should be approximately 4.5V (this voltage will vary with altitude). With flow stopped (photometer inlet disconnected or pump turned OFF) the voltage should be approximately 1V. If the voltage is incorrect, the flow sensor S3 is bad, the board is bad or there is a leak upstream of the sensor. 04315 Rev. C1 249 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.7.7. MOTHERBOARD 13.7.7.1. Test Channel / Analog Outputs Voltage The ANALOG OUTPUT submenu, located under the SETUP MORE DIAG menu is used to verify that the M400E analyzer’s three analog outputs are working properly. The test generates a signal on all three outputs simultaneously as shown in the following table: For each of the steps the output should be within 1% of the nominal value listed in the table below except for the 0% step, which should be within 0mV ±2 to 3 mV. Make sure you take into account any offset that may have been programmed into channel (See Section 7.4.5). Table 13-9: Analog Output Test Function - Nominal Values Voltage Outputs FULL SCALE OUTPUT OF VOLTAGE RANGE (see Section 7.4.3) 100MV 1V 5V 10V STEP % 1 0 0 NOMINAL OUTPUT VOLTAGE 0 0 0 2 20 20 mV 0.2 1 2 3 40 40 mV 0.4 2 4 4 60 60 mV 0.6 3 6 5 80 80 mV 0.8 4 8 6 100 100 mV 1.0 5 10 If one or more of the steps fails to be within these ranges, it is likely that there has been a failure of the either or both of the DACs and their associated circuitry on the motherboard. To perform the test connect a voltmeter to the output in question and perform an analog output step test as follows: 250 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.7.7.2. A/D Functions The simplest method to check the operation of the A-to-D converter on the motherboard is to use the Signal I/O function under the DIAG menu to check the two A/D reference voltages and input signals that can be easily measured with a voltmeter. 1. Use the Signal I/O function (See Section 13.1.3 and Appendix A) to view the value of REF_4096_MV and REF_GND. If both are within 3 mV of nominal (4096 and 0), and are stable, ±0.5 mV then the basic A/D is functioning properly. If not then the motherboard is bad. 2. Choose a parameter in the Signal I/O function such as PHOTO_LAMP_DRIVE or SAMPLE_FLOW. Compare these voltages at their origin (see the interconnect drawing and interconnect list in Appendix D) with the voltage displayed through the signal I/O function. If the wiring is intact but there is a large difference between the measured and displayed voltage (±10 mV) then the motherboard is bad. 13.7.7.3. Status Outputs To test the status output electronics: 1. Connect a jumper between the “D“pin and the “” pin on the status output connector. 2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested. 3. Connect a voltmeter between the “” pin and the pin of the output being tested (see table below). 4. Under the DIAG SIGNAL I/O menu (See Section13.1.3), scroll through the inputs and outputs until you get to the output in question. 5. Alternately, turn on and off the output noting the voltage on the voltmeter. It should vary between 0 volts for ON and 5 volts for OFF. Table 13-10: 04315 Rev. C1 Status Outputs Check PIN (LEFT TO RIGHT) STATUS 1 ST_SYSTEM_OK 2 ST_CONC_VALID 3 ST_HIGH_RANGE 4 ST_ZERO_CAL 5 ST_SPAN_CAL 6 ST_DIAGMODE 7 ST_FLOW_ALARM 8 ST_PRESS_ALARM 251 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.7.7.4. Control Inputs The control input bits can be tested by applying a trigger voltage to an input and watching changes in the status of the associated function under the SIGNAL I/O submenu: EXAMPLE: to test the “A” control input: 1. Under the DIAG SIGNAL I/O menu (See Section13.1.3), scroll through the inputs and outputs until you get to the output named EXT_ZERO_CAL. 2. Connect a jumper from the “+” pin on the appropriate connector to the “U” on the same connector. 3. Connect a second jumper from the “” pin on the connector to the “A” pin. 4. The status of EXT_ZERO_CAL should change to read “ON”. Table 13-11: M400E Control Input Pin Assignments and Corresponding Signal I/O Functions INPUT 1 CORRESPONDING I/O SIGNAL A EXT_ZERO_CAL B EXT_LOW_SPAN_CAL1 C EXT_SPAN_CAL D, E& F NOT USED Only operates if either Z/S or IZS option is installed 13.7.8. CPU There are two major types of failures associated with the CPU board: complete failure and a failure associated with the Disk-On Chip on the CPU board. If either of these failures occur, contact the factory. For complete failures, assuming that the power supplies are operating properly and the wiring is intact, the CPU is bad if on powering the instrument: The vacuum fluorescent display shows a dash in the upper left hand corner. The CPU Status LED, DS5, is not flashing (See Section 13.3.1). There is no activity from the primary RS-232 port on the rear panel even if “? ” is pressed. In some rare circumstances this failure may be caused by a bad IC on the motherboard, specifically U57 the large, 44 pin device on the lower right hand side of the board. If this is true, removing U57 from its socket will allow the instrument to startup but the measurements will be incorrect. If the analyzer stops part way through initialization (there are words on the vacuum fluorescent display) then it is likely that the DOC has been corrupted. 252 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.7.9. RS-232 COMMUNICATIONS 13.7.9.1. General RS-232 Troubleshooting Teledyne Instruments analyzers use the RS-232 communications protocol to allow the instrument to be connected to a variety of computer-based equipment. RS-232 has been used for many years and as equipment has become more advanced, connections between various types of hardware have become increasingly difficult. Generally, every manufacturer observes the signal and timing requirements of the protocol very carefully. Problems with RS-232 connections usually center around 4 general areas: Incorrect cabling and connectors. See Section 8.1.2 for connector and pin-out information. The BAUD rate and protocol are incorrectly configured. See Section 8.1.3. If a modem is being used, additional configuration and wiring rules must be observed. See Section 8.2 Incorrect setting of the DTE – DCE Switch is set correctly. See Section 8.1.1 Verify that cable (03596) that connects the serial COM ports of the CPU to J12 of the motherboard is properly seated 13.7.9.2. Troubleshooting Analyzer/Modem or Terminal Operation These are the general steps for troubleshooting problems with a modem connected to a Teledyne Instruments analyzer. Check cables for proper connection to the modem, terminal or computer. Check to make sure the DTE-DCE is in the correct position as described in Section 8.1.1. Check to make sure the set up command is correct (See Section 8.2) Verify that the Ready to Send (RTS) signal is at logic high. The M400E sets pin 7 (RTS) to greater than 3 volts to enable modem transmission. Make sure the BAUD rate, word length, and stop bit settings between modem and analyzer match, See Section 8.1.3. Use the RS-232 test function to send “w” characters to the modem, terminal or computer; See Section 8.1.5. Get your terminal, modem or computer to transmit data to the analyzer (holding down the space bar is one way); the green LED should flicker as the instrument is receiving data. Make sure that the communications software or terminal emulation software is functioning properly. NOTE Further help with serial communications is available in a separate manual “RS-232 Programming Notes” Teledyne Instruments part number 013500000. 04315 Rev. C1 253 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.8. TROUBLE SHOOTING THE PHOTOMETER 13.8.1. CHECKING MEASURE / REFERENCE VALVE To check the function of the photometer’s measure / reference valve: 1. Set the analyzer’s front panel display to show the O3 REF test function (see Section 6.2.1). 2. Follow the instruction in Section 9.2.3 for performing a zero point calibration. Press ZERO and allow the analyzer to stabilize. 3. Before completing the calibration by pressing the ENTR key, note of the displayed value. 4. Press the EXIT key to interrupt the zero point calibration process (DO NOT PRESS the ENTR key). 5. Follow the instruction in Sections Section 9.2.3 for performing a span point calibration of the photometer. Press SPAN and allow the analyzer to stabilize. 6. Before completing the calibration by pressing the ENTR key, note of the displayed value of O3 REF. If the O3 REF value has decreased by more than 2 mV from its value with zero gas, then there is a "cross-port" leak in the M/R valve or a bad O3 scrubber. 7. Press the EXIT key to interrupt the span point calibration process (DO NOT PRESS the ENTR key). 13.8.2. CHECKING THE PHOTOMETER UV LAMP POWER SUPPLY NOTE A schematic and physical diagram of the Lamp Power Supply can be found in Appendix D. CAUTION Electrical Shock Hazard Hazardous voltage present - use caution. It is not always possible to determine with certainty whether a problem is the result of the UV Lamp or the lamp power supply, however, the following steps will provide a reasonable confidence test of the lamp power supply. 1. Unplug the cable connector at P1 on the lamp power supply and confirm that +15VDC is present between Pins 1 and 2 on the cable connector. 2. If this voltage is incorrect, check the DC test points on the relay PCA as described in Section 13.7.2. 