Teledyne 401 O3 Calibrator Users Manual

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INSTRUCTION MANUAL
MODEL 401
O3 CALIBRATOR
© TELEDYNE INSTRUMENTS
ADVANCED POLLUTION INSTRUMENTATION DIVISION
(T-API)
9480 CARROLL PARK DRIVE
SAN DIEGO, CA 92121-5201
TOLL-FREE: 800-324-5190
FAX: 858-657-9816
TEL: 858-657-9800
E-MAIL: api-sales@teledyne.com
WEB SITE: www.teledyne-api.com
01124
REV. J2
Copyright 2005 Teledyne Advanced Pollution
Instrumentation 11 July, 2005
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
SAFETY MESSAGES
Your safety and the safety of others is very important. We have provided many important safety
messages in this manual. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each safety
message is associated with a safety alert symbol. These symbols are found in the manual and
inside the instrument. The definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the instructions for details on the
specific danger.
CAUTION: Hot Surface Warning
CAUTION: Electrical Shock Hazard
Technician Symbol: All operations marked with this symbol are to be performed
by qualified maintenance personnel only.
CAUTION
The analyzer should only be used for the purpose
and in the manner described in this manual.
If you use the analyzer in a manner other than that for which
it was intended, unpredictable behavior could ensue with
possible hazardous consequences.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
TABLE OF CONTENTS
SAFETY MESSAGES .......................................................................................... II
TABLE OF CONTENTS...................................................................................... III
LIST OF FIGURES.............................................................................................VII
LIST OF TABLES..............................................................................................VIII
1 INTRODUCTION ............................................................................................ 1-1
1.1 PREFACE .........................................................................................................................................1-1
1.2 WARRANTY.....................................................................................................................................1-1
1.3 PRINCIPLE OF OPERATION ..............................................................................................................1-2
1.3.1 Interferent Rejection ...............................................................................................................1-4
1.4 SPECIFICATIONS ..............................................................................................................................1-5
1.4.1 Noise (PPB RMS)....................................................................................................................1-6
1.4.2 Lower Detectable Limit (LDL) PPB .......................................................................................1-6
1.4.3 Zero Drift (PPB) .....................................................................................................................1-6
1.4.4 Span Drift................................................................................................................................1-6
1.4.5 Linearity..................................................................................................................................1-6
1.4.6 Lag Time .................................................................................................................................1-6
1.4.7 Rise And Fall Times................................................................................................................1-6
1.4.8 Temperature Range.................................................................................................................1-6
1.4.9 Humidity Range ......................................................................................................................1-6
1.4.10 Flow Rates ............................................................................................................................1-7
1.4.11 Power....................................................................................................................................1-7
1.4.12 Weight ...................................................................................................................................1-7
1.5 INSTALLATION AND OVERVIEW......................................................................................................1-7
1.6 ELECTRICAL AND PNEUMATIC CONNECTIONS ..............................................................................1-14
1.6.1 Electrical Connections..........................................................................................................1-14
1.6.2 RS-232...................................................................................................................................1-14
1.6.3 Pneumatic System .................................................................................................................1-16
1.6.4 Exhaust Connections (See Figure 1-5) .................................................................................1-16
1.6.5 Output Flow Adjustment .......................................................................................................1-16
1.7 OPERATION VERIFICATION............................................................................................................1-20
1.7.1 Final Test And Calibration Values .......................................................................................1-21
1.8 OPTIONS........................................................................................................................................1-22
1.8.1 Rack Mount With Slides........................................................................................................1-22
1.8.2 Status Outputs.......................................................................................................................1-22
2 OPERATION .................................................................................................. 2-1
2.1 KEY FEATURES ...............................................................................................................................2-1
2.1.1 O3 Readout..............................................................................................................................2-1
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
2.1.2 O3 Analog Output....................................................................................................................2-1
2.1.3 E2 ROM Backup Of Software Configuration ..........................................................................2-1
2.1.4 Adaptive Filter ........................................................................................................................2-1
2.1.5 Data Acquisition .....................................................................................................................2-2
2.1.6 RS-232 Interface .....................................................................................................................2-2
2.1.7 Password Protection...............................................................................................................2-2
2.2 FRONT PANEL .................................................................................................................................2-4
2.2.1 Front Panel Display................................................................................................................2-4
2.2.2 Programmable Pushbuttons ...................................................................................................2-7
2.2.3 Status LEDs.............................................................................................................................2-9
3 CALIBRATION............................................................................................... 3-1
3.1 MANUAL ZERO AIR SUPPLY............................................................................................................3-1
3.2 MANUAL O3 GENERATION ..............................................................................................................3-1
3.3 AUTOMATIC ZERO/SPAN (OR MULTIPOINT) CHECK ........................................................................3-2
3.4 MANUAL ZERO/SPAN (OR MULTI-POINT) CHECK ...........................................................................3-2
3.5 SUMMARY OF FRONT PANEL CALIBRATION CONTROLS..................................................................3-3
3.6 PHOTOMETER CALIBRATION ...........................................................................................................3-3
3.7 REMOTE ZERO/SPAN CHECK (CONTACT CLOSURE)........................................................................3-4
3.8 REMOTE ZERO/SPAN CHECK OR ADJUSTMENT (RS-232) ...............................................................3-5
3.9 HOLD OFF .......................................................................................................................................3-5
4 SETUP MODE................................................................................................ 4-1
4.1 SETUP MODE OPERATION ...............................................................................................................4-1
4.2 SETTING AUTOMATIC MULTIPOINT (ASEQ) CHECK.......................................................................4-1
4.3 SETTING AUTOMATIC ZERO/SPAN DURATION.................................................................................4-1
4.4 EXAMINING THE OZONE FORMULA SLOPE AND OFFSET.................................................................4-2
4.5 SETTING THE O3 GENERATION MODE .............................................................................................4-3
4.5.1 BNCH Mode............................................................................................................................4-3
4.5.2 REF Mode...............................................................................................................................4-3
4.5.3 CNST Mode.............................................................................................................................4-3
4.6 SETTING THE TIME-OF-DAY...........................................................................................................4-3
4.7 SETTING THE DATE.........................................................................................................................4-3
4.8 ADJUSTING THE CLOCK SPEED .......................................................................................................4-4
4.9 SETTING THE O3 CONCENTRATION RANGE .....................................................................................4-4
4.10 SETTING THE ANALOG OUTPUT OFFSET .......................................................................................4-4
4.11 SETTING THE RS-232 BAUD RATE................................................................................................4-4
4.12 SETTING THE ANALYZER I.D. .......................................................................................................4-5
4.13 DISABLING THE CALIBRATION PASSWORD ...................................................................................4-5
4.14 SETTING THE FAULT LED TIMEOUT .............................................................................................4-5
4.15 SOFTWARE CONFIGURATION.........................................................................................................4-6
4.16 SUMMARY OF SETUP VARIABLES .................................................................................................4-6
5 DIAGNOSTICS............................................................................................... 5-1
5.1 TEST MEASUREMENTS ....................................................................................................................5-1
5.2 DIAGNOSTIC TESTS .........................................................................................................................5-1
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
5.2.1 D/A Output..............................................................................................................................5-2
6 HANDLING WARNINGS................................................................................ 6-1
7 RS-232 COMMUNICATIONS......................................................................... 7-1
7.1 DAS REPORTING.............................................................................................................................7-2
7.2 WARNINGS......................................................................................................................................7-3
7.3 STATUS/CONTROL...........................................................................................................................7-4
7.4 DIAGNOSTICS ..................................................................................................................................7-6
7.5 TEST MEASUREMENTS ....................................................................................................................7-7
7.6 VIEWING AND MODIFYING VARIABLES ..........................................................................................7-8
8 ADJUSTMENTS............................................................................................. 8-1
8.1 POWER SUPPLY BOARD ADJUSTMENT.............................................................................................8-1
8.1.1 Box Temperature Limits..........................................................................................................8-1
8.2 A/D - D/A CALIBRATION PROCEDURE ............................................................................................8-3
8.3 OUTPUT VOLTAGE RANGE CHANGES..............................................................................................8-4
8.4 FLOW READOUT ADJUSTMENT........................................................................................................8-4
8.5 DC POWER SUPPLY.........................................................................................................................8-6
8.6 CPU................................................................................................................................................8-6
8.7 STATUS LINES .................................................................................................................................8-7
8.8 UV LAMP POWER SUPPLY ADJUSTMENT ........................................................................................8-7
8.9 OZONE GENERATOR LAMP SETUP...................................................................................................8-8
8.10 OZONE GENERATOR CALIBRATION ...............................................................................................8-9
8.11 DARK CURRENT SIGNAL ADJUST PROCEDURE ..............................................................................8-9
8.12 BENCH FEEDBACK OPTION..........................................................................................................8-10
9 TROUBLESHOOTING ................................................................................... 9-1
9.1 OVERVIEW ......................................................................................................................................9-1
9.2 TROUBLESHOOTING FUNDAMENTAL CALIBRATOR OPERATION ......................................................9-1
9.2.1 Checking The Power Sub-Systems..........................................................................................9-2
9.2.2 Checking The CPU And Display.............................................................................................9-3
9.2.3 Checking The Keyboard..........................................................................................................9-3
9.3 TROUBLESHOOTING USING WARNING MESSAGES...........................................................................9-3
9.4 TROUBLESHOOTING USING TEST FUNCTION VALUES .....................................................................9-5
9.5 TROUBLESHOOTING DYNAMIC PROBLEMS ......................................................................................9-6
9.5.1 Noisy Or Unstable Readings At Zero .....................................................................................9-7
9.5.2 Noisy, Unstable, Or Non-Linear Span Readings....................................................................9-7
9.5.3 Slow Response To Changes In Concentration........................................................................9-7
9.5.4 Analog Outputs Do Not Agree With Front Panel Readings ...................................................9-8
9.5.5 Cannot Zero ............................................................................................................................9-8
9.5.6 Cannot Span............................................................................................................................9-8
9.6 TROUBLESHOOTING INDIVIDUAL SUB-ASSEMBLIES AND COMPONENTS.........................................9-9
9.6.1 Troubleshooting Flow Problems ............................................................................................9-9
9.6.2 Troubleshooting Temperature Problems..............................................................................9-10
9.6.3 Checking The V/F Card ........................................................................................................9-11
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
9.6.4 Checking The DC Power Supply Board................................................................................9-13
9.6.5 Checking The Pneumatic Sensor Board ...............................................................................9-14
9.6.6 Checking The Source Lamp And Detector............................................................................9-14
9.6.7 Checking Main Switching Valve...........................................................................................9-16
9.6.8 Checking The Lamp Power Supply.......................................................................................9-16
9.7 WARRANTY/REPAIR QUESTIONNAIRE .........................................................................................9-18
10 ROUTINE MAINTENANCE ........................................................................ 10-1
10.1 MAINTENANCE SCHEDULE ..........................................................................................................10-1
10.2 LEAK CHECKING .........................................................................................................................10-2
10.3 CLEANING OF SAMPLE CELL.......................................................................................................10-2
10.4 CHANGING THE PROM.................................................................................................................10-3
11 MODEL 401 SPARE PARTS AND EXPENDABLES KITS........................ 11-1
11.1 SPARE PARTS FOR CE MARK UNITS ...........................................................................................11-1
11.2 SPARE PARTS FOR NON-CE MARK UNITS ..................................................................................11-3
Appendix A LIST OF AVAILABLE MODEL 401 OPTIONS ................................................. A-1
Appendix B RECOMMENDED ZERO AIR SYSTEM............................................................. B-1
Appendix C REFERENCES....................................................................................................... C-1
Appendix D SOFTWARE MENU TREES ................................................................................D-1
Appendix E ELECTRICAL SCHEMATIC INDEX ...................................................................E-1
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
LIST OF FIGURES
FIGURE 1-1: MODEL 401 OZONE CALIBRATOR BLOCK DIAGRAM..........................................................1-11
FIGURE 1-2: M401 REAR PANEL ELECTRICAL CONNECTIONS................................................................1-12
FIGURE 1-3: REAR PANEL ELECTRICAL AND PNEUMATIC CONNECTIONS (CE VERSION).......................1-13
FIGURE 1-4: RS-232 PIN ASSIGNMENTS.................................................................................................1-15
FIGURE 1-5: M401 CALIBRATOR PNEUMATIC CONNECTIONS ................................................................1-17
FIGURE 1-6: M401 REAR PANEL (EXTERNAL DRY ZERO AIR)...............................................................1-18
FIGURE 1-7: M401 CALIBRATOR CHASSIS LAYOUT ...............................................................................1-19
FIGURE 2-1: MODEL 401 FRONT PANEL...................................................................................................2-4
FIGURE 2-2: ILLUSTRATION OF NORMAL DISPLAY ..................................................................................2-8
FIGURE 8-1: ELECTRICAL BLOCK DIAGRAM ............................................................................................8-2
FIGURE 8-2: FLOW AND PRESSURE READOUT ADJUSTMENT....................................................................8-5
FIGURE A-1: MODEL 401 SAMPLE SOFTWARE MENU TREE.................................................................... D-1
FIGURE A-2: MODEL 401 SETUP SOFTWARE MENU TREE....................................................................... D-2
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
LIST OF TABLES
TABLE 1-1: TEST VALUES.......................................................................................................................1-21
TABLE 2-1: PASSWORD LEVELS ...............................................................................................................2-3
TABLE 2-2: SYSTEM MODES ....................................................................................................................2-5
TABLE 2-3: TEST MEASUREMENTS ..........................................................................................................2-6
TABLE 2-4: WARNING MESSAGES............................................................................................................2-7
TABLE 2-5: STATUS LEDS........................................................................................................................2-9
TABLE 3-1: CALIBRATION CONTROLS......................................................................................................3-3
TABLE 4-1: SETUP VARIABLES.................................................................................................................4-7
TABLE 5-1: TEST CHANNEL OUTPUT........................................................................................................5-2
TABLE 5-2: DIAGNOSTIC TESTS ...............................................................................................................5-2
TABLE 7-1: RS-232 MESSAGE TYPES ......................................................................................................7-1
TABLE 7-2: WARNING MESSAGE CLEAR COMMANDS..............................................................................7-4
TABLE 7-3: STATUS REPORTS ..................................................................................................................7-4
TABLE 7-4: CONTROL COMMANDS...........................................................................................................7-5
TABLE 7-5: DIAGNOSTIC COMMANDS ......................................................................................................7-6
TABLE 7-6: SPECIAL DIAGNOSTIC COMMANDS ........................................................................................7-7
TABLE 7-7: DIAGNOSTIC REPORTS...........................................................................................................7-7
TABLE 7-8: TEST MEASUREMENT REQUEST COMMANDS.........................................................................7-8
TABLE 7-9: RS-232 VARIABLE NAMES..................................................................................................7-10
TABLE 8-1: THE CALIBRATOR HAS THE FOLLOWING STATUS CONDITIONS.............................................8-7
TABLE 9-1: WARNING MESSAGES............................................................................................................9-4
TABLE 9-2: TEST FUNCTION VALUES.......................................................................................................9-5
TABLE 9-2: TEST FUNCTION VALUES (CONTINUED) ................................................................................9-6
TABLE 9-3: V/F BOARD JUMPERS - FACTORY SETTINGS........................................................................9-12
TABLE 9-4: V/F BOARD DIP SWITCHES - RANGES FOR ANALOG OUTPUT..............................................9-12
TABLE 9-5: UV SOURCE LAMP AND DETECTOR DIAGNOSTICS..............................................................9-15
TABLE 10-1: MAINTENANCE SCHEDULE ................................................................................................10-1
TABLE 11-1: SPARE PARTS FOR CE MARK UNITS..................................................................................11-1
TABLE 11-1: SPARE PARTS FOR CE MARK UNITS (CONTINUED)...........................................................11-2
TABLE 11-2: SPARE PARTS FOR NON-CE MARK UNITS.........................................................................11-3
TABLE 11-2: SPARE PARTS FOR NON-CE MARK UNITS (CONTINUED) ..................................................11-4
TABLE A-1: AVAILABLE MODEL 401 OPTIONS .......................................................................................A-1
TABLE E-1: ELECTRICAL SCHEMATIC INDEX ...........................................................................................E-1
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1 INTRODUCTION
1.1 Preface
Teledyne API is pleased that you have purchased the Model 401. We offer a full one year
warranty (see Section 1.2) and we at Teledyne API will be pleased to provide you with any
support required so that you may utilize our equipment to the fullest extent.