254 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 3. Remove the cover of the photometer and check for the presence of the following voltages on the UV lamp power supply PCA (see Figure 11-16): +4500 mVDC ± 10 mVDC between TP1 and TP4 (grnd) If this voltage is incorrect, either the UV lamp power supply PCA is faulty or the I2C bus is not communicating with the UV lamp power supply PCA. +5VDC between TP3 and TP4 (grnd) If this voltages is less than 4.8 or greater than 5.25 either the 5 VDC power supply or the UV lamp power supply PCA are faulty... If the above voltages check out, it is more likely that a problem is due to the UV lamp than due to the lamp power supply. Replace the lamp and if the problem persists, replace the lamp power supply. 13.9. TROUBLE SHOOTING THE IZS OPTIONS O3 GENERATOR The only significant components of the O3 generator that might reasonable malfunction is the power supply assembly for the UV source lamp and the lamp itself. 13.9.1. CHECKING THE O3 GENERATOR UV LAMP POWER SUPPLY The lamp power supply for the IZS options O3 generator is the same assembly used for the photometer’s lamp power supply. The method for checking it out is identical to that listed in Section 13.8.2 above. 04315 Rev. C1 255 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.10. REPAIR PROCEDURES 13.10.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY The Critical Flow Orifice is part of the Flow Control Assembly located on the sample pump assembly or optionally in the ozone generator for instruments with the IZS option. The jewel orifice is protected by a sintered filter, so it is unusual for the orifice to need replacing, but it is possible for the sintered filter and o-rings to need replacing. See the Spare Parts list in Appendix B for part numbers and kits. Procedure: 1. Turn off Power to the analyzer. 2. Locate the flow control assembly attached to the sample pump. See Figure 3-4. 3. Disconnect the pneumatic fittings. 4. Remove the assembly from the sample pump by disconnecting the ¼” tube fitting on the pump inlet elbow. 5. The inlet end of the assembly is the straight ¼” tube to 1/8” male NPT fitting. Remove the fitting and the components as shown in the exploded view in the following figure. 6. Replace the O-rings and the sintered filter. 7. If you are replacing the Critical Flow Orifice itself, make sure that the side with the red colored sapphire jewel is facing downstream to the flow gas flow. 8. Re-assemble in reverse order. See the Spares List in Appendix B for part numbers. 9. After re-connecting the power and pneumatic lines, verify flow rate is between 720 and 880 cc/min. Pneumatic Connector, Male 1/4” (P/N FT0000070) Spring (P/N HW0000020) Sintered Filter (P/N FL0000001) Critical Flow Orifice (P/N 00094-1000) O-Ring (P/N OR0000001) Housing (P/N 00085-0000) Figure 13-5: 256 Critical Flow Orifice Assembly (Instruments without IZS) 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual General Troubleshooting & Repair of the M400E Analyzer 13.10.2. REPLACING THE STANDARD REFERENCE O3 SCRUBBER 1. Turn off power to the instrument. 2. Remove instrument cover. 3. The reference scrubber is a blue colored canister located at the rear of the measure/reference valve Assembly. See Figure 3-4. 4. Disconnect the top 1/8” brass tube fitting from the scrubber. 5. Carefully remove the scrubber from the retaining clip. 6. Remove the bottom 1/8” brass tube fitting from the scrubber. 7. Perform the above steps in reverse to install the new scrubber. NOTE The new scrubber should be allowed to run in the instrument for at least 24 hrs after which the instrument should be re-calibrated. 13.10.3. REPLACING THE IZS O3 SCRUBBER 1. Turn off power to the instrument. 2. Remove instrument cover. 3. The IZS zero air scrubber is attached to the brass elbow inlet fitting on the top of the O3 generator assembly. See Figure 13-6. 4. Disconnect 1/4” Tube Fitting nut on O3 generator inlet fitting. 5. Disconnect 1/8” tube fitting on the other end of the scrubber. 6. Install new scrubber by reversing these steps. IZ S Z E R O A IR S C R U B B E R Figure 13-6: 04315 Rev. C1 IZS O3 Generator Zero Air Scrubber Location 257 General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual 13.10.4. METAL WOOL SCRUBBER OPTION Contact T-API for instructions on replacing the optional Metal Wool Scrubber. 13.10.5. DISK-ON-CHIP REPLACEMENT PROCEDURE Replacing the Disk-on-Chip, may be necessary in certain rare circumstances when a chip fails or when loading new instrument software. This will cause all of the instrument configuration parameters to be lost. However a backup copy of the operating parameters are stored in a second non-volatile memory and will be loaded into the new the Disk-on-Chip on power-up. To change the Disk-on-Chip, follow this procedure. 1. Turn off power to the instrument. 2. Fold down the rear panel by loosening the thumbscrews on each side 3. Locate the Disk-on-Chip in the rightmost socket near the right hand side of the CPU assembly. Remove the IC by gently prying it up from the socket. 4. Reinstall the new Disk-on-Chip, making sure the notch in the end of the chip is facing upward. 5. Close the rear panel and turn on power to the machine. 13.11. TECHNICAL ASSISTANCE If this manual and its trouble-shooting / repair sections do not solve your problems, technical assistance may be obtained from “ TELEDYNE-API, 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-sales@teledyne.com Website: http://www.teledyne-api.com/ Before you contact 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/. USER NOTES: 258 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 347BA Primer on Electro-Static Discharge 14. 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 static electricity occurs, why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring. 14.1. 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 = 3 ELECTRONS = 3 PROTONS = 3 ELECTRONS = 3 NET CHARGE = 0 NET CHARGE = 0 Figure 14-1: PROTONS = 3 ELECTRONS = 2 PROTONS = 3 ELECTRONS = 4 NET CHARGE = -1 NET CHARGE = +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 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 StyrofoamTM pellets during shipment can also build hefty static charges Table 14-1: Static Generation Voltages for Typical Activities MEANS OF GENERATION 65-90% RH 10-25% RH 1,500V 35,000V Walking across vinyl tile 250V 12,000V Worker at bench 100V 6,000V Poly bag picked up from bench 1,200V 20,000V Moving around in a chair padded with urethane foam 1,500V 18,000V Walking across nylon carpet 04315 Rev. C1 259 347BA Primer on Electro-Static Discharge M400E Ozone Analyzer Operator’s Manual 14.2. 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 14-1 with the those shown in the Table 14-2, listing device susceptibility levels, shows why Semiconductor Reliability News estimates that approximately 60% of device failures are the result of damage due to electro-static discharge. Table 14-2: Sensitivity of Electronic Devices to Damage by ESD. DEVICE DAMAGE SUSCEPTIBILITY VOLTAGE RANGE DAMAGE BEGINS OCCURRING AT CATASTROPHIC 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 This Film Resistors 300 7000 ECL 500 500 SCR 500 1000 Schottky TTL 500 2500 Potentially damaging electro-static discharges can occur: 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. 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. A typical 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 function. If the assembly is carrying a static charge, as it is connected to ground a discharge will occur. 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. 260 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 347BA Primer on Electro-Static Discharge 14.3. 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 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 other things, like you and your clothing, from discharging through the instrument and damaging it. 14.4. 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. 14.4.1. 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 Wrist Stra Ground Point Figure 14-2: 04315 Rev. C1 Basic anti-ESD Work Station 261 347BA Primer on Electro-Static Discharge M400E Ozone Analyzer Operator’s Manual 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 current 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. 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 surface, 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. 262 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 347BA Primer on Electro-Static Discharge 14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 14.4.2.1. Working at the Instrument Rack When working on the analyzer while it is in the instrument rack and plugged into a properly 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. 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. 14.4.2.2. Working at an Anti-ESD Work Bench. When working on an instrument of an electronic assembly while it is resting on a anti-ESD work bench 1. Plug you 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. This will allow any charges you are carrying to bleed away through the ground connection of the workstation and 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. Lay the bag or bin on the workbench surface. 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. 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. 5. 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. 6. Disconnecting your wrist strap is always the last action taken before leaving the workbench. 04315 Rev. C1 263 347BA Primer on Electro-Static Discharge M400E Ozone Analyzer Operator’s Manual 14.4.2.3. 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 surface charges on it to dissipate: If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at an anti-ESD workbench, lay the container down on the conductive work surface. In either case wait several seconds. 4. Place the item in the container. 5. 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. 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: Connect your wrist strap to ground. If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at a anti-ESD work bench, lay the container down on the conductive work surface In either case wait several seconds 7. Open the container. 14.4.2.4. Opening Shipments from Teledyne Instruments’ Customer Service Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of static 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: Always unpack shipments from Teledyne Instruments Customer Service by: 1. Opening the outer shipping box away from the anti-ESD work area 2. Carry the still sealed ant-ESD bag, tube or bin to the anti-ESD work area 3. Follow steps 6 and 7 of Section 14.4.2.3 above when opening the anti-ESD container at the work station 4. Reserve the anti-ESD container or bag to use when packing electronic components or assemblies to be returned to Teledyne Instruments 264 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual 347BA Primer on Electro-Static Discharge 14.4.2.5. 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, plastic bubble-pack, Styrofoam peanuts, open cell foam, closed cell foam, and adhesive tape 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: If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at an anti-ESD workbench, lay the container down on the conductive work surface. In either case wait several seconds. 3. Place the item in the container. 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. 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 bags or containers available, Teledyne Instruments’ Customer Service department will supply them (see Section 13.11 for contact information). Follow the instructions listed above for working at the instrument rack and workstation. USER NOTES: 04315 Rev. C1 265 M400E Ozone Analyzer Operator’s Manual Index INDEX 1 B 100 VAC, 206, 246 115 VAC, 206, 208, 246 Beer-Lambert Equation, 4, 189, 192 BOX TEMP, 28, 61, 62, 111, 146, 235, 237, 239, 244 BOX TEMP WARNING, 28, 62, 146, 235, 239 2 230 VAC, 206, 246 C 5 CAL Key, 41, 63, 155 CAL_VALVE, 241 CALDAT, 79 Calibration 50 Hz, 206, 208 6 60 Hz, 7, 9, 16, 207, 208, 246 A AC Power, 7, 207, 208 100 VAC, 206, 246 AC Power 115 VAC, 206, 208, 246 AC Power 230 VAC, 206, 246 AC Power 50 Hz, 206, 208 AC Power 60 Hz, 7, 9, 16, 207, 208, 246 AIN, 113 ANALOG CAL WARNING, 28, 62, 146 Analog Inputs, 113 Analog Outputs, 7, 17, 19, 47, 61, 64, 70, 98–113, 200, 237, 239, 250 AIN Calibration, 113 Configuration & Calibration, 64, 99, 100, 101, 102, 104, 106, 108, 109, 110, 113 Automatic, 11, 64, 102, 215 Manual-Current Loop, 105, 107 Manual-Voltage, 103 Converting Voltage to Current Output, 47 Current Loop, 47 DC Offset, 41 Electrical Connections, 17 Electronic Range Selection, 108 OUTPUT LOOP-BACK, 200 Over-Range Feature, 109 Recorder Offset, 110 Reporting Range, 31, 38, 61, 64 Setup, 70–76 Specifications, 7 Test Channel, 111, 200, 239, 250 APICOM, 4, 43, 119, 148 and Ethernet, 133, 134 and Failure Prediction, 219 and iDAS, 77, 78, 79, 82, 87, 89, 90, 92, 93 Interface Example, 148 Software Download, 93, 148 ATIMER, 78, 82, 84 AUTO, 61, 70, 71, 74, 149, 155, 161 AutoCal, 9, 38, 41, 42, 48, 49, 53, 59, 61, 64, 149, 162, 163 04315 Rev. C1 AIN, 113 Analog Ouputs, 11, 64, 102, 215 Analog Outputs Current Loop, 105, 107 Voltage, 103 Calibration Gasses Span Gas, 4, 21, 30, 32, 41, 149, 150, 151, 153, 156, 159, 160, 163, 172, 203, 204, 237, 241 Zero Air, 4, 13, 21, 22, 23, 149, 150, 151, 156, 159, 163, 172, 221, 224, 237, 257 Calibration Mode, 63 CALS Key, 41, 63, 155, 158, 159, 242, 244 CALZ Key, 63, 155, 158, 159, 242, 244 CANNOT DYN SPAN, 28, 62, 235 CANNOT DYN ZERO, 28, 62, 235 CE Mark, 7, 9 Certifications, 7 Charcoal O3 Filter, 53 Circuit Breaker, 206 CLOCK_ADJ, 69, 94 COMM PORT Default Settings, 116, 117 COMM Ports, 116, 118, 119, 120, 121, 126, 139 COM1, 7, 54, 115, 116, 129, 141 COM2, 7, 54, 55, 115, 116, 119, 129, 131, 132, 133, 141 Communication Modes, 119, 133 Machine ID, 122, 129 CONC, 79 CONC Key, 41, 94, 251 CONC_PRECISION, 94 CONC1, 82 Concentration Field, 11, 27, 215 CONFIG INITIALIZED, 28, 62 Control Inputs, 7, 19, 42, 48, 49, 53, 59, 149, 162, 200, 252 LOW_SPAN_CAL 1, 252 ZERO_CAL, 252 CPU, 26, 28, 52, 54, 62, 65, 69, 70, 77, 98, 113, 116, 117, 129, 131, 132, 169, 191, 197, 198, 199, 200, 201, 203, 204, 207, 211, 212, 213, 214, 216, 234, 235, 236, 237, 238, 240, 246, 248, 252, 253, 258 267 Index M400E Ozone Analyzer Operator’s Manual Analog to Digital Converter, 28, 62, 98, 198, 199, 200, 210, 251 Status LED’s, 240 Status LED's, 248, 252 Current Loop, 47, 105 Voltage Ranges, 103 Control Inputs, 19, 252 Ethernet, 4, 5, 20, 29, 54, 55, 56, 64, 115, 129, 133 Modem, 127, 253 Multidrop, 20, 54 RS-485, 131 Serial/COMM Ports, 20, 116, 117 Critical flow orifice, 195 Current Loop Outputs, 17, 47, 105, 107 Converting from Voltage Output, 47 Manual Calibration, 105 D DAS_HOLD_OFF, 94 data acquisition. See iDAS DATA INITIALIZED, 28, 62 DC Power, 18, 19, 206, 246, 247 DC Power Test Points, 246, 247 Default Settings COMM PORT, 116, 117 Ethernet, 134 Hessen Protocol, 142, 146 iDAS, 78, 79, 80 VARS, 94 DHCP, 20, 29, 43, 133, 134, 136 DIAG AIO, 96 DIAG AOUT, 96 DIAG ELEC, 96 DIAG FCAL, 96 DIAG I/O, 96 DIAG Mode, 59 DIAG OPTIC, 96 DIAG TCHN, 96 Diagnostic Menu (DIAG), 5, 64, 66, 67, 96, 250 03 GENERATOR CALIBRATION, 96 Accesing, 97 AIN CALIBRATED, 98, 113 ANALOG I/O AOUT CALIBRATED CONFIGURATION, 98, 100, 101 CONC_OUT_1, 98 CONC_OUT_2, 98 ANALOG I/O CONFIGURATION, 96, 99, 101, 102, 104, 106, 108, 109, 110, 113 ANALOG OUTPUT (Step Test), 96, 250 DARK CALIBRATION, 96, 167 FLOW CALIBRATION, 96, 168 SIGNAL I/O, 96, 237, 238, 240, 244, 245, 248, 251, 252 TEST CHAN OUPTUT, 96 TEST OUTPUT, 98, 200 Disk on Chip, 198 Display Precision, 94 DUAL, 70, 71, 73, 149, 155, 161 Electro-Static Discharge, 6, 15, 47, 263, 259–65 Warning, 265 ENTR Key, 5, 41, 60, 64, 67, 89, 151, 166, 220, 254 Environmental Protection Agency(EPA), 5, 7, 149, 173 Calibration, 21, 30, 49, 63, 149, 171–85 NIST Traceability, 150, 159, 163, 171, 172, 173 Contact Information, 171, 173, 185 EPA Calibration, 5 EPA Equivalency, 5, 9 Software Settings, 9 Reference Documents, 171, 173, 185 Specification, 7 Ethernet, 4, 44, 59, 122, 133 and Multidrop, 56 Baud Rate, 133 COM2 Port, 115 Configuration, 133–38 Manual, 136 Property Defaults, 134 using DHCP, 133 DHCP, 20, 29, 43, 133, 134, 136 HOSTNAME, 138 EXIT Key, 64, 254 EXITZR, 84 F Final Test and Validation Data Sheet, 15, 29, 219 Flash Chip, 198 Flow Diagram Basic, 14, 194 IZS, 14 Reference/Measurement Cycle, 192 Z/S, 48 Front Panel, 11, 12, 13, 42, 49, 55, 214, 215, 226, 235 Concentration Field, 11, 27, 215 Display, 11, 27, 41, 96, 111, 189, 215, 234, 235 Keypad, 149 Keypad Definition Field, 11 Message Field, 11, 215 Mode Field, 11, 27, 215 ON/OFF Switch, 206 Status LED’s, 11, 27, 77 Status LED's, 215 E FRONT PANEL WARN, 28, 62, 146, 235 EC Compliance, 7, 9 EEPROM G Disk on Chip, 87, 198, 235, 258 Flash Chip, 198 Electrical Connections, 16–20 AC Power, 16, 45, 207 Analog Outputs, 17, 70 268 Gas Inlets, 13, 177, 204, 235 Gas Outlets, 16, 22, 23, 24, 25, 30, 51, 179, 196, 210, 242 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Index H K Hessen Protocol, 119, 139, 140, 141, 142, 143, 144, 145, 146, 147 Keypad Definition Field, 11 Default Settings, 142 Status Bits Default Settings, 146 HOSTNAME, 138 I I2C, 43, 198, 200, 201, 211, 212, 239, 240, 245, 247, 255 Status LED, 240 iDAS System, 5, 11, 28, 41, 43, 44, 59, 61, 62, 64, 68, 70, 77–93, 189, 198, 215, 235 and APICOM, 93 Channels CALDAT, 79 CONC, 79 O3GEN, 79 O3REF, 79 PNUNTC, 79 HOLD OFF, 41, 78, 91, 94 Parameters, 85 CONC1, 82 STABIL, 146, 219, 235, 237 Triggerning Events, 84 ATIMER, 78, 82, 84 EXITZR, 84 SLPCHG, 84 Interferents, 193 Internal Zero/Span Option (IZS), 4, 8, 41, 52–53, 59, 199, 200 AC Power, 206 AutoCal, 42, 163 Calibration, 30, 37, 149, 157, 169 DIAG Functions, 96 EPA Equivalency, 9 Flow Diagram, 14, 52 Generator, 8, 34, 35, 52, 61, 94, 149, 169, 200, 203, 230, 237, 241, 245, 255, 257 Interferents, 30 Maintenance, 221, 224, 225, 230 O3 Scrubber, 28, 37, 62, 193, 221, 257 Pneumatic Setup, 23 Rear Panel, 12 Reference Detector, 36, 230 Span Gas for, 21 Spare PArts, 48 Specifications, 7, 8 Test Channel Functions, 111 Test Functions, 61 Troubleshooting, 219, 236, 239, 241, 242, 244, 245, 248, 252, 255, 256, 257, 258 Valve Control, 204 Valve States, 53 Warning Messages, 28, 62 Internal Zero/Span Option (IZS) \r, 39 Internal Zero/Span Option (IZS)Hessen Flags, 146 IZS Reference Feedback Option, 8 04315 Rev. C1 L LAMP DRIVER WARN, 28, 62 LAMP STABIL WARN, 28, 62, 146, 235 LO CAL A [type], 59 Local Area Network (LAN), 20, 29, 43, 44, 55, 115, 122, 129, 133, 134, 136 LOW_SPAN_CAL 1, 252 M Machine ID, 122, 129 Measure/Reference Valve, 192 Measurement / Reference Cycle, 192, 239 Menu Keys CAL, 41, 63, 155 CALS, 41, 63, 155, 158, 159, 242, 244 CALZ, 63, 155, 158, 159, 242, 244 CONC, 41, 94, 251 ENTR, 5, 41, 60, 64, 67, 89, 151, 166, 220, 