The Teledyne API Model 401 keyboard/operator interface with its "talking keys" makes the
Teledyne API a very user-friendly system. We hope you will not experience any problems with
the Teledyne API Model 401 but if you do, the built-in tests and diagnostics should allow you to
quickly and easily find the problem. In addition, our full time customer service department is
always available to answer your questions.
1.2 Warranty
WARRANTY POLICY (02024c)
Prior to shipment, Teledyne API equipment is thoroughly inspected and tested. Should
equipment failure occur, Teledyne API assures its customers that prompt service and support
will be available.
COVERAGE
After the warranty period and throughout the equipment lifetime, Teledyne 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-TELEDYNE API MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by Teledyne 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
Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in
material and workmanship under normal use and service for a period of one year from the date of
delivery. All replacement parts and repairs are warranted for 90 days after the purchase.
If a Product fails to conform to its specifications within the warranty period, Teledyne API shall
correct such defect by, in Teledyne API's discretion, repairing or replacing such defective
Product or refunding the purchase price of such Product.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
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 Teledyne 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. TELEDYNE API SHALL
NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES
ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API'S
PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR
OTHERWISE.
TERMS AND CONDITIONS
All units or components returned to Teledyne API should be properly packed for handling and
returned freight prepaid to the nearest designated Service Center. After the repair, the equipment
will be returned, freight prepaid.
1.3 Principle Of Operation
M401 Ozone calibrator consist of two major parts; the ozone generating device and the
photometer. Ozone generating device itself also consist of a pump, an air scrubber to self-
generate zero air, a pressure regulator to control flow rate, an ozone generator using UV lamp,
and a manifold. The pressure regulator provides very stable flow of zero air through the O3
generator, while the light intensity of the UV lamp is controlled to generate accurate and stable
ozone output.
The photometer is used as part of a feedback lamp control to assure stable O3 output even during
changing conditions. The photometer is compensated for both pressure and temperature
variations. This true photometer operation along with self-generated zero air results in a
completely self-contained O3 generating system.
The detection of ozone molecules of the photometer is based on absorption of 254 nm UV light
due to an internal electronic resonance of the O3 molecule. The Model 401 Photometer uses a
mercury lamp constructed so that a large majority of the light emitted is at the 254nm
wavelength. Light from the lamp shines down a hollow glass tube that is alternately filled with
sample gas, then filled with zero air. The ratio of the intensity of light passing through the zero
air to that of the sample forms a ratio I/Io. This ratio forms the basis for the calculation of the
ozone concentration.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
NOTE
Model 401 Photometric Calibrator is designed to be a dedicated
calibrator. The M401 Photometer should not be used as a monitor.
The Beer-Lambert equation, shown below, calculates the concentration of ozone from the ratio
of light intensities.
0
0
9
I
I
n
P
inHg92.29
K273
T
a
10
O
C3
l
l
×××
×
−=
Where:
I
= Intensity of light passed through the sample
0
I = Intensity of light through sample free of ozone
a = absorption coefficient
l = path length
C = concentration of ozone in ppm
T
= sample temperature in Kelvin
P
= pressure in inches of mercury
nl = natural logarithm
As you can see the concentration of ozone depends on more than the intensity ratio. Temperature
and pressure influence the density of the sample. The density changes the number of ozone
molecules in the absorption tube which impacts the amount of light removed from the light
beam. These effects are addressed by directly measuring temperature and pressure and including
their actual values in the calculation. The absorption coefficient is a number that reflects the
inherent ability of ozone to absorb 254 nm light. Most current measurements place this value at
308 cm-1 atm-1 at STP. The value of this number reflects the fact that ozone is a very efficient
absorber of UV radiation which is why stratospheric ozone protects the life forms lower in the
atmosphere from the harmful effects from solar UV radiation. Lastly, the absorption pathlength
determines how many molecules are present in the column of gas in the absorption tube.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
The intensity of light is converted into a voltage by the detector/preamp module. The voltage is
converted into a number by a voltage-to-frequency (V/F) converter capable of 80,000 count
resolution. The digitized intensities, along with the other variables, are used by the CPU to
compute the concentration using the above formula.
Every 8 seconds the M401 Photometer completes a measurement cycle consisting of a 2 second
wait period for the sample tube to flush, followed by 2 seconds of measuring the average light
intensity to determine I. The sample valve is switched to admit scrubbed sample gas for 2
seconds followed by 2 seconds measuring the average light intensity to obtain Io. Measurement
of the Io every 8 seconds minimizes instrument drift due to changing intensity of the lamp due to
aging and dirt. The 120 sec filter provides 32 averages.
1.3.1 Interferent Rejection
It should be noted that the UV absorption method for detecting ozone is subject to interference
from a number of sources. The Model 401 has been successfully tested for its ability to reject
interference from sulfur dioxide, nitrogen dioxide, nitric oxide, water, and meta-xylene.
While the instrument rejected interference from the aromatic hydrocarbon meta-xylene, it should
be noted that there are a very large number of volatile aromatic hydrocarbons that could
potentially interfere with ozone detection. If the Model 401 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.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.4 Specifications
Photometer
Ranges User selectable to any full scale range from 100 ppb to 20,000 ppb
Zero Noise < 0.3 ppb (rms)
Span Noise < 0.5% of reading (rms)
Lower Detectable Limit < 0.6 ppb (rms)
Zero Drift (24 hours) < 1.0 ppb*
Zero Drift (7 days) < 1.0 ppb*
Span Drift (24 hours) 1% of reading *
Span Drift (7 days) 2% of reading *
Linearity Better than 1% FS
Precision 1.0 ppb
Lag Time 10 sec
Rise/Fall Time (95%) <20 sec
Sample Flow Rate 800 cc/min ± 10%
Temperature Range 5-40° C
Humidity Range 0-95% RH, Non-Condensing
Temp Coefficient < 0.05 % per °C
Voltage Coefficient < 0.05 % per V
Dimensions HxWxD 7" x 17" x 27" (178 mm x 432 mm x 686 mm)
Weight, Analyzer 60 lb. (27 kg)
Power, Analyzer 110v/60Hz, 220v/50Hz 250 watts
Environmental Conditions Installation Category (Overvoltage Category) II
Pollution Degree 2
Recorder Instantaneous ± 100 mV, ± 1 v
(Bi-Polar) ± 5 v, ± 10 v
Status 12 Status Outputs from Opto-Isolators
Calibration Ozone Generator
Flow rate 2 to 5 LPM adjustable
Maximum concentration 1.0 ppm @ 5 LPM
Minimum concentration 0.050 ppm @ 2 LPM
Stability ± 0.002 ppm (bench feedback)
* at constant temperature and voltage
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.4.1 Noise (PPB RMS)
The standard deviation of reported concentration calculated over 25 samples times 7 runs
minimum, N-1 weighted.
1.4.2 Lower Detectable Limit (LDL) PPB
LDL is defined as twice the (RMS) noise at the lower end of the most sensitive operating range.
1.4.3 Zero Drift (PPB)
Zero drift is defined as unadjusted (automatic) operation maximum shift over the given period at
constant temperature and pressure.
1.4.4 Span Drift
Span drift is defined similarly to zero drift, requiring unadjusted operation at constant
temperature and pressure.
1.4.5 Linearity
< 1.0% of URL, best-straight-line deviation over range of LDL to URL.
1.4.6 Lag Time
Lag time is defined as the time interval between a step change, at the sample inlet port, of input
concentration and the first observable corresponding change in analyzer output.
1.4.7 Rise And Fall Times
Rise/fall times are defined as the time interval between a step change in input concentration and
95% of final response unless otherwise noted.
1.4.8 Temperature Range
5-40° C.
1.4.9 Humidity Range
0 to 95% relative humidity, non-condensing.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.4.10 Flow Rates
800 scc/min ± 10% (standard cubic centimeters/minute) sample flow rate.
2-5 l/min ± 10% (standard cubic liter/minute) O3 generator flow rate.
1.4.11 Power
Standard input power: 120VAC rms, 60 Hz, 250 watts maximum and 220, 240 V, 50 Hz.
5A resettable circuit breaker.
1.4.12 Weight
27 Kg (60 lb.) maximum.
1.5 Installation And Overview
The Model 401 is shipped with the following standard equipment:
1. Power cord.
2. Instruction manual.
CAUTION
To avoid personal injury, always use two persons to lift and carry
the Model 401.
Upon receiving the Model 401 please do the following:
1. Verify no apparent shipping damage. (If damage has occurred please advise shipper first,
then Teledyne API.)
2. Remove all red colored shipping screws from the underside of the instrument. Note: Save
these shipping screws and re-install them whenever the unit is shipped to another location.
3. When installing the Model 401, allow a minimum of 4 inches (100mm) of clearance at the
back of the instrument and 1 inch (25mm) of clearance on each side for proper ventilation.
4. Check that all options ordered are enclosed.
5. Connect analyzer' sample inlet line to the M401 sample port of manifold on rear panel.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
NOTE
See Figure 1-4 for rear panel pneumatic connections. Span gas
should only come into contact with PTFE or glass. Leak check
all fittings with soap solution.
Maximum pressure for leak check is 15 PSIG.
6. Connect the pump exhaust to a suitable vent outside the analyzer area.
CAUTION
Connect the exhaust fitting on the rear panel (see Figure 1-5) to a
suitable vent outside the analyzer area.
7. For internal pressurized zero air using an external dry air supply connect AIR IN port to a
clean, dry air supply (see Figure 1-6).
NOTE
For best O3 generator stability and to avoid moisture condensation,
it is recommended that zero air be dried to approximately -20°C dew
point.
For external pressurized dry zero air using an external dry pressurized source (see Figure 1-
6) proceed as follows:
a. Remove cap plug from the tee of zero air scrubber assembly and connect external dry
zero air line instead (air pressure should be about 30-40 psi).
b. Install the cap plug to dry air inlet port.
c. Verify the power is off and unplug O3 GENERATOR pump's power cable connector.
8. Connect a recording device to the terminal strip connections on the rear panel (see
Figure 1-2). See Table 9-4 for setting proper analog output voltage jumpers.
9. Connect the power cord to an appropriate power outlet (see the serial number tag for correct
voltage and frequency).