254 EXIT, 64, 254 MENUS AUTO, 61, 70, 71, 74, 149, 155, 161 DUAL, 70, 71, 73, 149, 155, 161 SNGL, 31, 38, 70, 71, 72 Message Field, 11, 215 Metal Wool Scrubber, 53, 61, 94, 111, 202, 203, 205, 209, 239, 241, 258 AC Power, 209 Troubleshooting, 244, 248, 258 microcomputer, 197, 198, 216 Mode Field, 11, 27, 215 Modem, 54, 127, 253 Motherboard, 28, 62, 98, 105, 197, 198, 200, 207, 235, 236, 240, 244, 246, 250 M-P CAL, 59 Multidrop, 20, 54, 56, 119, 122, 129, 130 O O3 Detector Output, 199 O3 DRIVE1, 61, 219 O3 GEN LAMP WARN, 28, 62 O3 GEN REF WARNING, 28, 62 O3 GEN TEMP, 237 O3 GEN TEMP WARN, 28, 62, 236 O3 GEN TMP1, 61 O3 GEN2, 61 O3 Generator IZS, 34, 35, 52, 61, 94, 149, 169, 200, 203, 230, 237, 241, 245, 255, 257 O3 MEAS, 61, 237 O3 Option Relay PCA Status LED’s, 241 O3 REF, 61, 219, 237, 254 O3 SCRUB TEMP WARN, 28, 62, 146 O3 SCRUB3, 61 269 Index O3 Scrubber, 28, 37, 62, 193, 221, 257 O3_GEN_HEATER, 241, 245 O3_GEN_LAMP, 94 O3_GEN_LOW1, 94 O3_GEN_LOW2, 94 O3_SCRUB_HEATER, 241 O3_SCRUB_SET, 94 O3GEN, 79 O3REF, 79 Offset, 61, 105, 110, 217, 219, 235 OFFSET, 61, 151, 217, 219, 220, 237 ON/OFF Switch, 206, 246 Operating Modes, 96, 219 Calibration Mode, 63, 146 Calibration Mode LO CAL A [type], 59 M-P CAL, 59 SPAN CAL [type], 59 ZERO CAL [type], 59 DIAG Mode, 59 Diagnostic Mode (DIAG), 96 1 SAMPLE A , 59 SAMPLE mode, 11, 26, 59, 60, 94, 162, 204, 215, 242 Secondaru Setup, 64 Setup, 64 SETUP [X.X], 59 M400E Ozone Analyzer Operator’s Manual RANGE2, 61, 73, 74, 143 REAR BOARD NOT DET, 28, 62, 235 Recorder Offset, 110 REF_4096_MV, 251 REF_GND, 251 Reference Feedback Option (IZS), 8, 36, 230 RELAY BOARD WARN, 28, 62 Relay PCA, 200–205 DC Power Test Points, 247 Status LED’s, 203, 207, 240, 241 CAL_VALVE, 241 O3_GEN_HEATER, 241, 245 O3_SCRUB_HEATER, 241 PHOTO_LAMP_HEATER, 241 PHOTO_REF_VALVE, 241 Troubleshooting, 239, 240, 241, 246, 247, 248 Reporting Range, 31, 38, 64, 70 Configuration, 64, 70 RS-232, 4, 5, 7, 20, 41, 44, 48, 49, 52, 53, 54, 55, 56, 59, 64, 78, 90, 92, 116, 117, 125, 148, 174, 198 Troubleshooting, 252, 253 RS-485, 4, 7, 44, 55, 59, 115, 119, 120, 122, 198 S Safety Messages, 3 P Particulate Filter, 42, 196, 214, 221, 223, 235 PHOTO LAMP, 61, 111, 213, 237, 239 PHOTO POWER, 61 PHOTO REF WARNING, 28, 62, 146, 236 PHOTO TEMP WARNING, 28, 62, 146, 235, 239 PHOTO_LAMP, 94, 241, 245, 251 PHOTO_LAMP_HEATER, 241 PHOTO_REF_VALVE, 241 PHOTOMETER, 206, 210, 227 Absorption Tube, 189, 198, 221, 227 CALIBRATION, 149, 167 Gas Flow, 168 Electronics, 211 Gas Pressure, 213 Layout, 210 Sensor Flow, 249 PRessure, 249 Status LED’s, 203 Temperature, 213 Theory of Operation, 211 UV Absorption Path, 190, 191, 192 UV detector, 210, 228, 229, 235 UV Lamp, 198, 200, 204, 212, 241, 254 PNUMTC, 79 PRES, 61, 213, 219, 225, 235, 237 Pump Sample, 42, 45, 61, 203, 208, 224, 235, 243, 246 R RANGE, 61, 71, 98, 143, 237 RANGE1, 61, 73, 74, 143 270 Electric Shock, 15, 16, 202, 220, 246, 254 Electro-Static Discharge, 265 General, 4, 15, 16, 21, 22, 24, 46, 51, 105, 225, 227, 233 SAMP FL, 61, 219, 225 SAMPL_FL, 213 SAMPLE A1, 59 Sample Flow Sensor, 61, 196, 199, 235 SAMPLE FLOW WARN, 28, 62, 235, 242 SAMPLE mode, 11, 26, 59, 60, 94, 162, 204, 215, 242 SAMPLE PRESS WARN, 28, 62, 146 Sample Pressure Sensor, 196, 235, 237 SAMPLE TEMP, 28, 61, 62, 111, 146, 213, 237, 239 SAMPLE TEMP WARN, 28, 62, 146, 235 Sample Temperature Sensor, 235 SAMPLE/CAL valve, 204 SAMPLE_FLOW, 251 Sensors O3 Detector Output, 199 Sample Flow, 61, 196, 199, 235 Sample Pressure, 196, 235, 237 Sample Temperature, 235 Thermistors, 199, 230, 245 Sample Temperature, 235 Thermocouple Inputs, 205 Serial I/O Ports, 7, 48, 49, 52, 53, 115–32, 198, 234, 235 Modem, 54, 127, 253 Multidrop, 20, 54, 56, 119, 122, 129, 130 RS-232, 4, 5, 7, 20, 41, 44, 48, 49, 52, 53, 54, 55, 56, 59, 64, 78, 90, 92, 115–30, 148, 174, 198 Troubleshooting, 252, 253 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual RS-485, 4, 7, 44, 55, 59, 119, 131–32, 198 SETUP [X.X], 59 Setup MODE, 64 Signal I/O Index Test Channel, 111, 239, 250 Test Functions, 29, 60, 61, 111, 219, 221, 228, 236, 237, 242, 250 BOX TEMP, 28, 61, 62, 111, 146, 235, 237, 239, 244 O3 DRIVE1, 61, 219 O3 GEN TEMP, 237 1 O3 GEN TMP , 61 2 O3 GEN , 61 O3 MEAS, 61, 237 O3 REF, 61, 219, 228, 237, 254 O3 SCRUB3, 61 OFFSET, 61, 151, 217, 219, 220, 237 PHOTO LAMP, 61, 111, 213, 237, 239 PHOTO POWER, 61 PRES, 61, 213, 219, 225, 235, 237 RANGE, 61, 71, 73, 74, 98, 143, 237 RANGE1, 61, 73, 74, 143 RANGE2, 61, 73, 74, 143 SAMP FL, 61, 219, 225 SAMPL_FL, 213 SAMPLE TEMP, 28, 61, 62, 111, 146, 213, 237, 239 SLOPE, 61, 151, 217, 219, 220, 237 STABIL, 28, 61, 62, 146, 219, 235, 237 4 TEST , 61 TIME, 61, 163, 237 PHOTO_LAMP, 251 REF_4096_MV, 251 REF_GND, 251 SAMPLE_FLOW, 251 Sintered Filter, 42 Slope, 61, 217, 219, 235 SLOPE, 61, 151, 217, 219, 220, 237 SLPCHG, 84 SNGL, 31, 38, 70, 71, 72 SPAN CAL [type], 59 Span Gas, 4, 21, 30, 32, 41, 149, 150, 151, 153, 156, 159, 160, 163, 172, 203, 204, 237, 241 Specifications, 5, 7, 8, 9, 198 EC Compliance, 7, 9 STABIL, 28, 61, 146, 219, 235, 237 Standard Temperature and Pressure, 75, 189 State of California Air Resources Board (CARB) Contact Information, 173 Status LED’s CPU, 240, 248, 252 Front Panel, 215 I2C, 240 Relay PCA, 203, 207, 240 CAL_VALVE, 241 O3 Option, 241 O3_GEN_HEATER, 241, 245 O3_SCRUB_HEATER, 241 PHOTO_LAMP_HEATER, 241 PHOTO_REF_VALVE, 241 Watchdog, 203, 240, 247 Status Outputs, 7, 18, 200, 251 ST_CONC_VALID, 251 ST_DIAG, 251 ST_FLOW_ALARM, 251 ST_HIGH_RANGE, 251 ST_PRESS_ALARM, 251 ST_SPAN_CAL, 251, 252 ST_SYSTEM_OK, 251 ST_ZERO_CAL, 251 TEST4, 61 Theory of Operation Beer-Lambert Equation, 4, 189, 192 Thermistors, 199, 230, 245 Thermocouple Inputs, 205 TIME, 61, 163, 237 U Ultraviolet Light, 4, 173, 190, 191, 192, 193, 210, 211 Units of Measurement, 31, 38, 75 Converting Volume Units to Weight Units, 75 UV Absorption Path, 190, 191, 192 UV detector, 210, 228, 229, 235 UV Source, 204 O3Generator, 230, 239, 245, 255 Status LED’s, 241 Photometer, 42, 198, 200, 203, 204, 210, 212, 254 Adjustment, 228, 229 Calibration, 167 Power Supply, 206 Replacement, 229 Status LED’s, 241 Troubleshooting, 236, 237, 244, 245 System Default Settings, 78, 79, 80 SYSTEM RESET, 28, 62, 146, 236 T Teledyne Contact Information Email Address, 45, 258 Fax, 45, 258 Website, 56 Phone, 3, 45, 258 Technical Assistance, 3, 258 Website, 3, 45, 258 Forms, 258 Manuals, 139, 141 Software Downloads, 93, 148 Terminal Mode, 123 Command Syntax, 124 Computer mode, 119, 123 Interactive mode, 123 04315 Rev. C1 V Valve Options, 30, 48, 149, 156, 158, 159 Heater Control, 204 Internal Zero/Span Option (IZS), 4, 8, 41, 53, 52–53, 59, 61, 199, 200 AC Power, 206, 209 AutoCal, 42, 163 Calibration, 30, 37, 149, 157, 169 Configuration, 34–39 DIAG Functions, 96 EPA Equivalency, 9 271 Index Flow Diagram, 14, 52 Generator, 34, 35, 52, 61, 94, 149, 169, 200, 203, 230, 237, 241, 245, 255, 257 Interferents, 30 Maintenance, 221, 224, 225, 230 O3 Scrubber, 28, 37, 62, 193, 221, 257 Pneumatic Setup, 23 Rear Panel, 12 Reference Detector, 36, 230 Span Gas for, 21 Spare PArts, 48 Specifications, 7, 8 Test Channel Functions, 111 Test Functions, 61 Troubleshooting, 219, 236, 239, 241, 242, 244, 245, 248, 252, 255, 256, 257, 258 Valve Control, 204 Valve States, 53 VARS, 94 Warning Messages, 28, 62 Internal Zero/Span Option (IZS)Hessen Flags, 146 Status LED’s, 203 Zero/Span, 48 and AutoCal, 42, 149, 162 Calibration, 30, 157, 159, 160, 161 EPA Equivalency, 9 Flow Diagram, 48 Rear Panel, 13, 49 Setup, 50 Troubleshooting, 241, 252 Valve States, 49 with Remote Contact Closure, 162 M400E Ozone Analyzer Operator’s Manual SAMPLE FLOW WARN, 28, 62, 235, 242 SAMPLE PRESS WARN, 28, 62, 146 SAMPLE TEMP WARN, 28, 62, 146, 235 SYSTEM RESET, 28, 62, 146, 236 Warranty, 5, 7, 10 Watchdog Circuit, 203, 240 Status LED, 203, 240, 247 Z Zero Air, 4, 13, 21, 22, 23, 149, 150, 151, 156, 159, 163, 172, 221, 224, 237, 257 ZERO CAL [type], 59 ZERO/SPAN valve, 162, 204 ZERO_CAL, 252 VARS Menu, 44, 64, 66, 67, 69, 78, 91, 94, 95 Variable Default Values, 94 Variable Names CLOCK_ADJ, 94 CONC_PRECISION, 94 O3_GEN_LAMP, 94 O3_GEN_LOW1, 94 O3_GEN_LOW2, 94 O3_SCRUB_SET, 94 PHOTO_LAMP, 94, 241, 245 VARS_HOLD_OFF, 94 Ventilation Clearance, 16 W Warning Messages, 27, 28, 61, 62, 234, 235, 236 ANALOG CAL WARNING, 28, 62, 146 BOX TEMP WARNING, 28, 62, 146, 235, 239 CANNOT DYN SPAN, 28, 62, 235 CANNOT DYN ZERO, 28, 62, 235 CONFIG INITIALIZED, 28, 62 DATA INITIALIZED, 28, 62 FRONT PANEL WARN, 28, 62, 146, 235 LAMP DRIVER WARN, 28, 62 LAMP STABIL WARN, 28, 62, 146, 235 O3 GEN LAMP WARN, 28, 62 O3 GEN REF WARNING, 28, 62 O3 GEN TEMP WARN, 28, 62, 236 O3 SCRUB TEMP WARN, 28, 62, 146 PHOTO REF WARNING, 28, 62, 146, 236 PHOTO TEMP WARNING, 28, 62, 146, 235, 239 REAR BOARD NOT DET, 28, 62, 235 RELAY BOARD WARN, 28, 62 272 04315 Rev. C1 M400E Ozone Analyzer Operator’s Manual Index USER NOTES: 04315 Rev. C1 273 Index M400E Ozone Analyzer Operator’s Manual USER NOTES: 274 04315 Rev. C1 Model 400E Instruction Manual APPENDIX A – Software Version-Specific Documentation APPENDIX A – Software Version-Specific Documentation APPENDIX A-1: Model 400E Software Menu Trees APPENDIX A-2: Model 400E Setup Variables Available Via Serial I/O APPENDIX A-3: Model 400E Warnings and Test Measurements Via Serial I/O APPENDIX A-4: Model 400E Signal I/O Definitions APPENDIX A-5: Model 400E iDAS Functions 04402 Rev D.4 A-1 APPENDIX A – Software Version-Specific Documentation Model 101E Instruction Manual USER NOTES: 2 Appendix A Model 400E Instruction Manual APPENDIX A-1: M400E Software Menu Trees, Revision D.4 APPENDIX A-1: M400E Software Menu Trees, Revision D.4 SAMPLE TEST1 1 CAL MSG1 CLR LOW2 HIGH2 Press to cycle through the active warning messages. Press to clear an active warning messages. ZERO SPAN CONC SETUP PRIMARY SETUP MENU RANGE=[Value] PPB RANGE1=[Value] PPB 2 CFG DAS RANGE PASS CLK MORE RANGE2=[Value] PPB 2 STABIL=[Value] PPB RSP=[Value] SEC O3 MEAS=[Value] MV TEST FUNCTIONS SECONDARY O3 REF=[Value] MV SETUP MENU Viewable by user PHOTO POWER=[Value] MV while instrument is PRES=[Value] IN-HG-A SAMP FL=[Value] CC/M in SAMPLE Mode SAMPLE TEMP=[Value]ºC COMM VARS DIAG PHOTO LAMP=[Value] ºC BOX TEMP=[Value] ºC 1 Only appears when warning messages are active. SLOPE=[Value] 2 OFFSET=[Value] PPB Only appears when reporting ranges are set for either DUAL or AUTO TEST=[Value] MV modes. TIME=[HH:MM:SS] Figure A-1: 04402 Rev D.4 Basic Sample Display Menu without Options A-3 APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Figure A-1: A-4 Model 400E Instruction Manual Basic Sample Display Menu with Options 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-1: M400E Software Menu Trees, Revision D.4 SAMPLE SETUP ACAL1 CFG DAS PASS RNGE CLK MORE ON PREV NEXT MODE OFF Go to iDAS Menu Tree TIME DATE SEQ 1) SEQ 2) SEQ 3) MODEL TYPE AND NUMBER PART NUMBER SERIAL NUMBER SOFTWARE REVISION LIBRARY REVISION iCHIP SOFTWARE REVISION CPU TYPE & OS REVISION DATE FACTORY CONFIGURATION SAVED Go to SECONDARY SETUP Menu Tree MODE PREV SET UNIT NEXT SNGL DUAL AUTO PPB PPM UGM MGM DISABLED ZERO ZERO-LO ZERO-HI ZERO-LO-HI LO HI LO-HI SETUP X.X 0 0 ACAL menu and its submenus only appear if analyzer is equipped with Zero/Span or IZS valve options. 2 Appears whenever the currently displayed sequence is not set for DISABLED. 3 Only appears when reporting range is set to AUTO range mode. 0 SETUP X.X 1 LOW RANGE:500.0 Conc 5 0 0 .0 ENTR EXIT HIGH RANGE:500.0 Conc 0 5 0 0 .0 ENTR EXIT SET2 TIMER ENABLE ON OFF DURATION STARTING DATE STARTING TIME DELTA DAYS DELTA TIME ON CALIBRATE OFF RANGE TO CAL3 LOW Figure A-2: 04402 Rev D.4 HIGH Primary Setup Menu (Except iDAS) A-5 APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Figure A-3: A-6 Model 400E Instruction Manual Primary Setup Menu (iDAS) 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Figure A-4: 04402 Rev D.4 Secondary Setup Menu (COMM & VARS) A-7 APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Model 400E Instruction Manual SAMPLE CFG ACAL DAS RNGE PASS SETUP MORE CLK COMM HESN2 INET1 ID COM1 COM2 ENTER PASSWORD: 818 ENTER PASSWORD: 818 ENTER PASSWORD: 818 BCC TEXT Go to COMM / VARS Menu Tree GAS LIST Go to DIAG Menu Tree STATUS FLAGS CMD NEXT O3, 0, 400, REPORTED 2 EDIT RESPONSE MODE PREV 1 DIAG VARS INS DEL YES EDIT PRNT NO Only appears if Ethernet Option is installed. Only appears if HESSEN PROTOCOL mode is ON. GAS TYPE GAS ID REPORTED O3 Set/create unique gas ID number ON OFF Figure A-5: A-8 Secondary Setup Menu (HESSEN) 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Figure A-6: 04402 Rev D.4 Secondary Setup Menu (DIAG & O3) A-9 APPENDIX A-1: M400E Software Menu Trees, Revision D.4 Model 400E Instruction Manual USER NOTES: A-10 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-2: Setup Variables, Revision D.4 APPENDIX A-2: Setup Variables, Revision D.4 Table A-1: M400E Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS DEFAULT VALUE VALUE RANGE DAS_HOLD_OFF Minutes 15 0.5–20 AUTO AUTO, 0, 1, 2, 3, 4 Number of digits to display to the right of the decimal point for concentrations on the display. Enclose value in double quotes (") when setting from the RS-232 interface. 0–100 Photometer lamp temperature set point and warning limits. DESCRIPTION Duration of DAS hold-off period. CONC_PRECISION — PHOTO_LAMP ºC O3_GEN_LAMP ºC Warnings: 43–53 0–100 O3 generator lamp temperature set point and warning limits. O3_GEN_LOW1 PPB 100 0–1500 O3 generator low set point for range #1. O3_GEN_LOW2 PPB 100 0–1500 O3 generator low set point for range #2. O3_SCRUB_SET ºC Warnings: 100–120 0–200 O3 scrubber temperature set point and warning limits. CLOCK_ADJ Sec./Day 0 -60–60 Time-of-day clock speed adjustment. 58 Warnings: 57–67 48 110 ENGL, LANGUAGE_SELECT — ENGL 0 SECD, EXTN Selects the language to use for the user interface. Enclose value in double quotes (") when setting from the RS-232 interface. MAINT_TIMEOUT Hours 2 0.1–100 Time until automatically switching out of software-controlled maintenance mode. LATCH_WARNINGS — ON ON, OFF ON enables latching warning messages; OFF disables latching CONV_TIME — 1 SEC AD_MAX_DELTA 4 mV 1000 1–10000 O3_DWELL Seconds 2 0.1–30 O3_SAMPLE Samples 1 1–30 Number of detector readings to sample. DARK_OFFSET mV 0 -1000–1000 Photometer dark offset for measure and reference readings. FILT_SIZE Samples 32 1–100 O3 concentration filter size. FILT_ASIZE Samples 6 1–100 Moving average filter size in adaptive mode. FILT_DELTA PPB 20 1–1000 Absolute concentration difference to trigger adaptive filter. FILT_PCT Percent 5 1–100 Percent concentration difference to trigger adaptive filter. FILT_DELAY Seconds 60 0–60 Delay before leaving adaptive filter mode. FILT_ADAPT — ON OFF, ON 04402 Rev D.4 0 33 MS, 66 MS, 133 MS, 266 MS, 533 MS, 1 SEC, 2 SEC Conversion time for photometer detector channel. Enclose value in double quotes (") when setting from the RS-232 interface. Maximum reading-to-reading change on any A/D channel to avoid spike suppression. Dwell time after switching measure/reference valve. ON enables adaptive filter. OFF disables it. A-11 APPENDIX A-2: Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS USER_UNITS — DIL_FACTOR — SLOPE_CONST Model 400E Instruction Manual DEFAULT VALUE VALUE RANGE DESCRIPTION UGM, MGM Concentration units for user interface. Enclose value in double quotes (") when setting from the RS-232 interface. 1 0.1–1000 Dilution factor. Used only if is dilution enabled with FACTORY_OPT variable. — 1 0.1–10 TPC_ENABLE — ON OFF, ON O3_GEN_MODE — CNST O3_GEN_SET1 PPB 400 0–1500 O3 generator high set point for range #1. O3_GEN_SET2 PPB 400 0–1500 O3 generator high set point for range #2. O3_GEN_DEF PPB 400 0–1500 O3 generator default set point. REF_DELAY Seconds 60 1–300 REF_FREQ Seconds 12 1–60 O3 generator reference adjustment frequency. REF_FSIZE Samples 4 1–10 O3 generator reference filter size. REF_INTEG — 0.1 0–10 O3 generator reference PID integral coefficient. REF_DERIV — 0 0–10 O3 generator reference PID derivative coefficient. DRIVE_STABIL mV 10 0.1–100 O3 generator drive stability limit for concentration cache updates. CACHE_RESOL PPB 2 0.1–20 O3 generator cache un-normalized concentration resolution. O3_LAMP_CYCLE Seconds 2 0.5–30 O3 generator lamp temperature control cycle period. O3_LAMP_PROP 1/DegC 0.2 0–10 O3 generator lamp temperature PID proportional coefficient. O3_LAMP_INTEG Gain 0.01 0–10 O3 generator lamp temperature PID integral coefficient. O3_LAMP_DERIV Gain 0.2 0–10 O3 generator lamp temperature PID derivative coefficient. O3_SPAN1 Conc 400 50–10000 Target O3 concentration during span calibration for range #1. O3_SLOPE1 — 1 0.850–1.150 O3 slope for range #1. O3_OFFSET1 PPB 0 -100–100 O3 offset for range #1. O3_SPAN2 Conc 400 50–10000 Target O3 concentration during span calibration for range #2. O3_SLOPE2 — 1 0.850–1.150 O3 slope for range #2. O3_OFFSET2 PPB 0 -100–100 O3 offset for range #2. DYN_ZERO — OFF OFF, ON ON enables dynamic zero calibration for contact closures and Hessen protocol. PPB 0 0 PPB, PPM, CNST, REF Slope constant factor to keep visible slope near 1. ON enables temperature/ pressure compensation; OFF disables it. O3 generator control mode. Enclose value in double quotes (") when setting from the RS-232 interface. Delay before beginning O3 generator reference feedback control. OFF disables it. DYN_SPAN — OFF OFF, ON ON enables dynamic span calibration for contact closures and Hessen protocol. OFF disables it. RANGE_MODE A-12 — SNGL 0 SNGL, DUAL, AUTO Range control mode. Enclose value in double quotes (") when setting from the RS232 interface. 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-2: Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS DEFAULT VALUE VALUE RANGE CONC_RANGE1 Conc 500 0.1–20000 D/A concentration range #1. CONC_RANGE2 Conc 500 0.1–20000 D/A concentration range #2. DESCRIPTION RS-232 COM1 mode flags. Add values to combine flags. 1 = quiet mode 2 = computer mode 4 = enable security 16 = enable Hessen protocol 5 32 = enable multi-drop RS232_MODE BitFlag 0 0–65535 64 = enable modem 128 = ignore RS-232 line errors 256 = disable XON / XOFF support 512 = disable hardware FIFOs 1024 = enable RS-485 mode 2048 = even parity, 7 data bits, 1 stop bit 4096 = enable command prompt BAUD_RATE — 19200 0 MODEM_INIT — “AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 0 Q1 &W0” RS232_MODE2 — 0 BAUD_RATE2 — 19200 0 300, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 RS-232 COM1 baud rate. Enclose value in double quotes (") when setting from the RS232 interface. Any character in the allowed character set. Up to 100 characters long. RS-232 COM1 modem initialization string. Sent verbatim plus carriage return to modem on power up or manually. 