NOTE
Power plug must have ground lug.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
10. Turn on the M401 by switching the switch on the lower right corner of the front panel (See
Figure 2-1). The front panel display should light with a sequence of messages,-API - M401 -
software version number, then a normal display as shown in Figure 2-2.
11. Allow about 60 minutes for the temperatures to come up to their respective setpoints then
press the leftmost button on the front keyboard to scroll through the TEST values. Compare
these values to those noted during the final factory checkout listed in Table 1-1. The values
observed should closely match the Table 1-1 values.
NOTE
Words in all caps are messages on the analyzer front panel.
12. Select the range the analyzer will be calibrated on.
a. From the MAIN menu press SETUP to enter the SETUP menu. (See Figure 2-2 for
appearance of front panel.)
b. Press MISC.
c. Press D/A.
d. Enter the PASSWORD (818).
e. Press RNGE (RANGE).
f. Enter the derived full scale range for analog outputs and press ENTR. (Example: if full
scale range is 500 ppb, then press corresponding digit's button until desired range is
selected and press ENTR.)
g. Press EXIT 3 times to return to the MAIN menu.
13. O3 generator flow adjustment. The O3 generator flow is controlled by a precision pressure
regulator and flow restrictor. Increasing upstream pressure of flow restrictor will increase
flowrate and vice versa. In order to increase pressure, adjust knob clockwise as needed while
monitoring the O3 flow test measurement display. In general, the O3 generator flow should be
at least 1 L/MIN in addition of total flow demands for the Model 401 (800 cc/min) and
remote analyzers.
NOTE
Adjustment of the O3 generator flow is to be performed by qualified
maintenance personnel only.
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14. Generate the Zero Air.
a. Press ZERO from the main menu and enter the password (512).
b. Press STBY to terminate or press O3GN to continue to generate O3 span gas.
15. Generate the O3 Span Gas.
a. Press O3GN from the main menu and enter the password (512).
b. Enter the O3 concentration value desired (0.05 - 1 ppm range).
c. Press CONC in order to change O3 gas concentration while generating specified O3 gas.
d. Press STBY to terminate O3 gas generation or press zero to continue to generate zero air.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Figure 1-1: Model 401 Ozone Calibrator Block Diagram
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8.7
Figure 1-2: M401 Rear Panel Electrical Connections
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Figure 1-3: Rear Panel Electrical and Pneumatic Connections (CE Version)
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.6 Electrical And Pneumatic Connections
1.6.1 Electrical Connections
Output #1 Ozone concentration - chart recorder
Output #2 Ozone concentration - DAS
Output #3 Test function analog output
Input #4 Zero valve request
Input #5 Span valve request
Input #6 N/C
There are 2 six-pin connector strips on the rear panel shown in Figure 1-2. The pins are divided
into 3-plus/minus pairs and have the functions shown above.
Outputs 1 and 2 have identical signals and electrical characteristics. Output 3 is the same as 1
and 2 electrically, but has analog TEST function signals routed to it. See Diagnostics in Section
5 for details.
1.6.2 RS-232
See Figure 1-4.
The RS-232 connection is a male 9-pin D-sub connector.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Figure 1-4: RS-232 Pin Assignments
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.6.3 Pneumatic System
The Model 401 Photometric Calibrator is equipped with a compression pump to deliver up to 5
L/MIN for ozone generator system. It is also equipped with a second pump capable of pulling
800 cc/min across a critical flow orifice. This allows a smooth, stable flow of sample through the
Photometer.
Compressed air is delivered through a charcoal scrubber. While one path is used as zero air
reference, the other path of same zero air is used to generate the stable ozone output. This will
ensure reliable ozone output as well as proper Photometer operation. Please see Figure 1-1 for
flow diagram and Figure 1-5 for pneumatic connections.
NOTE
The photometer output varies linearly with pressure and
temperature. Temperature and pressure compensation is
done automatically.
A critical flow orifice is used to control the sample flow. The orifice is a precision-drilled
sapphire jewel protected by a 20 micron sintered filter. The critical flow orifice never needs
adjustment and maintains precise flow control as long as the ratio of the up-stream to down-
stream pressures is greater than 0.53 (sonic flow conditions).
1.6.4 Exhaust Connections (See Figure 1-5)
A single 1/4" O.D. tube should be connected from the Analyzer sample exhaust to an area
outside of the room the analyzer occupies. The maximum length of the exhaust line should not
exceed 30 feet.
1.6.5 Output Flow Adjustment
The flow rate of gas supplied to the output manifold can be changed by adjusting the internal
pressure regulator located on the top of the optical bench (see Figure 1-7). The output flow, O3
FLOW, can be read on the front panel test functions. Adjust this flow rate to provide a minimum
of 1 LPM for each analyzer being calibrated plus 1 LPM for the internal photometer in the
M401. For example, when calibrating one analyzer the O3 flow rate should be set to at least 2
LPM.
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Figure 1-5: M401 Calibrator Pneumatic Connections
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Figure 1-6: M401 Rear Panel (External Dry Zero Air)
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Figure 1-7: M401 Calibrator Chassis Layout
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1.7 Operation Verification
The Model 401 Calibrator is now ready for operation.
1. Read Section 1.3 and all of Section 4 of the manual to understand the Calibrator operation.
2. Turn on the power by pressing the on/off switch on the front panel (see Figure 2-1). The
display should turn on and green (sample) status LED should be energized. The green LED
should blink indicating the instrument has entered the HOLD-OFF mode. The standby mode
can be entered immediately by pressing the EXIT button on the front panel. The red "fault"
light will also be on until the flows, temperatures and voltages are within operating limits.
Clear the fault messages.
3. After a 60 minute warm-up, review the TEST function values in the front panel display by
pushing the leftmost keyboard button labeled TEST. Not every TEST function is a diagnostic
of correct analyzer operation, therefore TEST functions not covered below can be ignored for
now.
4. O3 REF, O3 MEAS: TEST function values should be between 4200 mv and 4700 mv.
5. Pressure: 29 to 30 Inches-Mercury-Absolute at sea level. Other values will be displayed
depending on altitude of analyzer.
6. Sample Flow: 800 cc/min ± 10 %.
7. Sample Temp: Ambient temperature +10° C.
8. Analytical Lamp Temp: 52° C ± 0.1 The computer drives the temp to this setpoint -it should
be this value and not vary.
9. O3 GEN Lamp Temp: 48° C ± 1° C.
10. Box Temp: Ambient ± 10° C.
11. DC Power Supply: 2500 mV ± 100 mv. This is a composite of all of the DC voltages in the
instrument. The value is not important but it should be within the range indicated, and should
be constant.
12. If the TEST functions are within the limits given above the instrument should function
correctly. If there is a problem please read the manual and check your set-up. The Model 401
is now ready for calibration, see Section 3.
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1.7.1 Final Test And Calibration Values
Table 1-1: Test Values
Test Parameter Displayed Value Units
TIME HH:MM:SS
DCPS MV
BOX TEMP DEG C
O3 OFFSET PPB
O3 SLOPE -
REG PRESSURE IN-HG-A
O3 GEN TMP DEG C
O3 GEN FLOW L/MIN
ANA LAMP TMP DEG C
SAMPLE TEMP DEG C
SAMPLE FLOW SCC/MIN
SAMPLE PRESS IN-HG-A
O3 DRIVE MV
O3 GEN REF MV
O3 REF MV
O3 MEAS MV
O3 SET PPB/PPM
Options
RACK MOUNTS/SLIDES
POWER VOLTS/Hz
STATUS OUTPUT
RS-232 OUTPUT
Calibration Settings
O3 SPAN SETTING PPB
O3 ZERO SETTING PPB
O3 SLOPE
O3 OFFSET
PROM # Serial #
Date Technician
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
1.8 Options
1.8.1 Rack Mount With Slides
This option, including slides and rack mounting ears, permits the Analyzer to be mounted in a
standard 19" wide x 30" deep RETMA rack.
1.8.2 Status Outputs
The status output is an option that reports Analyzer conditions to a 50 pin connector from the
mother board. The contacts are NPN transistors which can pass 50 ma of direct current. See
Section 8.6 for status output pin assignments.
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2 OPERATION
2.1 Key Features
The important features of the Teledyne API Model 401 Photometric Calibrator are listed below.
2.1.1 O3 Readout
The Teledyne API Model 401 Photometric Calibrator constantly displays the current ozone
reading
(in PPB) in the upper right hand corner of the alphanumeric display.
2.1.2 O3 Analog Output
The Teledyne API Photometric Calibrator provides a buffered analog output of the current O3
readings on each of two pairs of outputs on the rear panel (see Figure 1-2) for DAS and recorder
reporting. The analog outputs provide for 20% overrange. For example, on the 500ppb range the
M401 will correctly report concentrations up to 600 ppb and output up to 6.00 volts to the DAS
and recorder outputs. (See Table 9-4 for setting proper analog output voltage jumpers.)
In addition TEST function values can be routed to a third analog output.
2.1.3 E2 ROM Backup Of Software Configuration
The Teledyne API Photometric Calibrator has few DIP switches or jumpers that need to be set
by the operator. Configuration of the calibrator is done under software control and the
configuration options are stored in electrically erasable (E2) ROM. Thus, configuration options
are saved even when the Analyzer is powered off.
There is one exception to this. The analog output voltage ranges are set by DIP switches on the
A/D-I/O board as shown in Section 9.6.3.
2.1.4 Adaptive Filter
The Teledyne API Photometric Calibrator is able to provide a smooth, stable output by means of
an adaptive filter. During conditions of constant or nearly constant concentration the filter is
allowed to grow to 32 samples (2 minutes) in length, providing a smooth, stable reading. If a
rapid change in concentration is detected, the filter is cut to 6 samples to allow the Analyzer to
quickly respond to rapidly varying signals.
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2.1.5 Data Acquisition
The Teledyne API Photometric Calibrator contains a built-in data acquisition system which
keeps track of the average O3 readings and the last 100 averages. This data is made available to
other systems via the RS-232 interface. The Photometric Calibrator can be programmed to
automatically output a 1 minute to 60 minute average. The last 100 averages can be called up
through the remote
RS-232 I/O or viewed on the display through keyboard call-up.
2.1.6 RS-232 Interface
The Teledyne API Photometric Calibrator features an optional RS-232 interface which can
output the instantaneous and/or average O3 data to another computer. It can also be used as a
command and status channel to allow another computer to control the Analyzer. Refer to Figure
1-4 for details on using the RS-232 interface.
2.1.7 Password Protection
The Teledyne API Photometric Calibrator provides password protection of the calibration and
setup functions to prevent incorrect adjustments to the Calibrator. There are three levels of
passwords which correspond to operator, supervisor/maintenance, and dynamic span level
functions. When prompted for a password, any of the valid passwords can be entered, but the
CPU will limit access to the functions allowed for that password level. Each level allows access
to the functions of all the levels below plus some additional functions. The table on the following
page lists the password levels and the functions allowed for each level.
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Table 2-1: Password Levels
Password Level Functions Allowed
No password required 0 TEST, MSG, CLR,
SETUP-DAS-VIEW
Operator (512) 1 ZERO, 03GN, ASEQ
Setup (818) 2 SETUP-EVNT,
SETUP-BCAL,
SETUP-COMM,
SETUP-MISC-O3 GEN,
SETUP-MISC-DARK,
SETUP-MISC-CLK,
SETUP-MISC-D/A,
SETUP-MISC-MORE,
SETUP-PASS,
SETUP-DIAG
Setup (717) 3 SETUP-MISC-O3-SLPE,
SETUP-MISC-03-OFFS
NOTE
All passwords can be disabled. To do this, enter setup-password,
enter 818 and turn "enable" off. If the wrong password is entered, the
analyzer will beep when enter is pressed.
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2.2 Front Panel
This section describes the operator interface from the point of view of the front panel. The front
panel consists of a 2-line by 40-character alphanumeric display, 8 pushbuttons, and 3 status
LEDs. Each of these features are described in Section 2.2.1.
2.2.1 Front Panel Display
The display is divided into 4 main "fields": the mode field in the upper left, the message field in
the top center, the sample concentration field consisting of the most recent instantaneous ozone
value field in the upper right, and the MENU field which occupies the entire bottom line of the
display. A typical display is shown in Figure 2-1.
Figure 2-1: Model 401 Front Panel
The mode field indicates the current mode of the Analyzer. Usually, it shows "STBY ZS ",
indicating that the instrument is in the standby mode and that automatic zero/span checking is
enabled. Manual span checking or calibration can only be performed by pressing the buttons on
the front panel labeled "ZERO", "O3GN" or “ASEQ.” ASEQ is a sequence of multipoint
calibration which is displayed only if automatic multipoint sequence is selected (see Section 3.3
for detailed information). Automatic span check only occurs at the preset time. Calibration and
span adjustments are discussed in greater detail in Section 3.6. Table 2-2 lists all the possible
modes in the Analyzer and their meanings.
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Table 2-2: System Modes
Mode Meaning
STBY xxxx (1) Standby mode (Photometer is operating normally)
ZERO CAL x (2) Zero check in progress
O3GN CAL x (2) Span check in progress
ASEQ xxx (5) x (2) Multi-point calibration in progress
HOLD OFF Hold off delay after power reset
D/A OUTPUT (3) Test analog output channels
BCAL ZERO Bench zero calibration
BCAL SPAN Bench span calibration
SETUP xxx (4) Configuring analyzer (operation continues)
(1) xxxx = AZS ( Auto Zero & Span programmed), AZ2S (Auto Zero & 2 span points; 25% &
100% of O3 set concentration) programmed AZ5S
(Zero & 5 span points; 20%, 40%, 60%, 80% & 100% of O3 set concentration) programmed.