0–65535 RS-232 COM2 mode flags. (Same settings as RS232_MODE.) 300, 1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200 RS-232 COM2 baud rate. Any character in the allowed character set. Up to 100 characters long. RS-232 COM2 modem initialization string. Sent verbatim plus carriage return to modem on power up or manually. MODEM_INIT2 — “AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0” 0 RS232_PASS Password 940331 0–999999 MACHINE_ID ID 400 0–9999 (Hessen: 0–999) Unique ID number for instrument. Any character in the allowed character set. Up to 100 characters long. RS-232 interface command prompt. Displayed only if enabled with RS232_MODE variable. COMMAND_PROMPT 04402 Rev D.4 — “Cmd> ” 0 RS-232 log on password. A-13 APPENDIX A-2: Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS Model 400E Instruction Manual DEFAULT VALUE VALUE RANGE DESCRIPTION NONE, PHOTO MEAS, PHOTO REF, O3 GEN REF, SAMPLE PRESSURE, TEST_CHAN_ID — NONE 0 SAMPLE FLOW, SAMPLE TEMP, Diagnostic analog output ID. Enclose value in double quotes (") when setting from the RS-232 interface. PHOTO LAMP TEMP, O3 SCRUB TEMP, O3 LAMP TEMP, CHASSIS TEMP 0 REMOTE_CAL_MODE — LOW PASS_ENABLE — OFF OFF, ON PHOTO_LAMP_POWER mV 4500 0–5000 LAMP_PWR_ENABLE — OFF OFF, ON LOW, HIGH Range to calibrate during contact closure or Hessen calibration. Enclose value in double quotes (") when setting from the RS-232 interface. ON enables passwords. OFF disables them. Photometer lamp power setting. ON enables photometer lamp power cycling. OFF disables it. LAMP_PWR_PERIOD Hours 24 0.01–1000 LAMP_OFF_DELAY Seconds 0.1 0.02–5 Length of time photometer lamp is turned off. DET_VALID_DELAY Seconds 20 1–300 Delay until valid concentration is computed. REF_SDEV_LIMIT mV 3 0.1–100 PHOTO_CYCLE Seconds 5 0.5–30 PHOTO_PROP — 0.5 0–10 Photometer lamp temperature PID proportional coefficient. PHOTO_INTEG — 0.1 0–10 Photometer lamp temperature PID integral coefficient. PHOTO_DERIV — 0 0–10 Photometer lamp temperature PID derivative coefficient. O3_SCRUB_CYCLE Seconds 10 0.5–30 O3_SCRUB_PROP — 0.5 0–10 O3 scrubber temperature PID proportional coefficient. O3_SCRUB_INTEG — 0.1 0–10 O3 scrubber temperature PID integral coefficient. O3_SCRUB_DERIV — 0 0–10 O3 scrubber temperature PID derivative coefficient. PATH_LENGTH cm 41.96 0.01–100 STABIL_FREQ Seconds 10 1–300 STABIL_SAMPLES Samples 25 2–40 SAMP_PRESS_SET In-Hg 29.92 Warnings: 0–100 15–35 A-14 Photometer lamp power cycling period. Photometer reference standard deviation must be below this limit to switch out of startup mode. Photometer lamp temperature control cycle period. O3 scrubber temperature control cycle period. Photometer detector path length. Stability measurement sampling frequency. Number of samples in concentration stability reading. Sample pressure set point and warning limits. Set point is used for T/P compensation. 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-2: Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS DEFAULT VALUE SAMP_FLOW_SET cc/m Warnings: 500–999.5 0–1200 SAMP_FLOW_SLOPE — 1 0.001–100 SAMP_TEMP_SET ºC BOX_SET ºC GAS_STD_TEMP GAS_STD_PRESS VALUE RANGE DESCRIPTION 700 30 Sample flow set point and warning limits. Slope term to correct sample flow rate. 0–100 Sample temperature set point and warning limits. Set point is used for T/P compensation. Warnings: 5–39.5 0–100 Internal box temperature set point and warning limits. ºC 0 -100–100 ATM 1 0.1–10 Warnings: 10.5–49.5 30 GAS_MOL_WEIGHT MolWt 28.890 SERIAL_NUMBER — “00000000 ” DISP_INTENSITY — HIGH I2C_RESET_ENABLE — ON 1–99.999 0 0 Any character in the allowed character set. Up to 100 characters long. HIGH, MED, LOW, DIM OFF, ON Standard temperature for unit conversions. Standard pressure for unit conversions. Molar mass of sample gas for computing concentrations by weight instead of volume. Assumed to be 78% Nitrogen (N2, 28.0134) and 22% Oxygen (O2, 31.9988). Unique serial number for instrument. Front panel display intensity. Enclose value in double quotes (") when setting from the RS-232 interface. 2 I C bus automatic reset enable. Time-of-day clock format flags. Enclose value in double quotes (“) when setting from the RS-232 interface. “%a” = Abbreviated weekday name. “%b” = Abbreviated month name. “%d” = Day of month as decimal number (01 – 31). “%H” = Hour in 24-hour format (00 – 23). “%I” = Hour in 12-hour format (01 – 12). CLOCK_FORMAT — “TIME= %H:%M:%S” Any character in the allowed character set. Up to 100 characters long. “%j” = Day of year as decimal number (001 – 366). “%m” = Month as decimal number (01 – 12). “%M” = Minute as decimal number (00 – 59). “%p” = A.M./P.M. indicator for 12-hour clock. “%S” = Second as decimal number (00 – 59). “%w” = Weekday as decimal number (0 – 6; Sunday is 0). “%y” = Year without century, as decimal number (00 – 99). “%Y” = Year with century, as decimal number. “%%” = Percent sign. 04402 Rev D.4 A-15 APPENDIX A-2: Setup Variables, Revision D.4 SETUP VARIABLE NUMERIC UNITS Model 400E Instruction Manual DEFAULT VALUE VALUE RANGE DESCRIPTION Factory option flags. Add values to combine options. 1 = enable dilution factor 2 = O3 generator installed 2 4 = O3 generator and reference detector 2 installed 8 = zero and span valves installed FACTORY_OPT — 0 0–65535 16 = display units in concentration field 32 = enable software-controlled maintenance mode 64 = enable heated O3 scrubber 128 = enable switch-controlled maintenance mode 256 = internal zero valve only installed 2048 = enable Internet option 0 1 2 3 4 3 Enclose value in double quotes (") when setting from the RS-232 interface. Hessen protocol. Must power-cycle instrument for these options to fully take effect. iChip option. Spike suppression option. A-16 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-3: Warnings and Test Functions, Revision D.4 APPENDIX A-3: Warnings and Test Functions, Revision D.4 Table A-2: M400E Warning Messages, Revision D.4 NAME MESSAGE TEXT WSYSRES SYSTEM RESET WDATAINIT DATA INITIALIZED WCONFIGINIT CONFIG INITIALIZED WPHOTOREF PHOTO REF WARNING WLAMPSTABIL DESCRIPTION Instrument was power-cycled or the CPU was reset. REAL TIME Yes 1 Data storage was erased. No Configuration storage was reset to factory configuration or erased. No Photometer reference reading less than 2500 mV or greater than 4999 mV. Yes LAMP STABIL WARN Photometer lamp reference step changes occur more than 25% of the time. Yes WO3GENREF O3 GEN REF WARNING O3 reference detector drops below 50 mV during reference feedback O3 generator control. Yes WO3GENINT O3 GEN LAMP WARN O3 concentration below 1000 PPB when O3 lamp drive is above 4500 mV during O3 generator calibration. Yes WSAMPPRESS SAMPLE PRESS WARN Sample pressure outside of warning limits specified by SAMP_PRESS_SET variable. Yes WSAMPFLOW SAMPLE FLOW WARN Sample flow outside of warning limits specified by SAMP_FLOW_SET variable. Yes WSAMPTEMP SAMPLE TEMP WARN Sample temperature outside of warning limits specified by SAMP_TEMP_SET variable. Yes WBOXTEMP BOX TEMP WARNING Chassis temperature outside of warning limits specified by BOX_SET variable. Yes WO3GENTEMP O3 GEN TEMP WARN O3 generator lamp temperature outside of warning limits specified by O3_GEN_LAMP variable. Yes WO3SCRUBTEMP O3 SCRUB TEMP WARN O3 scrubber temperature outside of warning limits specified by O3_SCRUB_SET variable. Yes WPHOTOLTEMP PHOTO TEMP WARNING Photometer lamp temperature outside of warning limits specified by PHOTO_LAMP variable. Yes WDYNZERO CANNOT DYN ZERO Contact closure zero calibration failed while DYN_ZERO was set to ON. Yes 2 WDYNSPAN CANNOT DYN SPAN Contact closure span calibration failed while DYN_SPAN was set to ON. Yes 3 WREARBOARD REAR BOARD NOT DET Rear board was not detected during power up. Yes WRELAYBOARD RELAY BOARD WARN Firmware is unable to communicate with the relay board. Yes WLAMPDRIVER LAMP DRIVER WARN Firmware is unable to communicate with either the O3 2 generator or photometer lamp I C driver chip. Yes WFRONTPANEL FRONT PANEL WARN Firmware is unable to communicate with the front panel. Yes WANALOGCAL ANALOG CAL WARNING The A/D or at least one D/A channel has not been calibrated. Yes 1 Cleared 45 minutes after power up. 2 Cleared the next time successful zero calibration is performed. 3 Cleared the next time successful span calibration is performed. 04402 Rev D.4 A-17 APPENDIX A-3: Warnings and Test Functions, Revision D.4 Table A-3: NAME 1 M400E Test Functions, Revision D.4 MESSAGE TEXT RANGE Model 400E Instruction Manual RANGE=500.0 PPB DESCRIPTION 2 D/A range in single or auto-range modes. RANGE1=500.0 PPB 2 D/A #1 range in dual range mode. RANGE2 RANGE2=500.0 PPB 2 D/A #2 range in dual range mode. STABILITY STABIL=0.0 PPB 2 PHOTOMEAS O3 MEAS=2993.8 MV Photometer detector measure reading. PHOTOREF O3 REF=3000.0 MV Photometer detector reference reading. O3GENREF O3 GEN=4250.0 MV O3GENDRIVE O3 DRIVE=0.0 MV O3 generator lamp drive output. PHOTOPOWER PHOTO POWER=4500.0 MV Photometer lamp drive output. SAMPPRESS PRES=29.9 IN-HG-A RANGE1 Concentration stability (standard deviation based on setting of STABIL_FREQ and STABIL_SAMPLES). O3 generator reference detector reading. Sample pressure. SAMPFLOW SAMP FL=700 CC/M SAMPTEMP SAMPLE TEMP=31.2 C Sample temperature. PHOTOLTEMP PHOTO LAMP=52.3 C Photometer lamp temperature. O3SCRUBTEMP O3 SCRUB=110.2 C O3 scrubber temperature. O3GENTEMP O3 GEN TMP=48.5 C O3 generator lamp temperature. BOXTEMP BOX TEMP=31.2 C SLOPE SLOPE=1.000 Slope for current range, computed during zero/span calibration. OFFSET OFFSET=0.0 PPB 2 Offset for current range, computed during zero/span calibration. O3 O3=191.6 PPB 2 TESTCHAN TEST=2753.9 MV CLOCKTIME TIME=14:48:01 Sample flow rate. Internal chassis temperature. O3 concentration for current range. Value output to TEST_OUTPUT analog output, selected with TEST_CHAN_ID variable. Current instrument time of day clock. 