(2) x = M (manual), A (auto), R (remote)
(3) diagnostic test modes
(4) xxx = software revision
(5) 0%, 20%, 25%, 40%, 60%, 80%, 100%
The message field shows test measurements or warning messages. Table 2-3 and Table 2-4
summarize the test measurements and warning messages and their meanings. Refer to Sections 4
and 5 for detailed information on viewing test measurements and warning messages and clearing
warnings.
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Table 2-3: Test Measurements
Test Message Meaning
TIME=xx:xx:xx Current time-of-day (HH:MM:SS)
O3 SET =xxxx PPB Ozone generator set concentration
O3 MEAS=xxxx MV Current measure channel in mV
O3 REF =xxxx MV Current reference channel in mV
O3 GEN =xxxx MV O3 GEN ref channel feedback voltage
PRES=xxx IN-HG-A Absolute pressure : inches Hg
SMP FLW=xxx CC/M Sample flow through Photometer (cc/min)
SAMPLE TEMP=xxx C Temperature in the absorption tube
ANA LAMP TMP=xxx C Analytical Lamp Housing Temperature
O3 FLOW=x.x L/M Gas flow through O3 generator
O3 LAMP TMP=xx C O3 GEN Lamp Housing temp. (deg. C)
REG = xx.x IN-HG-A Regulator pressure - Inches Hg.
BOX TEMP=xxx C Internal box temperature (deg. C)
DCPS=xxxxxx MV DC power supply (mV)
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Table 2-4: Warning Messages
Warning Message Meaning
SYSTEM RESET Issued whenever Analyzer is powered on
RAM INITIALIZED RAM was erased (including DAS reports)
ANA LAMP WARNING Analyzer lamp < 40000 OR >= 80000 counts
O3 LAMP SHUTDOWN O3 lamp temperature control not working
O3 FLOW WARNING O3 GEN flow < 1.8 L/M or > 5.5 L/M
O3 REF DET WARN O3 reference detector < 50 mV
SAMPLE FLOW WARNING Sample flow < 500 cc/m or > 1000 cc/m
SAMPLE PRESSURE WARN Sample pressure < 15 or > 35 In-Hg-A
SAMPLE TEMP WARNING Sample temperature < 12 or > 48 deg. C
BOX TEMP WARNING Box temp. < 12 deg. C or > 48 deg. C
O3 GEN LAMP TEMP WARN O3 lamp < 43 or > 53 deg. C
ANA LAMP TEMP WARN Analyzer lamp < 51 or > 61 deg. C
V/F NOT INSTALLED A/D - I/O card not installed, bad, or no handshake.
The menu field changes depending on the mode of the Analyzer and the buttons that have been
pressed. It indicates the current function of each of the 8 pushbuttons below the display. See
Section 2.2.2 for information on using the pushbuttons.
2.2.2 Programmable Pushbuttons
The 8 pushbuttons below the display are programmable by the CPU in that their functions
change depending on the mode of the Analyzer or the operations being performed. The legend
above a button identifies its current function. If there is no legend above a button, it has no
function and will be ignored if pressed.
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Figure 2-2: Illustration Of Normal Display
If TEST is pushed, the upper center display cycles through the menu of test parameters, e.g.
Sample flow (see Table 2-3).
If STBY is pushed, the calibrator is in stand-by mode.
If ZERO is pushed, the sequence of operations for generating ZERO gas is initiated.
O3GN is used to initiate span setting using sample gas, such as during a formal calibration.
Pushing ASEQ will initiate multi-point calibration if it is preset. (see Section 3.4)
Pushing MSG will cause a message to appear on the upper center display if warning exits (also
red status led will be blinking).
Pushing CLR will erase a message, provided the condition causing the message has ceased.
Pushing SETUP changes the function of the pushbuttons and is used for setting basic parameters
as described in Section 4.
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2.2.3 Status LEDs
The three status LEDs to the right of the display indicate the general status of the Model 401
Photometric Calibrator. The green SAMPLE LED indicates the sampling status. The yellow
CAL LED indicates the calibration status. The red FAULT LED indicates the fault status. Table
2-5 summarizes the meanings of the status LEDs.
Table 2-5: Status LEDs
LED State Meaning
Green Off
On Not monitoring (should never be off)
Monitoring normally
(STBY/ZERO/O3GN/ASEQ MODE)
Yellow Off
On
Blinking
Auto cal. disabled
Auto cal. enabled
Calibrating
Red Off
Blinking No warnings exist
Warnings exist
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INTENTIONALLY BLANK
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3 CALIBRATION
The M401 is designed to be used as a dedicated ozone calibrator with built-in photometer.
Zero/Span gas generation and calibration of Model 401 are discussed in Section 3. The emphasis
in Section 3 is on the operation of the buttons and the internal adjustments they make in the
instrument.
3.1 Manual Zero Air Supply
The Model 401 calibrator can generate zero air using the internal scrubbing module. Press zero
and enter password (512) to generate zero air. The IZS pump will start to run and flow control
system will maintain stable flowrate of zero air to both the photometer and the analyzer being
calibrated. Supply flowrate should exceed demand flowrate to ensure good zero measurement.
Dry air should be provided into the inlet of rear panel for internal zero air supply.
3.2 Manual O3 Generation
Press O3GN, then enter the password (512), to generate the O3 span gas. Specify O3 gas
concentration up to 1000 ppb and minimum of 50 ppb and press enter to select. Again, the O3
generator pump will start to run and the flow control system will maintain stable flowrate
through the O3 generator. Supply flowrate should exceed demand flowrate to ensure good span
measurement. Pressing CONC allows a change of O3 gas concentration during specified O3 gas
generation.
NOTE
The M401 software has a "Learning" feature that will remember the
parameters from the last several concentrations that were generated
by the instrument. The first time a specific concentration is
requested, the response time may be somewhat slow. Any subsequent
requests for that same concentration will be much faster since the
instrument will remember the previous settings. This information
remains in memory even when the instrument is turned off.
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3.3 Automatic Zero/Span (or Multipoint) Check
Automatic zero/span gas supply must be enabled in the setup mode. There are five parameters
that affect zero/span checking: the zero and span duration, the time of day for calibration, the
time shift, the zero and multipoint calibration switch, and the feedback mode. These are
described individually below.
To set the duration of the zero/span check, press the following sequence of buttons from the
STBY mode: SETUP-EVNT-WAIT. Enter the duration for the zero check and then press
ENTR. Similarly enter the duration for the span check and then press enter. To shift the Z/S
check time backwards each day, select "-" and enter a number from 1 to 60. To disable shifting
of the check time (i.e. to Z/S check at the same time each day), enter a time shift of 0.
To enable automatic zero/span checking, press following sequence of SETUP-EVNT-ASEQ.
The CPU will display the current setting in the menu field above the first button. Press "OFF" in
order to disable automatic sequence, then press "ENTR". Likewise, select AZS for zero and span
(See Section 3.2 or 3.4 How To preset O3 concentration which is specified in O3 GN or ASEQ of
main menu.), AZ2S for zero and two span points, (25% AND 100% of preset O3 concentration)
and AZ5S for zero and five span multipoint (20%, 40%, 60%, 80%, and 100% of preset O3
concentration) sequence.
O3 generator has three different modes of lamp feedback control. Press sequence of SETUP-
MISC-O3-GEN-MODE to select constant (CNST) lamp current control, reference (REF)
detector feedback control, or bench (BNCH) feedback lamp control. Bench feedback is
recommended to generate fast response, stable, and accurate O3 concentration in which the
optical bench is used as a feedback detector to control O3 generating lamp.
3.4 Manual Zero/Span (or Multi-Point) Check
Manual zero/span (or multi-point) is activated by pressing "ASEQ" button from the main menu
display. Then enter the password, specify full scale concentration between 50ppb - 1000ppb
which would be 100% of span concentration, and press ENTER to select. This feature is
identical to the automatic zero/span check sequence except it is activated manually. This ASEQ
entry is not shown on display unless it is programmed. In order to enable this feature, automatic
zero/span check parameters must be preset (See Section 3.3 or 4.2). While multipoint calibration
is in progress pressing "STBY" will terminate "ASEQ".
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
3.5 Summary Of Front Panel Calibration Controls
The calibration controls are summarized below in terms of the button sequences used to access
them.
Table 3-1: Calibration Controls
Button Sequence Function Default Limits
STBY Select stand by mode - -
ZERO-ENTR Begin zero calibration - -
O3GN-ENTR Begin span calibration - -
ASEQ-ENTR Begin multi-point calibration - -
SETUP-WAIT Zero/span/duration 15 min 1-20 min
SETUP-EVNT-TIME Auto check time-of-day 23:30 00:00-23:59
SETUP-EVNT-ASEQ En/disable auto multi-point check OFF OFF/ZS/Z2S/Z5S
SETUP-EVNT-SHFT Auto check time shift 0 min
SETUP-MISC-O3-
GEN-MODE Select lamp control mode Bench ± 60 min
CNST/REF/BNCH
3.6 Photometer Calibration
Model 401 is capable of accurately reproducing O3 span gas. However, it should be
quantitatively verified by relating to a master standard such as certified Model 400 O3
photometric analyzer. The calibration of Model 401 photometer can be verified by periodic
(recommended every 3 months) intercomparison between Model 401 photometer and a master
standard.
Photometer Zero Calibration
1. Turn the power on for both Model 401 and Model 400 (as master standard) and allow them
to stabilize for minimum of one hour.
2. Start to generate the zero gas by pressing "zero" button from the main menu and enter the
password (512). In case of using external dry zero air, verify proper IZS flow and pressure of
external air source. (See Figure 1-5 for pneumatic connections.)
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
3. Allow to sample zero gas for approximately 10 minutes.
4. Follow sequence of SETUP, BCAL, and ZERO. Then select "yes" to adjust zero.
NOTE: in case of using external dry zero air, check if dry zero air is supplied into the rear
panel port (see Figure 1-5 for pneumatic connections) at about 30 - 40 PSI pressure. O3
generator flow should be exceeding at least 1 l/min in addition of total flow demands. (See
Section 1.6.5 for O3 generator flow adjustment.)
Photometer Span Calibration
1. Turn the power on for both Model M401 and Model M400 (master standard). Let them
stabilize for minimum of one hour.
2. Start to generate the span (O3) gas by pressing O3GN from the main menu and enter the
password (512). (In case of using external dry zero air, verify proper pressure of external air
source.)
3. Allow to sample span gas for approximately 10 minutes.
4. Follow the sequence of SETUP, BCAL, and enter correct span concentration related to the
Model M400 (master standard). Then select "yes" to set span.
3.7 Remote Zero/Span Check (Contact Closure)
In addition to calibration check via the front panel buttons, the calibrator can be activated by
means of two contact closures called EXT-ZERO-CAL and EXT-SPAN-CAL. (See Figure 1-2
for the location of the terminals for connection of the contacts on the rear panel.) The CPU
monitors these two contact closures every 1 second and looks for a positive transition (i.e. 0 ->
1) on either signal. If a positive transition occurs on EXT-ZERO-CAL, the M401 will perform a
zero check. If a positive transition occurs on EXT-SPAN-CAL, the M401 will perform a span
check. If a positive transition occurs on both EXT-ZERO-CAL and EXT-SPAN-CAL
simultaneously and ASEQ is preset, then the M401 will perform a multi-point sequence as
selected in SETUP-EVNT-ASEQ menu (see Section 4.2.). When a negative transition (i.e. 1 ->
0) is detected, the CPU will go into standby mode.
Also, if a positive transition occurs on either signal while the M401 is in zero, span check or
ASEQ mode, it will immediately switch to the specified mode. For example, if the analyzer is in
zero check and a positive transition is detected on EXT_SPAN_CAL, then the instrument will
immediately go into span check. To perform a zero check followed by a span check, first
generate a positive transition on EXT-ZERO-CAL, and then when you want to do the span
check, generate a positive transition on EXT-SPAN-CAL.
The remote calibration signals may be activated in any sequence, providing a virtually unlimited
number of calibration types.
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NOTE
Teledyne API recommends that contact closures remain closed at
least
10 minutes to allow for an accurate average zero or span value
to be established.
3.8 Remote Zero/Span Check Or Adjustment (RS-232)
Besides Z/S checking from the front panel, automatic Z/S checking, and remote Z/S checking via
the contact closure inputs, the Analyzer can also be checked via the RS-232 interface. Remote
checking via the RS-232 interface supports zero, span, and zero followed by span check, and is
identical to remote check via the contact closure inputs.
This RS-232 control feature is provided mainly so that a host computer at another location can
control the Analyzer. See Section 7 for detailed information on using the RS-232 interface to do
a remote Z/S check.
3.9 Hold Off
Every type or check or adjustment (zero, span, manual, remote, etc.) is followed by a hold-off
period of 30 seconds during which the internal data acquisition system (DAS) does not
accumulate ozone readings into the DAS average.
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4 SETUP MODE
This section describes the setup variables which are used to configure the analyzer.
4.1 Setup Mode Operation
All the setup variables are stored in the analyzer's EEPROM and are retained during power off
and even when new software revisions are installed.