1 The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”. 2 Current instrument units. A-18 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-4: M400E Signal I/O Definitions, Revision D.4 APPENDIX A-4: M400E Signal I/O Definitions, Revision D.4 Table A-4: SIGNAL NAME M400E Signal I/O Definitions, Revision D.4 BIT OR CHANNEL NUMBER DESCRIPTION Internal inputs, U7, J108, pins 9–16 = bits 0–7, default I/O address 322 hex 0–7 Spare Internal outputs, U8, J108, pins 1–8 = bits 0–7, default I/O address 322 hex 0–5 Spare 1 = reset I2C peripherals I2C_RESET 6 0 = normal 0 = hardware reset 8584 chip I2C_DRV_RST 7 1 = normal Control inputs, U11, J1004, pins 1–6 = bits 0–5, default I/O address 321 hex 0 = go into zero calibration EXT_ZERO_CAL 0 1 = exit zero calibration 0 = go into low span calibration 1 EXT_LOW_SPAN_CAL 1 1 = exit span calibration 0 = go into span calibration EXT_SPAN_CAL 1 2 1 = exit span calibration 3–5 Spare 6–7 Always 1 Control inputs, U14, J1006, pins 1–6 = bits 0–5, default I/O address 325 hex 0–5 Spare 6–7 Always 1 Control outputs, U17, J1008, pins 1–8 = bits 0–7, default I/O address 321 hex 0–7 Spare Control outputs, U21, J1008, pins 9–12 = bits 0–3, default I/O address 325 hex 0–3 Spare Alarm outputs, U21, J1009, pins 1–12 = bits 4–7, default I/O address 325 hex 1 = system OK ST_SYSTEM_OK2 4 0 = any alarm condition or in diagnostics mode 5–7 Spare A status outputs, U24, J1017, pins 1–8 = bits 0–7, default I/O address 323 hex 0 = system OK ST_SYSTEM_OK 0 1 = any alarm condition 0 = conc. valid ST_CONC_VALID 1 1 = hold off or other conditions 0 = high auto-range in use ST_HIGH_RANGE 2 1 = low auto-range 0 = in zero calibration ST_ZERO_CAL 3 1 = not in zero 0 = in span calibration ST_SPAN_CAL 4 1 = not in span 0 = any temperature alarm ST_TEMP_ALARM 5 1 = all temperatures OK 0 = any flow alarm ST_FLOW_ALARM 6 1 = all flows OK 0 = any pressure alarm ST_PRESS_ALARM 7 1 = all pressures OK B status outputs, U27, J1018, pins 1–8 = bits 0–7, default I/O address 324 hex 04402 Rev D.4 A-19 APPENDIX A-4: M400E Signal I/O Definitions, Revision D.4 BIT OR CHANNEL NUMBER SIGNAL NAME Model 400E Instruction Manual DESCRIPTION 0 = in diagnostic mode 1 = not in diagnostic mode 0 = in low span calibration ST_LOW_SPAN_CAL 1 1 = not in low span 0 = any lamp alarm ST_LAMP_ALARM 2 1 = all lamps OK 3–7 Spare 2 Front panel I C keyboard, default I2C address 4E hex 0 = maintenance mode MAINT_MODE 5 (input) 1 = normal mode 0 = select second language LANG2_SELECT 6 (input) 1 = select first language (English) 0 = sample LED on SAMPLE_LED 8 (output) 1 = off 0 = cal. LED on CAL_LED 9 (output) 1 = off 0 = fault LED on FAULT_LED 10 (output) 1 = off 0 = beeper on (for diagnostic testing only) AUDIBLE_BEEPER 14 (output) 1 = off Relay board digital output (PCF8575), default I2C address 44 hex Alternate between 0 and 1 at least every 5 seconds to keep RELAY_WATCHDOG 0 relay board active 0 = O3 scrubber heater on O3_SCRUB_HEATER 1 1 = off 2–5 Spare 0 = let span gas in SPAN_VALVE 6 1 = let zero gas in 0 = photometer valve in reference position PHOTO_REF_VALVE 7 1 = measure position 0 = let cal. gas in CAL_VALVE 8 1 = let sample gas in 9–13 Spare 0 = O3 photometer lamp heater on PHOTO_LAMP_HEATER 14 1 = off 0 = O3 generator lamp heater on O3_GEN_HEATER 15 1 = off Rear board primary MUX analog inputs PHOTO_DET 0 Photometer detector reading O3_GEN_REF_DET 1 O3 generator reference detector reading 2 Spare SAMPLE_PRESSURE 3 Sample pressure 4 Temperature MUX 5 Spare ST_DIAG_MODE SAMPLE_FLOW TEST_INPUT_7 TEST_INPUT_8 REF_4096_MV A-20 0 Sample flow 6 7 8 9 10–11 Diagnostic test input Diagnostic test input 4.096V reference from MAX6241 Spare 04402 Rev D.4 Model 400E Instruction Manual SIGNAL NAME APPENDIX A-4: M400E Signal I/O Definitions, Revision D.4 BIT OR CHANNEL NUMBER DESCRIPTION O3_SCRUB_TEMP 12 O3 scrubber temperature 13 Spare 14 DAC loopback MUX REF_GND 15 Ground reference Rear board temperature MUX analog inputs BOX_TEMP 0 Internal box temperature SAMPLE_TEMP 1 Sample temperature PHOTO_LAMP_TEMP 2 Photometer lamp temperature O3_GEN_TEMP 3 O3 generator lamp temperature 4–5 Spare TEMP_INPUT_6 6 Diagnostic temperature input TEMP_INPUT_7 7 Diagnostic temperature input Rear board DAC MUX analog inputs DAC_CHAN_1 0 DAC channel 0 loopback DAC_CHAN_2 1 DAC channel 1 loopback DAC_CHAN_3 2 DAC channel 2 loopback DAC_CHAN_4 3 DAC channel 3 loopback Rear board analog outputs CONC_OUT_1 0 Concentration output #1 CONC_OUT_2 1 Concentration output #2 2 Spare TEST_OUTPUT 3 Test measurement output I2C analog output (AD5321), default I2C address 18 hex PHOTO_LAMP_DRIVE 0 O3 photometer lamp drive (0–5V) I2C analog output (AD5321), default I2C address 1A hex O3_GEN_DRIVE 0 O3 generator lamp drive (0–5V) 1 IZS option. 04402 Rev D.4 A-21 APPENDIX A-4: M400E Signal I/O Definitions, Revision D.4 Model 400E Instruction Manual USER NOTES: A-22 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-5: M400E iDAS Functions, Revision D.4 APPENDIX A-5: M400E iDAS Functions, Revision D.4 Table A-5: 04402 Rev D.4 M400E DAS Trigger Events, Revision D.4 NAME DESCRIPTION ATIMER Automatic timer expired EXITZR Exit zero calibration mode EXITLS Exit low span calibration mode EXITHS Exit high span calibration mode EXITMP Exit multi-point calibration mode SLPCHG Slope and offset recalculated EXITDG Exit diagnostic mode PHREFW Photometer reference warning PHSTBW Photometer lamp stability warning PHTMPW Photometer lamp temperature warning O3REFW Ozone generator reference warning O3LMPW Ozone generator lamp intensity warning O3TMPW Ozone generator lamp temperature warning O3SBTW Ozone scrubber temperature warning STEMPW Sample temperature warning SFLOWW Sample flow warning SPRESW Sample pressure warning BTEMPW Box temperature warning A-23 APPENDIX A-5: M400E iDAS Functions, Revision D.4 Table A-6: Model 400E Instruction Manual M400E iDAS Functions, Revision D.4 NAME DESCRIPTION UNITS PHMEAS Photometer detector measure reading mV PHREF Photometer detector reference reading mV PHSTB Photometer lamp stability % SLOPE1 Slope for range #1 — SLOPE2 Slope for range #2 — OFSET1 Offset for range #1 PPB OFSET2 Offset for range #2 PPB ZSCNC1 Concentration for range #1 during zero/span calibration, just before computing new slope and offset PPB ZSCNC2 Concentration for range #2 during zero/span calibration, just before computing new slope and offset PPB CONC1 Concentration for range #1 PPB CONC2 Concentration for range #2 PPB STABIL Concentration stability PPB O3REF Ozone generator reference detector reading mV O3DRIV Ozone generator lamp drive O3TEMP Ozone generator lamp temperature Degrees C O3STMP Ozone scrubber temperature Degrees C O3SDTY Ozone scrubber temperature duty cycle mV Fraction (1.0 = 100%) PHTEMP Photometer lamp temperature PHLDTY Photometer lamp temperature duty cycle SMPTMP Sample temperature SMPFLW Sample flow rate cc/m SMPPRS Sample pressure Inches Hg Internal box temperature Degrees C Degrees C Fraction (1.0 = 100%) BOXTMP TEST7 Diagnostic test input (TEST_INPUT_7) mV TEST8 Diagnostic test input (TEST_INPUT_8) mV TEMP6 Diagnostic temperature input (TEMP_INPUT_6) Degrees C TEMP7 Diagnostic temperature input (TEMP_INPUT_7) Degrees C REFGND RF4096 A-24 Degrees C Ground reference mV Precision 4.096 mV reference mV 04402 Rev D.4 Model 400E Instruction Manual APPENDIX A-6: Terminal Command Designators, Revision D.4 APPENDIX A-6: Terminal Command Designators, Revision D.4 Table A-7: COMMAND Terminal Command Designators, Revision D.4 ADDITIONAL COMMAND SYNTAX ? [ID] LOGON [ID] Display help screen and commands list password LOGOFF [ID] T [ID] W [ID] C [ID] D [ID] V [ID] DESCRIPTION Establish connection to instrument Terminate connection to instrument SET ALL|name|hexmask Display test(s) LIST [ALL|name|hexmask] [NAMES|HEX] Print test(s) to screen name Print single test CLEAR ALL|name|hexmask Disable test(s) SET ALL|name|hexmask Display warning(s) LIST [ALL|name|hexmask] [NAMES|HEX] Print warning(s) name Clear single warning CLEAR ALL|name|hexmask Clear warning(s) ZERO|LOWSPAN|SPAN [1|2] Enter calibration mode ASEQ number Execute automatic sequence COMPUTE ZERO|SPAN Compute new slope/offset EXIT Exit calibration mode ABORT Abort calibration sequence LIST Print all I/O signals name[=value] Examine or set I/O signal LIST NAMES Print names of all diagnostic tests ENTER name Execute diagnostic test EXIT Exit diagnostic test RESET [DATA] [CONFIG] [exitcode] Reset instrument PRINT ["name"] [SCRIPT] Print iDAS configuration RECORDS ["name"] Print number of iDAS records REPORT ["name"] [RECORDS=number] [FROM= ][TO= ][VERBOSE|COMPACT|HEX] (Print DAS records)(date format: MM/DD/YYYY(or YY) [HH:MM:SS] Print iDAS records CANCEL Halt printing iDAS records LIST Print setup variables name[=value [warn_low [warn_high]]] Modify variable name="value" Modify enumerated variable CONFIG Print instrument configuration MAINT ON|OFF Enter/exit maintenance mode MODE Print current instrument mode DASBEGIN [] DASEND CHANNELBEGIN propertylist CHANNELEND Upload iDAS configuration Upload single iDAS channel CHANNELDELETE ["name"] Delete iDAS channels The command syntax follows the command type, separated by a space character. Strings in [brackets] are optional designators. The following key assignments also apply. 