NOTE
If a variable is modified, but ENTR is not pressed, the variable will
not be changed and the analyzer will beep when EXIT is pressed.
4.2 Setting Automatic Multipoint (ASEQ) Check
Automatic sequence of multipoint calibration can be programmed to select one zero and five
span points 20%, 40%, 60%, 80%, and 100% of selected (see Section 3.4 How to set
concentration) O3 concentration by pressing sequence of SETUP-EVNT-ASEQ-AZ5S.
Likewise, select AZS for zero and one span point (selected O3 concentration), select AS2S for
zero and two span points 25% and 100% of selected O3 concentration, or press OFF to disable
pre-programmed automatic sequence. If ASEQ is selected, then front panel's yellow status LED
will be turned on.
4.3 Setting Automatic Zero/Span Duration
Duration of each zero/span calibration step can be programmed by selecting SETUP-EVNT-
WAIT. Enter the duration between 1 - 20 minutes for the zero check and then press ENTR.
similarly enter the duration for span check and press ENTR.
NOTE
Teledyne API recommends that the durations are set at least 10
minutes to allow for an accurate and reliable ZERO or SPAN value
to be established.
Automatic zero/span calibration will be initiated once per day on a timed basis. Set starting time
of the automatic calibration by selecting SETUP-EVNT-TIME. Time should be between 00:00
- 23:59.
Starting time of the automatic cal. can be shifted ± 60 min to avoid missing data of remote
analyzer during same time of the day. Set desired shift time by selecting SETUP-ENVT-SHFT.
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4.4 Examining The Ozone Formula Slope And Offset
The slope and offset parameters can be examined (or changed) by SETUP-MISC-O3-SLPE or
SETUP-MISC-O3-OFFS. The slope and offset parameters are set only during zero and span
calibration routines. These parameters are used to adjust the span and zero values to their exact
values.
NOTE
Do not change slope or offset value unless it is absolutely necessary
to restore the known original values. Take a note of new slope and
offset values after each bench calibration for reference.
The current value of the ozone reading that is displayed on the front panel and output on the
D/A terminals on the back panel is computed as follows:
1. The Model 401 Analyzer switches into reference mode.
2. The Analyzer waits 2 seconds to purge the sample tube.
3. The instrument measures the intensity of light striking the detector during the next 1.067 sec.
This reading forms the reference intensity Io in the ozone concentration equation.
4. The photometer now switches to the sample mode and waits 2 seconds as in step 2 above.
5. The instrument measures the intensity of light striking the detector during the next 1.067 sec.
This reading forms the sample concentration intensity I in the ozone concentration equation.
6. The concentration of ozone is computed using the Beer-Lambert equation corrected for
temperature and pressure.
7. Slope and offset corrections are made to the ozone concentration according to the equation:
OffsetnncentratioMeasuredCoSlopeononcentratiCorrectedC
+
×
=
8. An average of the last 32 samples is computed and converted to the number displayed on the
front panel.
This is the ozone concentration. The number is also routed to the D/A converter and the resulting
voltage is output to the back panel.
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4.5 Setting the O3 Generation Mode
There are three modes of feedback operation that can be selected for the ozone generator. The
mode can be changed by pressing SETUP-MISC-O3-GEN-MODE. The three modes are shown
below. Please note that changing to any Mode other than BNCH may affect the concentration
accuracy of the gas being produced.
4.5.1 BNCH Mode
This is the default mode. In Bench Feedback mode the ozone output is actively controlled by
adjusting the UV lamp intensity in the ozone generator. The gas being produced is continuously
sampled by the internal photometer and adjustments are continuously made to maintain the
desired ozone concentration. The Bench Feedback mode produces the most accurate ozone
concentration.
4.5.2 REF Mode
In Reference feedback mode, the ozone generator UV lamp intensity is controlled by using
optical feedback from the reference detector mounted on the ozone generator.
4.5.3 CNST Mode
In Constant mode, no feedback is used to control the UV lamp in the ozone generator. The lamp
is set to an initial drive value from the lamp power supply and is not changed.
4.6 Setting The Time-Of-Day
To set the current time-of-day, which is used for determining when to do an automatic
calibration and for time-stamping the RS-232 reports, press SETUP-MISC-CLK-TIME. The
CPU will display the current time-of-day as four digits in the format "H :M", where "H" is the
hour in 24-hour format (i.e. hours range from 00 to 23) and "M" is the minute (00 - 59). The
operator may change the time-of-day and then press ENTR to accept the new time, or press
EXIT to leave the time unchanged.
4.7 Setting The Date
To set the current date, which is used for time-stamping the RS-232 reports, press SETUP-
MISC-CLK-DATE. The CPU will display the current date as "D MMM Y". For example, April
1, 1990 would be displayed as "0 1 APR 9 0". Change the date by pressing the button under each
field until the desired date is shown. Then press ENTR to accept the new date or press EXIT to
leave the date unchanged.
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4.8 Adjusting The Clock Speed
In order to compensate for clocks which run a little bit fast or slow, there is a variable called
SETUP-MISC-CLK-ADJ. This variable is set to the number of seconds per day by which to
speed up or slow down the clock. It should only need to be set once for each Analyzer. For
example, if the clock is running 10 seconds fast each day, set the variable to -10 and press
ENTR. (Note that -10 indicates that we want the clock to run 10 seconds slower each day.) If the
clock is running 10 seconds slow each day, set the variable to +10, indicating that we want the
clock to run 10 seconds faster each day.
If the clock speed adjust variable has already been set to a value other than 0 and the speed is
still too fast or too slow, ADD the required adjustment to the current value of the variable. For
example if the clock speed adjustment is already set to +10 and the clock is 5 seconds too slow
per day, add +5 to the current value, yielding +15 as the new value.
4.9 Setting The O3 Concentration Range
To set the range for the ozone reading to the D/A's press SETUP-MISC-D/A-RNGE. The
operator can select any arbitrary full scale range between 100 and 20,000 ppb. Whatever range is
selected, the value chosen will correspond to 5.00 volts on the analog outputs. For other analog
voltage ranges check the jumper table for the V/F board schematic (drawing 00515 in the
Appendix). The front panel display does not have a range setting due to the fact that it can
display any concentration value up to 20,000 ppb.
4.10 Setting The Analog Output Offset
In order to permit the Analyzer to connect to a wider variety of strip chart recorders and other
instruments, the analog output of the ozone readings can be adjusted by up to ± 500 mV for
0-5 V range (or ± 10% of current analog output range) in software. The default output offset is
0 mV. To change it, press SETUP-MISC-D/A-OFFS and enter a value of from -500 mV to
+500 mV (other ranges will ratio accordingly), followed by ENTR to accept the change, or
EXIT to leave it unchanged. The offset will be reflected immediately on the strip chart recorder
or other instrument.
4.11 Setting The RS-232 Baud Rate
To set the baud rate for the RS-232 channel, press SETUP-COMM-BAUD. Press 300, 1200, or
2400, followed by ENTR to accept the new baud rate, or EXIT to leave the baud rate
unchanged.
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4.12 Setting The Analyzer I.D.
Each Analyzer may be programmed with a unique I.D. number which appears on all RS-232
messages. To set the Analyzer I.D., press SETUP-COMM-ID. Enter a 4-digit number from
0000 to 9999, followed by ENTR to accept the new I.D., or EXIT to leave the I.D. unchanged.
If changed, the new I.D. number will appear on all RS-232 reports from this Analyzer.
4.13 Disabling The Calibration Password
Normally, operators are required to enter the calibration password when doing a manual
calibration via the ZERO or O3GN buttons. To allow calibration without entering the password,
press SETUP-PASS and set it to OFF, and then press ENTR to accept the change, or EXIT to
leave it unchanged. To require the calibration password, set the variable to ON.
4.14 Setting The Fault LED Timeout
The Model 401 can be set up so that the red fault LED on the front panel turns off automatically
if no warning conditions persist. Any warning messages will still be displayed, however. To set
the fault LED timeout, press SETUP-MISC-MORE-FILT and enter a value of from 0 to 300
seconds. A value of 0 disables the timeout, meaning that the fault will continue to blink as long
as a warning message is displayed. For example, to cause the fault LED to turn off if no warning
conditions have occurred for at least 5 minutes, set the variable to 300 sec.
NOTE
It is not advisable to set the timeout to an extremely short value such
as 1 second. Doing this may make the fault LED behave strangely.
This is because if a warning condition persists and the fault LED
timeout is very short, then the warning condition will be trying to
turn it off. The result will be an irregular blinking of the fault LED.
You should set the timeout to a value of at least 15 seconds.
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4.15 Software Configuration
The software configuration can be displayed by entering the button sequence SETUP-CFG-
LIST. For example the M401 could display:
"O3 CALIBRATOR"
"SBC40 CPU"
Stating that the instrument was an Ozone Calibrator using the SBC40 computer. This feature is
useful for showing any special features that are present in the currently installed PROM.
4.16 Summary Of Setup Variables
The setup variables are summarized in Table 4-1 in terms of the button sequences used to access
them.
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Table 4-1: Setup Variables
Button Sequence Function Default Limits
SETUP-EVNT-WAIT Zero cal. duration
Span cal. duration 15 min.
15 min. 1-20 min.
1-20 min.
SETUP-EVNT-TIME Cal. time-of-day 23:30 00:00-23:59
SETUP-EVNT-ASEQ Auto. Multipoint cal. enable OFF OFF/ZS/Z2S/Z5S
SETUP-EVNT-SHFT Auto check shift 0 min. ± 60 min.
SETUP-COMM-BAUD RS-232 baud rate 2400 baud 300, 1200, 2400
SETUP-COMM-ID Analyzer ID number 0000 0000-9999
SETUP-MISC-O3-SLPE Slope adjust parameter 1.00 0.85 - 1.15
SETUP-MISC-O3-GEN-ADJ O3 GEN lamp setup/adjust OFF ON - OFF
SETUP-MISC-O3-GEN-CAL O3 GEN calibration OFF ON - OFF
SETUP-MISC-O3-GEN-
MODE Feedback mode selection BNCH
SETUP-MISC-O3-OFFS Offset adjust parameter 0.0 ± 1000.0
SETUP-MISC-DARK-VIEW Dark current offset 0 mV 1000 mV
SETUP-MISC-CLK-TIME Current time-of-day 00:00 00:00 - 23:59
SETUP-MISC-CLK-DATE Current date 01 JAN 00 31 DEC 99
SETUP-MISC-CLK-ADJ Clock speed adjust 0 sec/day ± 60 sec.
SETUP-MISC-D/A-RNGE D/A output range 500 ppb 100-10000
SETUP-MISC-D/A-OFFS D/A offset setting 0 mV ± 500 mV
SETUP-MISC-MORE-FLT Fault LED timeout 5 min 0 - 10 min
SETUP-MISC-MORE-UNITS O3 conc. units ppb ppb/ppm/ug/mg
SETUP-MISC-MORE-TCHN TEST to analog output OFF OFF-ON
SETUP-PASS Cal. password enable ON OFF-ON
SETUP-CFG-LIST Software configuration O3 CALIB. Display
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5 DIAGNOSTICS
The Teledyne API ozone analyzer contains two levels of diagnostics: test measurements which
can be viewed at all times (except when in setup) by pressing TEST, and lower level diagnostic
operations which can only be performed by pressing SETUP-DIAG.
5.1 Test Measurements
As stated, test measurements can be viewed at any time except when in setup. To view a
different test measurement, simply press the TEST button. Table 2-3 lists the test measurements
which are available. Viewing these test measurements does not interfere with the operation of
the Model 401 or the ozone reading of the photometer in any way, so they may be viewed freely.
Additionally, the values of most TEST functions can output as an analog voltage at the
instrument's rear panel (see Figure 1-2). The TEST function to be output is selected by pressing
SETUP-MISC-MORE-TCHN. Table 5-1 lists the Test functions available for analog output.
In addition to outputting a value to the analog output channel, these tests activate a new test
measurement which displays the analog voltage reading on the front panel as:
"TEST=XXXXX.X MV".
5.2 Diagnostic Tests
The diagnostic tests are used to help diagnose a problem in the Analyzer and should only be used
by skilled maintenance people. To get into the diagnostic test mode, press SETUP-DIAG. When
the diagnostic mode is entered, a message is sent to the RS-232 channel indicating entry into the
diagnostic mode.
The TEST button is used to scroll through the test measurements until the one of interest is
displayed.
The EXIT button exits the diagnostic mode and turns all the diagnostic tests OFF. This ensures
that a diagnostic test is not accidentally left ON. A message is also sent to the RS-232 channel to
indicate that the diagnostic mode has been exited.
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Table 5-1: Test Channel Output
Test # Name Purpose
1 NONE No output
2 O3 DETECT Outputs O3 detector
3 REF DETECT Outputs IZS ref. det.
4 SAMP PRESS Outputs sample press.
5 SAMP FLOW Outputs sample flow
6 SAMP TEMP Outputs sample temp.
7 ALAMP TEMP Outputs ana lamp temp.
8 O3 FLOW Outputs O3 flow
9 O3 LAMP TEMP Outputs O3 lamp temp
10 CHASSIS TEMP Outputs chassis temp
11 DCPS VOLT Outputs DC power
Table 5-2: Diagnostic Tests
Test # Name Type Purpose
1 D/A OUTPUT Analog Tests analog outputs
5.2.1 D/A Output
This test cycles 3 of the analog output channels from 0% to 100% of Full Scale in 20% FS steps.
It starts by outputting 0 volts to all four channels and displaying a 0% button. Then, every five
seconds, the output is increased 20% FS and the button is changed accordingly. Thus, the button
(and the analog outputs) will cycle through the following values:
0%, 20%, 40%, 60%, 80%, 100%, 0%
To pause the output at the current voltage, press the n% button. To resume automatic cycling,
press the n% button again.
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6 HANDLING WARNINGS
When a system warning occurs, a warning message is displayed and the FAULT LED blinks. A
warning indicates that something in the system needs to be checked or adjusted. Failure by the
operator to respond to a warning may result in poor system performance and/or less accurate
data acquisition. Warnings should be taken seriously.
When a warning is displayed, the MSG and CLR buttons will appear on the menu line (when
not in setup mode). Pressing MSG will scroll through the warning messages if there is more than
one. CLR will clear the currently displayed warning message, and if there are no more warning
messages remaining, the MSG and CLR buttons will disappear and the FAULT LED will be
turned OFF. If after pressing CLR, warning messages still exist, the FAULT LED will continue
to blink and the MSG and CLR buttons will remain on the menu line.
If after clearing a message, the warning condition for that message still exists, the message will
reappear after a period of time which depends on how frequently the condition is checked by the
CPU (usually every few seconds). If a warning message reappears every time after CLR is
pressed, the problem should be solved and the Analyzer restarted. Some problems may be
temporary and may not reappear after CLR is pressed (e.g. temperature too high, too low, etc.).
To ignore the warning messages and display the test measurement again, simply press TEST.
The warning messages will remain active and may be viewed again by pressing MSG.
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7 RS-232 COMMUNICATIONS
The Model 401 Photometric Calibrator features a powerful RS-232 interface which is used both
for reporting test results and for controlling the Photometer from a host computer. Because of the
dual nature of the RS-232 interface, the message format has been carefully designed to
accommodate both printers and host computers.
All message outputs from the Model 401 Photometric Calibrator have the following format:
"X DDD:HH:MM IIII MESSAGE<CRLF>"
The "X" is a character indicating the message type (see Table 7-1).
Table 7-1: RS-232 Message Types
Character Message Type
R DAS Report
W Warning
C Control/Status
D Diagnostic
T Test Measurement
V Variable Value
? HELP Screen
The "DDD:HH:MM" is a time-stamp indicating 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.
The "IIII" is a 4-digit Analyzer I.D. number.
The "MESSAGE" field contains variable information such as warning messages, test
measurements, DAS reports, etc.
The "<CRLF>" is a carriage return-line feed combination which terminates the message and also
makes the messages appear neatly on a printer.
The uniform nature of the output messages makes it easy for a host computer to parse them.
Input messages to the Model 401 have a format which is similar to that for output messages:
"X COMMAND<CRLF>"
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The "X" indicates the message type as shown above in Table 7-1 and "COMMAND" is the
command type, each of which is described individually below.
The "<CRLF>" is used to terminate the command. Typing "<CRLF>" a few times by itself is a
good way to clear the input buffer of any extraneous characters.
7.1 DAS Reporting
Every N minutes (N is software selectable) the data acquisition system issues a report to the RS-
232 interface. This report shows the average O3 reading during the last N minutes, the range, and
the number of 1-minute samples taken during that interval. The message format is:
"R DDD:HH:MM IIII RANGE=xxxx O3=xxxx PPB SAMPLES=xx<CRLF>"
Whenever the Model 401 is in calibration or diagnostics mode, no O3 readings are included in
the average. Thus, it is possible for an average to contain 0 samples. If the number of samples in
an average is 0, then "XXXX" is shown as the O3 readings.
The host computer can request the DAS reports stored in the battery-backed RAM by means of
the command:
"R NNN<CRLF>"
where "NNN" is the number of reports requested (starting from the most recent one). The CPU
will output NNN reports to the RS-232 interface, each report having the following format:
"R DDD:HH:MM IIII O3 PPB SAMPLES=xx<CRLF>"
where the fields have the same meaning as described above. For example, if the last DAS report
was at 10:00 a.m. and the report frequency is 60 minutes and the host computer requests the most
recent 3 reports by issuing the command:
"R 3<CRLF>"
and the CPU will respond by outputting something like the following:
"R 91:08:00 0000 O3= 0 PPB SAMPLES=60<CRLF>"
"R 91:09:00 0000 O3= 2 PPB SAMPLES=60<CRLF>"
"R 91:10:00 0000 O3= 0 PPB SAMPLES=60<CRLF>"
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7.2 Warnings
Whenever a warning message is displayed on the display, it is also sent to the RS-232 output.
See Table 2-4 for a list of the warning messages. These messages are very helpful when trying to
track down a system problem and for determining whether or not DAS average data is actually
valid. The message format is:
"W DDD:HH:MM IIII WARNING MESSAGE<CRLF>"
An example of an actual warning message is:
"W 194:11:03 0000 SAMPLE FLOW WARN<CRLF>"
Warnings may be cleared via the RS-232 interface by issuing a command of the form:
"W COMMAND<CRLF>"
where "COMMAND" indicates which warning message to clear. For example, to clear the
"SAMPLE FLOW WARN" message, the host computer can issue the command:
"W WSMPFLOW<CRLF>"
To clear all warning messages:
"W CLEAR ALL<CRLF>"
Attempting to clear a warning which is not active has no effect. Table 7-2 lists the command to
use to clear each possible warning message.
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Table 7-2: Warning Message Clear Commands
Command Warning Message Cleared
"W WSYSRES<CRLF>" SYSTEM RESET
"W WRAMINIT<CRLF>" RAM INITIALIZED
"W WALMPINT<CRLF>" ANA LAMP WARNING
"W WO3LMPHLT<CRLF>" O3 GEN LAMP SHUTDOWN
"W WO3REFDET<CRLF>" O3 GEN DETECTOR WARNING
"W WO3FLOW<CRLF>" O3 GEN FLOW WARNING
"W WSMPFLOW<CRLF>" SAMPLE FLOW WARNING
"W WSMPPRES<CRLF>" SAMPLE PRESSURE WARNING
"W WSMPTEMP<CRLF>" SAMPLE TEMP WARNING
"W WBOXTEMP<CRLF>" BOX TEMP WARNING
"W WO3LMPTMP<CRLF>" O3 GEN LAMP TEMP WARNING
"W WALMPTMP<CRLF>" ANA LAMP TEMP WARNING
"W WVFINS<CRLF>" V/F NOT INSTALLED
7.3 Status/Control
This subset of messages is concerned with reporting the status of the calibrator and controlling
the calibrator remotely. Whenever the calibrator does a calibration it issues a report to the RS-
232 output. The table on the following page summarizes the status reports.
Table 7-3: Status Reports
Report
"C DDD:HH:MM IIII START ZERO CALIBRATION"
"C DDD:HH:MM IIII FINISH ZERO CALIBRATION"
"C DDD:HH:MM IIII START SPAN CALIBRATION"
"C DDD:HH:MM IIII FINISH SPAN CALIBRATION"
"C DDD:HH:MM IIII START MULTI-POINT CALIBRATION"
"C DDD:HH:MM IIII FINISH MULTI-POINT CALIBRATION"
"C DDD:HH:MM IIII START CALIBRATION HOLD"
"C DDD:HH:MM IIII FINISH CALIBRATION HOLD"
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To do a remote adjustment via the RS-232 interface, the host computer should issue a message
with the following format:
"C COMMAND<CRLF>"
The commands are summarized in Table 7-4.
Table 7-4: Control Commands
Command Message Meaning
"C ZERO<CRLF>" Do a zero check
"C O3GEN<CRLF>" Do a span check
"C ASEQ<CRLF>" Do a multi-point check
"C STBY<CRLF>" Exit zero, span, or ASEQ
NOTE
The commands in Table 7-4 can only be entered via the RS-232 port
when the calibrator is in the stand by mode. "C ASEQ" is enabled
only if ASEQ is pre-selected.
When a control command is issued, the CPU will respond by issuing a status report. For example
if the host computer issues the command:
"C ZERO<CRLF>"
to do a zero check, the CPU will send the report:
"C DDD:HH:MM IIII GENERATE ZERO"
to the RS-232 output.
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7.4 Diagnostics
The diagnostics mode can be entered from the RS-232 port as well as from the front panel. The
diagnostics commands available are listed below.
NOTE
The diagnostics mode may only be entered via the RS-232 port when
the calibrator is in stand by mode.
Table 7-5: Diagnostic Commands
Command Function
"D ENTER<CRLF>" Enter diagnostics mode
"D EXIT<CRLF>" Exit diagnostics mode
"D PREV<CRLF>" Go to previous test
"D NEXT<CRLF>" Go to next test
"D ON<CRLF>" Turn test signal ON
"D OFF<CRLF>" Turn test signal OFF
"D PAUSE<CRLF>" Pause analog output test
"D RESUME<CRLF>" Resume analog output test
These commands may be used whether the diagnostics have been entered from the keyboard
(SETUP-DIAG) or the RS-232 ("D ENTER <CRLF>"). However, when the diagnostics are
entered via the keyboard, no feedback is sent to the RS-232 channel. This prevents the RS-232
output from getting unnecessarily cluttered with diagnostic data.
In addition to the above commands, three special diagnostics commands have been added to
provide complete control over a remote Analyzer. These commands may be executed no matter
what mode the instrument is in.
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Table 7-6: Special Diagnostic Commands
Command Function
"D SYS-RESET<CRLF>" Reset Calibrator (same as power off/on)
"D RAM-RESET<CRLF>" Reset Calibrator and erase RAM
"D EE-RESET <CRLF>" Reset Calibrator and erase RAM & EEPROM
Whenever the diagnostic mode is entered or exited, a report is issued to the RS-232 output.
Table 7-7 summarizes the diagnostic reports.
Table 7-7: Diagnostic Reports
Report
"C DDD:HH:MM IIII ENTER DIAGNOSTIC MODE"
"C DDD:HH:MM IIII EXIT DIAGNOSTIC MODE"
7.5 Test Measurements
All the test measurements which can be displayed by pressing the TEST button are also available
to the host computer via the RS-232 interface. The host computer should issue a request for a test
measurement, and then the CPU will send the current value of the test measurement to the
RS-232 output. The format of the test measurement message is:
"T DDD:HH:MM IIII TEST MEASUREMENT<CRLF>"
For example, the format of the PMT output in millivolts would be:
"T 194:11:29 0000 PMT= 254 MV<CRLF>"
To request a test measurement, the host must issue a command of the form:
"T MEASUREMENT<CRLF>"
For a summary of all test functions issue the command "T LIST". Table 7-8 lists the commands
and the corresponding test measurements which will be returned.
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Table 7-8: Test Measurement Request Commands
Command Test Measurement
"?<CRLF>" RS-232 HELP screen
"T LIST<CRLF>" Summary of all Tests
"T O3MEAS<CRLF>" Current O3 meas counts
"T O3REF<CRLF>" Current O3 reference counts
"T SPRESS<CRLF>" Sample pressure
"T SFLOW<CRLF>" Sample flow rate
"T STEMP<CRLF>" Sample temperature
"T ALTEMP<CRLF>" Analyzer lamp temperature
"T BOXTEMP<CRLF>" Internal box temperature
"T DCPS<CRLF>" DC power supply output
"T CLKTIME<CRLF>" Current time-of-day
7.6 Viewing And Modifying Variables
The most powerful feature of the RS-232 interface is the ability of a host computer to view and
modify the calibrator's internal variables. Just as the operator modifies the variables by means of
the setup mode, the host computer modifies them by means of the RS-232 interface.
To view a variable's value, the host computer issues a command of the following format:
"V VARIABLE<CRLF>"
The CPU will respond by sending a message of the following format to the RS-232 output:
"V VARIABLE=VALUE WARNLO WARNHI <DATALO-DATAHI> <CRLF>"
In both cases "VARIABLE" is the name of the variable that is being viewed. "VALUE" is the
current value of the variable. "WARNLO" and "WARNHI" are the low and high warning limits,
respectively, but may not appear for all variables since some variables do not have warning
limits. "DATALO" and "DATAHI" are the low and high data entry limits, respectively, and are
given for all variables. The CPU will not set a variable's value or warning limits to values which
are outside of the data entry limits.
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For example, to see the analyzer lamp temperature set point, the host computer would issue the
command:
"V ALAMP_SET<CRLF>"
and the CPU would respond with something like:
"V DDD:HH:MM IIII ALAMP_SET=25 20 30 <0-100><CRLF>"
indicating that the current set point is 25 degrees, the warning limits are 20 to 30 degrees, and
the data entry limits are 0 to 100 degrees.
To modify a variable's value, almost the same format of command is used:
"V VARIABLE=VALUE WARNLO WARNHI<CRLF>"
The "VARIABLE" field is the name of the variable being modified, and the "VALUE" field is
the new value. "WARNLO" and "WARNHI" are the low and high warning limits, respectively,
and may only be given if the variable uses warning limits. They are optional for variables which
use warning limits and, if not given, the warning limits are not changed.