04402 Rev D.4 A-25 APPENDIX A-6: Terminal Command Designators, Revision D.4 Table A-8: Model 400E Instruction Manual Terminal Key Assignments, Revision D.4 TERMINAL KEY ASSIGNMENTS ESC Abort line CR (ENTER) Execute command Ctrl-C Switch to computer mode COMPUTER MODE KEY ASSIGNMENTS LF (line feed) Execute command Ctrl-T Switch to terminal mode USER NOTES A-26 04402 Rev D.4 Model 400E Ozone Analyzer Instruction Manual APPENDIX B APPENDIX B – M400E Spare Parts and Expendables NOTE Use of replacement parts other than those supplied by API may result in non-compliance with European standard EN 61010-1. • 05363 – Spare Parts List, M400E • 04346 – Recommended Spare Parts Stocking Levels, M400E • 04382 – Spare Parts Kit, M400E • 0061902 – Expendables Kit, M400E • 04473 – IZS Expendables Kit , M400E 04403E B-1 APPENDIX B B-2 Model 400E Ozone Analyzer Instruction Manual 04403E M400E Spare Parts List Part Number 000941000 001760400 003290000 005960000 006120100 006190200 009690000 009690100 016290000 016300700 022710000 037340300 037860000 039550100 040010000 040030100 040660000 041200000 041200200 041440000 041710000 042010000 042410200 042580000 042890100 042890200 042890300 042890400 042900100 043160000 043820000 043870100 043910100 043940000 044730000 045230100 048620200 048660000 048670000 049290000 052400000 052910000 055100200 055560000 058021100 064130000 Description ORIFICE, 13 MIL (SAMPLE FLOW & OZONE GENERATOR) ASSY, FLOW CONTROL, 800CC ASSY, THERMISTOR KIT, EXPENDABLES, ACTIVATED CHARCOAL ASSY, UV LAMP, OZONE GENERATOR KIT, EXPENDABLES, M400E KIT, TFE FILTER ELEMENTS, 5 UM (100) AKIT, TFE FLTR (FL6), 47MM, 5UM (30) WINDOW, SAMPLE FILTER, 47MM (KB) ASSY, SAMPLE FILTER, 47MM ABSORPTION TUBE, QUARTZ, M400A/E (KB) ASSY, AIR DRYER, ORANGE SILICA GEL ORING, TEFLON, RETAINING RING, 47MM (KB) PCA, RELAY CARD, E SERIES, S/N'S <523 ASSY, FAN REAR PANEL, E SERIES PCA, PRESS SENSORS (1X), w/FM4, E SERIES ASSY, REPLACEMENT CHARCOAL FILTER PCA, DET PREAMP w/OP20, M400E/M700E/M703 PCA, DET PREAMP w/OP20 M700E/ M400E/M703 PCA, DC HEATER/TEMP SENSOR, OPTICAL BENCH ASSY, CPU, CONFIGURATION ASSY, SAMPLE THERMISTOR, M400E ASSY, PUMP, INT, SOX/O3/IR * PCA, KEYBOARD, E-SERIES, W/V-DETECT ASSY, PUMP CONFIG PLUG, 100-115V/60 HZ ASSY, PUMP CONFIG PLUG, 100-115V/50 HZ ASSY, PUMP CONFIG PLUG, 220-240V/60 HZ ASSY, PUMP CONFIG PLUG, 220-240V/50 HZ PROGRAMMED FLASH, E SERIES MANUAL, OPERATION, M400E KIT, SPARES DOC, w/SOFTWARE, M400E* AKIT, EXP KIT, ORANGE SILICA GEL PCA, INTERFACE, ETHERNET, E-SERIES IZS EXPENDABLES KIT, M400E PCA, RELAY CARD, E SERIES, S/N'S >522 PCA, SERIAL INTERFACE, w/ MD, E SERIES ASSY, THERMOCOUPLE, AG SCRUBBER, M400E ASSY, HEATER, FIBER O3 SCRUBBER, 400E CLIP, THERMISTOR HOLDER ASSY, UV LAMP, OPTICAL BENCH (CR) ASSY, OPTICAL BENCH, M400E/M700E/M703E OPTION, PUMP ASSY, 240V * ASSY, VALVE, VA59 W/DIODE, 5" LEADS PCA, E-SERIES MOTHERBD, GEN 5-ICOP ASSY, DC HEATER/THERM PCA, O3 GEN 05363R - M400E Spare Parts List (DCN5364) Page 1 of 2 4/28/09 M400E Spare Parts List Part Number CN0000458 CN0000520 DS0000025 FL0000001 FL0000012 FM0000004 HW0000005 HW0000020 HW0000036 KIT000219 KIT000246 KIT000289 KIT000290 OP0000014 OP0000031 OR0000001 OR0000025 OR0000026 OR0000039 OR0000048 OR0000089 OR0000094 PU0000022 RL0000015 SW0000051 SW0000059 WR0000008 Description CONNECTOR, REAR PANEL, 12 PIN CONNECTOR, REAR PANEL, 10 PIN DISPLAY, E SERIES (KB) FILTER, SS SCRUBBER, OZONE, REFERENCE FLOWMETER (KB) FOOT, CHASSIS SPRING TFE TAPE, 1/4" (48 FT/ROLL) KIT, 4-20MA CURRENT OUTPUT (E SERIES) KIT, IZS RETROFIT, M400E KIT, UV LAMP P/S PCA, 041660100 KIT, UV LAMP P/S PCA, 041660500 QUARTZ DISC, OPTICAL BENCH WINDOW, OPTICAL BENCH & OZONE GEN FEEDBACK ORING, SAMPLE FLOW & OZONE GENERATOR ORING, AIR DRYER CANISTER ORING, ABSORPTION TUBE ORING, OPTICAL BENCH & OZONE GEN FEEDBACK ORING, OZONE GEN UV LAMP ORING, OPTICAL BENCH ORING, SAMPLE FILTER REBUILD KIT, FOR PU20 & 04241 (KB) RELAY, DPDT, (KB) SWITCH, POWER, CIRC BR PRESSURE SENSOR, 0-15 PSIA, ALL SEN POWER CORD, 10A 05363R - M400E Spare Parts List (DCN5364) Page 2 of 2 4/28/09 Recommended Spare Parts Stocking Levels Model 400E Part Number 022710000 024190000 045230100 040010000 040030100 041200000 041440000 041660500 041710000 042580000 KIT000209 052400000 042410200 058021100 DS0000025 PS0000037 PS0000038 Description ABSORPTION TUBE, QUARTZ, M400A/E (KB) ASSY, HTR/THERM, OPTICAL BENCH, 03 PCA, RELAY CARD, E SERIES ASSY, FAN REAR PANEL, E SERIES PCA, PRESS SENSORS (1X), w/FM4, E SERIES PCA, DET PREAMP w/OP20, M400E/M700E/M703 PCA, DC HTR/TEMP SENS, M400E/M700E/M703E PCA, UV LAMP P/S, OPT BENCH, M400E/M703E ASSY, CPU, CONFIGURATION, "E" SERIES * PCA, KEYBOARD, E-SERIES, W/V-DETECT KIT, RETROFIT, M400E RELAY ASSY, BENCH UV LAMP, (BIR), CR * ASSY, PUMP, INT, SOX/O3/IR * PCA, E-SERIES MOTHERBOARD, GEN 5-I DISPLAY, E SERIES (KB) PS, 40W SWITCHING, +5V, +/-15V(KB) * PS, 60W SWITCHING, 12V(KB) * 006120100 041200200 041660100 055560000 With IZS, ZS Option ASSY, OZONE GEN LAMP (BIR) (OP5) PCA, DET PREAMP w/OP20 M700E/ M400E/M703 PCA, UV LAMP P/S, O3 GEN, M400E/M703E ASSY, VALVE, VA59 W/DIODE, 5" LEADS * For 240V operation, use 055100200 ** For upgrade from 039550100, use KIT000209 04346P - M400E RSSL (DCN 5220) 1 2-5 6-10 11-20 1 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 4 2 2 2 2 1 2 2 1 1 2 1 *1 1 1 2 2 4 3 2 3 3 2 3 2 1 1 2 1 1 2 1 2 2 1 1 1 2 2 1 2 3 1 1 1 1 1 1 1 21-30 UNITS ** * 06/02/09 M400E Spare Parts Kit Part Number 000941000 040010000 041440000 04382 Rev A Description ORIFICE, 13 MIL (SAMPLE FLOW) ASSY, FAN, REAR PANEL, E SERIES PCA, DC HEATER/TEMP SENSOR, OPTICAL BENCH Quantity 1 1 1 3/15/06 M400E Expendables Kit Part Number 009690100 FL0000001 HW0000020 NOTE01-23 OR0000001 PU0000022 0061902 Rev B Description KIT, TFE FILTER ELEMENTS, 47MM, 5UM (30) FILTER, SS SPRING SERVICE NOTE, HOW TO REBUILD THE KNF PUMP ORING, SAMPLE FLOW REBUILD KIT, FOR PU20 & 04084 Quantity 1 2 2 1 4 1 3/3/06 M400E IZS Expendables Kit Part Number FL0000001 040660000 04473 Rev A Description FILTER, SS ASSY, REPLACEMENT CHARCOAL FILTER Quantity 2 1 3/15/06 Model M400E Manual Appendix C TELEDYNE Warranty/Repair Questionnaire Model 400E INSTRUMENTS Advanced Pollution Instrumentation A Teledyne Technologies Company CUSTOMER:_______________________________ PHONE: _____________________________________ CONTACT NAME: __________________________ FAX NO. _____________________________________ SITE ADDRESS:____________________________________________________________________________ MODEL TYPE: ______________ SERIAL NO.:_________________ FIRMWARE REVISION: _____________ Are there any failure messages? _______________________________________________________________ _________________________________________________________________________________________ __________________________________________________________________________________________ ________________________________________________________________________ (Continue on back if necessary) PLEASE COMPLETE THE FOLLOWING TABLE: PARAMETER RECORDED VALUE ACCEPTABLE VALUE RANGE PPB/PPM 1 – 10,000 PPB STABIL <= 0.3 PPM WITH ZERO AIR O3 MEAS mV 2500 – 4800 mV O3 REF mV 2500 – 4800 mV O3 GEN1 mV 80 mV. – 5000 mV. O3 DRIVE1 mV 0 – 5000 mV. PRES IN-HG-A ~ - 2”AMBIENT ABSOLUTE SAMPLE FL 3 CM /MIN 800 ± 10% SAMPLE TEMP ºC 10 – 50 ºC PHOTO LAMP ºC 58 ºC ± 1 ºC ºC 48 ºC ± 3 ºC ºC 10 – 50 ºC O3 GEN TMP 1 BOX TEMP SLOPE OFFSET 1.0 ± .15 PPB 0.0 ± 5.0 PPB FOLLOWING VALUES ARE UNDER THE SIGNAL I/O SUBMENU REF_4096_MV mV 4096mv±2mv and Must be Stable REF_GND mV 0± 0.5 and Must be Stable Depending on options installed, not all test parameters shown below will be available in your calibrator) 1 If IZS valve option installed. Cap the SAMPLE flow inlet and record the flow rate and pressure: What is sample flow rate _______________ cc/min What is the sample pressure _______________ in-Hg-A What are the failure symptoms? ________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ TELEDYNE INSTRUMENTS CUSTOMER SERVICE EMAIL: api-customerservice@teledyne.com PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816 04404 Rev C C-1 Model M400E Manual Appendix C Warranty/Repair Questionnaire Model 400E TELEDYNE INSTRUMENTS Advanced Pollution Instrumentation A Teledyne Technologies Company What tests have you done trying to solve the problem? ______________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Thank you for providing this information. Your assistance enables Teledyne Instruments to respond faster to the problem that you are encountering. OTHER NOTES: ____________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ TELEDYNE INSTRUMENTS CUSTOMER SERVICE EMAIL: api-customerservice@teledyne.com PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816 04404 Rev C C-2 Model 400E Ozone Analyzer Instruction Manual Appendix D APPENDIX D – ELECTRONIC SCHEMATICS Document # 04396 04405D Document Title Interconnect Diagram, M400E 04406 Interconnect List, M400E 05703 PCA, 05702, Motherboard, E-Series Gen 4 03632 PCA 03631, 0-20mA Driver 04259 PCA 04258, Keyboard & Display Driver 04354 PCA 04003, Pressure/Flow Transducer Interface 04420 PCA 04120, UV Detector Preamp 04421 PCA 04166, UV Lamp Power Supply 04422 PCA 04144, DC Heater/Thermistor 03956 PCA 03955-0100, Relay Board 04468 PCA, 04467, Analog Output Series Res D-1 Appendix D D-2 Model 400E Ozone Analyzer Instruction Manual 04405D
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