After changing the variable's value, the CPU will respond with:
"V VARIABLE=VALUE WARNLO WARNHI [DATALO-DATAHI] <CRLF>"
which should reflect the new value. The values in square brackets are not required for all
variables. If needed, the values are included on the command line, separated by spaces. For
example, to change the instrument ID, the host computer would issue a command like this:
"V MACHINE_ID=1234<CRLF>"
and the CPU should respond with:
"V DDD:HH:MM IIII MACHINE_ID = 1234 (0-9999)<CRLF>"
Table 7-9 lists the variable names which are variable through the RS-232 interface and their
corresponding button sequences.
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Table 7-9: RS-232 Variable Names
Var. Name Button Sequence Legal Values
AUTO-TIME SETUP-IZSC-TIME 00:00-23:59
AUTO-SHIFT SETUP-IZSC-SHFT -60 - +60
TIME-ZERO SETUP-IZSC-WAIT 1-20
TIME-SPAN SETUP-IZSC-WAIT 1-20
O3-SPAN SETUP-IZSC-SPAN 0-9000
REPORT-FREQ SETUP-DAS-FREQ 1-60
MACHINE-ID SETUP-COMM-ID 0000-9999
BAUD-RATE SETUP-COMM-BAUD 300, 1200, 2400
ILAMP-SET (not available) 20-70
IZSLAMP-SET (not available) 20-70
LAMP-PCT SETUP-MISC-O3-GEN 0-100
CURR-TIME SETUP-MISC-CLK-TIME 00:00-23:59
CURR-DATE SETUP-MISC-CLK-DATE 01/01/00-12/31/99
CLOCK-ADJ SETUP-MISC-CLK-ADJ -60 - +60
DA-RANGE SETUP-MISC-D/A-RNGE
0=100, 1=500, 2=1000,
3=5000, 4=10000
DA-OFFSET SETUP-MISC-D/A-OFFS -500 - +500
DARK-OFFSET SETUP-MISC-DARK-VIEW -1000 - +1000
PASS-ENABLE SETUP-PASS OFF, ON
FAULT-TIME SETUP-MISC-MORE-FLT 0-300
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8 ADJUSTMENTS
NOTE
The operations outlined in this chapter are to be
performed by qualified maintenance personnel only.
All adjustments to the Model 401 are easy to make. Pots and test points are readily accessible
without removing any components.
Figure 1-7 is a plan view of the Model 401 Photometric Calibrator showing all the major
components.
Figure 8-1 is an electrical diagram of Model 401 Photometric Calibrator.
8.1 Power Supply Board Adjustment
The power supply board provides ± 15 v + 12 v and + 5 v DC power to the Calibrator. Four
temperature linearization circuits, for the Calibrator main lamp, Sample temp, Box temp, and
IZS ozone generator are also located on the power supply board.
Each circuit is a whetstone bridge with the measuring thermistor being one leg. A feedback
circuit performs the required linearization. Zero adjust pots have been factory set and no field
adjustment should be required.
NOTE
The power supply board also contains a "Brown-Out" detector.
8.1.1 Box Temperature Limits
The box temperature is measured by a thermistor located on the motherboard. The box
temperature is not controlled in the Model 401. The temperature is measured and displayed as a
TEST function on the front panel (see Section 5.1). The alarm limits can be set via an RS-232
port command.
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Figure 8-1: Electrical Block Diagram
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8.2 A/D - D/A Calibration Procedure
Due to the stability of modern electronics, this procedure should not have to be performed more
than once a year or whenever a major sub-assembly is exchanged or whenever analog output
voltage range is changed .
To calibrate the ADC, do the following:
1. Press SETUP-MISC-D/A-CAL.
2. The M401 display will read "DAC #0: 60 mV", where 60 mV* is the target voltage which
should be coming out the DAC (it should be 60 mV). Put the probe of a voltmeter between
TP3 (AGND) and TP9 (DAC #0) on the top of the V/F card (See Drawing 00514, Appendix
E), then press the up/down buttons on the M400 front panel until the voltmeter displays the
target voltage (60 mV on the 5 V range). Note that the value on the M401 display will not
change. When the voltmeter shows the same value (± 3 mV) as the M401 display, press
ENTR.
* The reading will be close to 60 mV if the analyzer is setup for the 5 V range, 120 mV for
the 10 V range, etc. DAC #0 is the recorder output, DAC #1 is the DAS output, and DAC #3
is the test output.
3. The M401 display will now show a new voltage in the same format as above. This voltage
will be 90% of the full scale DAC output range (4500 mV on the 5 V range). As before, press
the up/down buttons on the M401 front panel until the voltmeter displays the same (± 3 mV)
reading as the M400 display, then press ENTR. The first DAC is now calibrated and will be
used as a voltage reference for calibrating the ADC.
4. The M401 display will now read ZR:60 = 60 ± 3 mV, where 60 mV is the voltage being
output from the DAC as input to the ADC, and 60 ± 3 mV is the voltage as read from the
ADC. The two values should be the same (60 = 60). If they are not, adjust the zero pot (R27)
on the V/F card (as indicated by ZR on the display) until the two values are the same, then
press ENTR.
5. The M401 display will now read GN:4500=4500 ± where 4500 is the voltage being output
from the DAC as input to the ADC, and 4500 ± 3 is the voltage as read from the ADC. The
two values should be the same. If they are not, adjust the gain pot (R31) on the V/F card (as
indicated by GN on the display) until the two values are the same (4500 = 4500 ± 3 mV),
then press ENTR. The ADC is now calibrated and M401 will automatically calibrate all the
DAC’s. The display will show the percent completion as the analyzer goes through the
procedure.
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Next, to automatically calibrate all the DACs, press SETUP-MISC-D/A-CAL-DAC. The display
will show the percent completion as the analyzer goes through the procedure. You must calibrate
the ADC before calibrating the DACs because the ADC is used during the DAC calibration
procedure. Once the ADC is calibrated, you may recalibrate the DACs anytime simply by
pressing SETUP-MISC-D/A-CAL, ENTR, ENTR, ENTR, ENTR.
8.3 Output Voltage Range Changes
Output voltage ranges are set by jumper placement on the V/F board. To change the range for the
analog outputs:
1. Turn off instrument power. Remove instrument cover. Locate the V/F board near the top of
the drawing using Figure 1-7.
2. Locate jumpers B6, B7, B9 along the top edge of the card. Select the desired range per the
table in drawing 00515 located in Appendix D.
NOTE
To adjust analog recorder offset, see Section 4.10.
8.4 Flow Readout Adjustment
The sensor module in the M401 consists of one flow sensor and two pressure sensors. See
Figure 8-2 for a diagram of this module. From these three sensors three values are computed and
displayed on the front panel TEST function area. These are:
1. Sample flow
2. Sample cell pressure
3. O3 GEN flow
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Figure 8-2: Flow And Pressure Readout Adjustment
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8.5 DC Power Supply
Overall performance of the DC power supply may be checked by observing the value displayed
during test DCPS. If this value, a composite of the five (5) regulator outputs, deviates by more
than 10% from the value recorded in Table 1-1 of this manual under Test Values, the outputs of
the individual regulators should be measured.
Test points 1, 2, 3 and 4 provide connection to the temperature outputs on drawing no. 00016 in
Appendix D.
8.6 CPU
If the display is operating and the green sample light is on, the CPU should be operating. If not,
check the red LED on the CPU board itself, it should be blinking.
If the RED led on the CPU board is not blinking, make the following checks:
1. Verify the +5 Volt supply on the power connector to the CPU Backplane.
2. Check for any loose memory chips on the CPU board.
3. Try removing and reseating the CPU – V/F Card assembly in the motherboard.
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8.7 Status Lines
Table 8-1: The Calibrator Has The Following Status Conditions
Output # Pin Pair
High/Low Status Condition
1 1, 2 ZERO CAL In Zero Calibrate
2 3, 4 SPAN CAL In Span Calibrate
3 5, 6 FLOW ALARM Flow Warning
4 7, 8 TEMP ALARM Any Temp Warning
5 9, 10 DIAG MODE In Diagnostic Mode
6 11,12 POWER On As Long As M401 Is Running
7 13,14 PRESS ALARM Alarms On Low Pressure
8 15,16 IZS FLOW Warn Alarms If No IZS Flow
9 17,18 SYSTEM OK Alarms If Any Fault Is Present
10 19,20 LAMP WARNING
Alarms If The Calibrator Lamp Intensity
Is Out Of Limits
8.8 UV Lamp Power Supply Adjustment
Adjust the drive power of the lamp power supply as follows:
1. Remove the cover of the lamp power supply. Attach a DVM across TP7 and TP10, and
adjust the pot (VR1) until the DVM reads 20 volts ± 1 volt.
2. Adjust the positioning of the source lamp, as follows:
a. At the front panel of the instrument, Press the TEST key until O3 REF=XXXXX is
displayed.
b. Loosen the lamp retaining thumb-screw and rotate the lamp until the O3 REF reading on
display is 4500 mV ± 320 mV. Re-tighten the thumb-screw. (Note that the full range of
lamp adjustment can be achieved within ¼ revolution of the lamp. Note also that the O3
REF display is updated approximately once every six seconds, and slow rotation of the
lamp is needed for proper adjustment.)
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CAUTION
UV light present. Do not pull the lamp from the optical
bench assembly.
3. Adjust the UV Detector Pre-Amp gain as follows:
a. Remove the access cap on the Detector cover at the front end of the optical bench, and
adjust the pot (R7) until the O3 REF reading on the display is 4500 mV ± 50 mV.
b. If it is still not possible to achieve a 4500 mV O3 REF reading, increase the UV lamp
drive power by adjusting the lamp power supply as described in Step 1. (DO NOT,
however, allow the voltage measured across the TP7 and TP10 to exceed 21 volts.)
4. Re-calibrate the automatic Detector Dark Current compensation by pressing SETUP-MISC-
DARK-CAL at the front panel. See Section 9.3 for dark current adjustment procedure.
8.9 Ozone Generator Lamp Setup
This procedure only needs to be done if the lamp is replaced or if the lamp is accidentally
moved. The procedure adjusts the lamp for optimum operation of the O3 generator and its
feedback circuit.
1. Enter the SETUP menu by pressing SETUP-MISC-O3-GEN-ADJ. This causes the lamp
drive circuit to output a constant 2.5 V.
If you are installing a new lamp, allow approximately 30 min for lamp output to stabilize.
2. Select the "O3 GEN" TEST function on the front panel display. Loosen the O3 generating
lamp and rotate until the reading on the display is 2500 mv ± 500 mV.
CAUTION
UV light present. Do not pull the lamp from the IZS assembly.
Re-tighten the hold-down screws securing the ozone lamp to the O3 generator assembly.
3. Remove access cap from the O3 generator preamp cover and adjust the pot to refine the front
panel reading to 2500 mv ± 25.
4. The O3 generator lamp and feedback circuit are now set up. Proceed to Section 8.11 to finish
calibration of the O3 generator.
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8.10 Ozone Generator Calibration
The ozone generator can be calibrated against the analyzer calibration by using the analytical
section of the M401 to determine the ozone generator's output. Calibration of the generator
allows the operator to enter the desired calibration concentration directly in PPB's.
The M401 should be calibrated by relating to the master standard using the method described in
Section 3 before doing this procedure.
Press SETUP-MISC-O3-GEN-CAL to start the calibration process, which works as follows:
1. The M401 will measure the O3 generator reference signal and the O3 concentration at 5
different O3 concentrations.
2. For each test point, the machine outputs the drive setting and waits 10 minutes for the M401
to stabilize. Then it takes two readings and stores them in a table for future use.
3. During calibration, the analyzer displays % completion so that you monitor the progress of
the calibration. Full calibration will take 1 hour (6 points x 10 minutes/point).
4. You can abort calibration by pressing EXIT. This will not restore the table contents already
computed, however. If you EXIT within the first 10 minutes of the calibration, the table will
not be modified.
NOTE
You can now use the O3 generator. See Section 3 for details.
8.11 Dark Current Signal Adjust Procedure
The detector dark current changes little as the detector ages. Therefore this procedure should not
need to be performed except whenever a major sub-assembly is changed (such as a new UV
lamp or UV lamp power supply).
To calibrate the dark current signal, press SETUP-MISC-DARK-CAL and the analyzer will do
the following:
1. Turn the analyzer lamp off.
2. Average 6 successive O3 detector readings, taken 1 second apart.
3. Turn the analyzer lamp back on.
This offset will then be stored and subtracted from all future O3 detector readings.
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To view the current dark offset, press SETUP-MISC-DARK-VAL. Press EXIT when finished.
No password is required to view the dark offset, only to change it.
8.12 Bench Feedback Option
The Bench Feedback Option uses the Photometer to control the lamp drive current. This option
assures very stable and repeatable ozone concentrations. Press SETUP-MISC-O3-GEN-MODE-
BNCH to activate this option. It is recommended to select the bench feedback mode for stable
and precise O3 calibration gas.
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9 TROUBLESHOOTING
NOTE
The operations outlined in this chapter are to be
performed by qualified maintenance personnel only.
9.1 Overview
The Model 401 Photometric Calibrator has been designed to rapidly detect possible problems
and allow their quick evaluation and repair. During operation, the calibrator continuously
performs self-check diagnostics and provides the ability to monitor the key operating parameters
of the instrument without disturbing monitoring operations. These capabilities will usually allow
the quick isolation and resolution of a problem.
A systematic approach to troubleshooting will generally consist of the following four steps,
performed in order:
1. Confirm the proper operation of fundamental instrument sub-systems (Power Supplies, CPU,
Display).
2. Note any warning messages and take corrective action as required.
3. Examine the values of all TEST functions and compare to factory values. Note any major
deviations from the factory values and take corrective action as required.
4. Address any dynamic (Sample related) problems.
The following sections provide a guide for performing each of these steps. Figure 1-7 in this
manual shows the general layout of components and sub-assemblies in the analyzer and can be
referenced in performing the checks described in the following sections.
9.2 Troubleshooting Fundamental Calibrator Operation
When the Calibrator is turned on, several actions will normally occur which indicate the proper
functioning of basic instrument sub-systems. These actions are:
1. The green sample light on the front panel should turn on.
2. The Display should energize and display a log-on message followed by a standard "STBY"
display (See Figure 2-2 for illustration of a normal display.
3. The pumps should start momentarily.
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If these actions all occur, it is probable that the Calibrator's Power Supplies, CPU, and Display
are working properly.
If any of these actions fail to occur, power and/or CPU operation should be checked as follows.
9.2.1 Checking The Power Sub-Systems
1. Check incoming line power for proper Voltage and Frequency.
2. Check the Circuit breaker on the Calibrator's rear panel.
3. Check the 3-wire safety power-input plug on the Calibrator's rear panel.
4. Check for proper internal AC power by confirming that the Red(right-most) LED on the
Power Supply Module is lit. If this LED is not lit, replace the fuse at the bottom center of the
Power Supply Module.
CAUTION
Hazardous voltages are present on the power supply module. Always
remove AC power cord from instrument before attempting to
remove or replace any parts.
5. Check for proper DC Voltages by measuring for the following voltages on the V/F Board:
+5V between TP4 and TP5
+15V between TP1 and TP3
-15V between TP2 and TP3
If any of these voltages are incorrect, check the DC Power Supply as described in
Section 9.6.4.
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9.2.2 Checking The CPU And Display
When the analyzer is turned on, the front panel display should energize and the green "Sample"
LED should light. If proper DC power is present (see Section 9.2.1), the absence of these actions
will usually indicate either a CPU or Display failure. To determine which module is defective,
perform the following procedure:
1. Turn off power.
2. Remove the ribbon cable from the CPU board to the Display;
3. Turn Power on.
4. A cursor character should appear in the upper left corner of the display. If it does not, the
display is defective and should be replaced. If the cursor does appear, it is probable that the
CPU is faulty.
9.2.3 Checking The Keyboard
During normal Calibrator operation, depressing the right most key of the keyboard should cause
a change of display modes. If it does not, check:
1. Cable connections.
2. CPU and Display operation (see Section 9.2.2).
If these checks are satisfactory, it is probable that the keyboard is defective and should be
replaced.
9.3 Troubleshooting Using Warning Messages
The most common and/or serious instrument failures will result in a warning message (or
messages) being displayed on the front panel. Table 9-1 lists the warning messages which the
Calibrator may display, along with their meaning and the recommended corrective action. It
should be noted that if multiple (more than 2 or 3) warning messages occur at the same time, it is
often an indication that some fundamental analyzer sub-system (power supply, V/F board, CPU)
has failed rather than an indication of the multiple failures referenced by the warnings. In this
situation, it is recommended that proper operation of power supplies (see Section 9.6.4) and the
V/F Board (see Section 9.6.3) be confirmed before addressing the specific warning messages.
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Table 9-1: Warning Messages
Warning Message Meaning Corrective Action
ANA LAMP
WARNING The O3 REF value is greater than 5000 mV
or less than 2500 mV. Check and adjust Source Lamp
and UV detector as described in
Section 9.6.6.
ANA LAMP
SHUTDOWN Temperature control of the Source Lamp
cannot be maintained at its 52oC set point. Check source lamp heater and
thermistor as described in
Section 8.10.
O3 GEN LAMP
WARNING The Ozone Generator is unable to produce
at least 1000 ppb at its maximum output or
the O3 GEN feedback control is adjusting
the Ozone generator drive signal by more
than a factor of two.
Check and adjust the O3 GEN
lamp and reference det as
described in Section 9.6.8.
O3 GEN LAMP
SHUTDOWN Temperature control of the O3 GEN Lamp
cannot be maintained at its 48oC
set point.
Check O3 GEN lamp heater and
thermistor as described in
Section 8.10.
SAMPLE
PRESSURE The Sample Pressure is less than 15"Hg or
is greater than 35"Hg. Check for pressure transducer
problems as described in
Sections 9.6.1 and 9.6.5.
SAMPLE FLOW
WARNING The sample flow is less than 500 cc/min or
greater than 1000 cc/min. Check for
pneumatic system problems as described
in Section 9.6.1.
Check for flow transducer
problems as described in
Section 9.6.5.
BOX TEMP
WARNING The inside chassis temp is less than 5oC or
is greater than 50oC. See Section 9.6.2.
SAMPLE TEMP
WARNING The Sample Temperature is less than 10oC
or is greater than 50oC. See Section 9.6.2.
V/F NOT
INSTALLED The CPU is unable to communicate with
the V/F Board. Check and re-seat CPU and V/F
board. See Section 9.6.3.
SYSTEM RESET A power Off-On cycle has occurred. None required.
RAM
INITIALIZED Dynamic memory has been re-initialized
in response to the installation of a new
PROM or memory chip.
None required.
O3 FLOW
WARNING IZS flow rate is less than 1.8 L/M or >5.5
L/M. Adjust pressure regulator to set
proper flow rate.
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9.4 Troubleshooting Using Test Function Values
The Model 401 Photometric Calibrator provides the capability to display, on operator demand,
the values of Test Functions which allow the observation of key analyzer operating parameters.
These Test Functions can be accessed by depressing the TEST Button on the instrument's front
panel, with each depression of the button causing the next test function to be displayed. By
comparing the values of Test Functions to acceptable operating limits, it is possible to quickly
isolate and correct most problems.
Table 9-2 provides a list of available Test Functions along with their meaning, their range of
acceptable values, and the recommended corrective actions if the value is not in the acceptable
range. Additionally, Table 1-1 in this manual provides a list of the values of all Test Functions at
the time the analyzer left the factory.
Table 9-2: Test Function Values
Test
Function Meaning Acceptable Values Corrective Action for
Unacceptable Values
RANGE The Full Scale Range of the
analyzer's analog outputs in
PPB.
Any between 100 -
10000 PPB None required.
O3 MEAS The most recent detector
reading taken in Measure
mode (i.e. with sample gas
bypassing the Ozone
Scrubber).
2500-4700 mV Check and adj source lamp
and UV det as described in
Section 9.6.6.
O3 REF The most recent detector
reading taken in Reference
mode (i.e. with sample gas
passing through the Ozone
Scrubber).
2500-4700 mV Check and adj source lamp
and UV det as described in
Section 9.6.6.
O3 GEN The reading from the O3
GEN lamp reference
detector.
75-175 mV with O3
gen off >75 mV with
O3 gen on.
Check and adjust the IZS lamp
and reference detector as
described in Section 8.10.
PRES The absolute pres of the
sample gas in the absorption
cell.
0"-1.0" Hg below
ambient pressure Check for pneumatic system
problems. See Section 9.6.1.
Check for pressure transducer
problems. See Section 9.6.5.
(table continued)
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Table 9-2: Test Function Values (Continued)
Test
Function Meaning Acceptable Values Corrective Action for
Unacceptable Values
SAMPLE
FLOW Sample mass flow rate. 700-900 cc./min Check for pneumatic system
problems. See Section 9.6.1.
Check for flowmeter
problems. See Section 9.6.5.
SAMPLE
TEMP The temperature of the
sample gas in the absorption
cell.
1°-5° C
above ambient
See Section 9.6.2.
ANA LAMP
TEMP The temperature of the
Source Lamp. 52° C
(After warm-up)
See Section 9.6.2.
IZS LAMP The temperature of the O3
GEN Lamp. 48° C
(After warm-up)
See Section 9.6.2.
BOX TEMP The temperature inside the
analyzer chassis. 1°-5° C above
ambient
See Section 9.6.2.
DCPS DC Power Supply reference-
-A composite of all voltages
provided by the DC Power
Supply.
2400-2600 mV See Section 9.6.4.
O3 FLOW The flow rate of O3 GEN. 2-5 L/M Adjust pressure regulator to
set proper flow rate.
9.5 Troubleshooting Dynamic Problems
Dynamic problems (i.e. problems which only manifest themselves when the analyzer is
monitoring sample gas) can be the most difficult and time consuming to isolate and resolve.
Additionally, analyzer behavior which appears to be a dynamic problem is often a symptom of a
seemingly unrelated static problem. For these reasons, it is recommended that dynamic problems
not be addressed until all static problems and warning conditions, as described in the preceding
sections, have been isolated and resolved.
If all the checks described in the preceding sections have been successfully performed, the
following will provide an itemization of the most common dynamic problems with
recommended troubleshooting checks and corrective actions.
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9.5.1 Noisy Or Unstable Readings At Zero
1. Check for leaks in the pneumatic system as described in Section 10.3.
2. Confirm that the Zero gas is free of Ozone.
3. Confirm that the Source Lamp is fully inserted and that the lamp hold-down thumb- screw is
tight.
4. Check for a dirty Absorption Cell and/or pneumatic lines. Clean as necessary as described in
Section 10.4.
5. Disconnect the exhaust line from the optical bench (the pneumatic line at the lamp end of the
bench) and plug the port in the bench. If readings remain noisy, the problem is in one of the
electronic sections of the instrument. If readings become quiet, the problem is in the
instrument's pneumatics.
9.5.2 Noisy, Unstable, Or Non-Linear Span Readings
1. Check for leaks in the pneumatic systems as described in Section 10.3.
2. Check for proper operation of the Main Switching Valve as described in Section 9.6.7.
3. Check for dirty absorption cell and/or pneumatic system components and clean or replace as
necessary as described in Section 10.4.
4. Check for proper adjustment of DAC and ADC electronics by performing the adjustment
procedure in Section 8.2.
5. Confirm the Sample Temperature, Sample Pressure, and Sample Flow readings are correct.
Check and adjust as required.
6. Verify sufficient flow from the O3 generator in excess of the total flow needed. The total
flow needed is the sum of the M401 sample flow and the remote analyzers sample flow.
9.5.3 Slow Response To Changes In Concentration
1. Check for dirty pneumatic components and clean or replace as necessary as described in
Section 10.4.
2. Check for pneumatic leaks as described in Section 10.3.
3. Check for improper materials in the inlet manifold.
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9.5.4 Analog Outputs Do Not Agree With Front Panel Readings
1. Confirm that the DAC offset (SETUP-MISC-D/A-OFFS) is set to zero.
2. Perform a DAC/ADC adjustment and Dark Signal adjustment by following the procedure
described in Sections 8.2 and 8.3.
9.5.5 Cannot Zero
1. Check for leaks in the pneumatic system as described in Section 10.3.
2. Confirm that the Zero gas is free of Ozone.
3. Verify sufficient flow from the O3 generator in excess of the total flow needed. The total flow
needed is the sum of the M401 sample flow and the remote analyzers sample flow.
9.5.6 Cannot Span
1. Check for leaks in the pneumatic systems as described in Section 10.3.
2. Check for proper operation of the Main Switching Valve and Ozone Scrubber as described in
Section 9.6.7.
3. Check for dirty pneumatic system components and clean or replace as necessary as described
in Section 10.4.
4. Check for proper adjustment of DAC and ADC electronics by performing the adjustment
procedure in Section 9.2.
5. Confirm the Sample Temperature, Sample Pressure, and Sample Flow readings are correct.
Check and adjust as required.
6. Verify sufficient flow from the O3 generator in excess of the total flow needed. The total
flow needed is the sum of the M401 sample flow and the remote analyzers sample flow.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
9.6 Troubleshooting Individual Sub-Assemblies And
Components
The following sections provide troubleshooting/check-out methods for the specific sub-
assemblies and components of the Calibrator.
9.6.1 Troubleshooting Flow Problems
When troubleshooting flow problems, it is a good idea to first confirm that the actual flow and
not the flow-meter is in error. If available, use an independent flow meter (rotameter or mass
flow meter) to measure flow(s). Sample flow can be measured at the inlet port at the optical
bench and O3 generator flow can be measured at the outlet of the O3 generator. If no independent
flow meter is available, placing a finger over an inlet port and feeling for a vacuum will at least
give an indication whether flow is present.
If the independent flowmeter shows the flow to be correct, check the Pneumatic Sensor Board as
described in Section 9.6.5.
In general, flow problems can be divided into 3 categories:
1. Flow is zero (no flow).
2. Flow is greater than zero, but is too low, and/or unstable.
3. Flow is too high.
Figure 1-1 in this Manual provides a schematic diagram of the Flow in a Model 401.
Flow Is Zero
1. Confirm that the sample pump (sample flow) and/or O3 GEN pump, (O3 GEN flow) are
operating (turning). If not, check the 115V power to the pump. If the pump does not operate
with 115V present at its terminal, replace the pump. Check for plugged pneumatic lines,
filters, or orifices.
Low Flow
1. Check for leaks as described in Section 10.3. Repair and re-check.
2. Check for dirty sample filter or dirty orifice filter(s).
3. Check for partially plugged pneumatic lines, orifices, or valves.
High Flow
1. The most common cause of high flow is a leak around an orifice.
9-9
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
9.6.2 Troubleshooting Temperature Problems
The Model 401 has been designed to operate at ambient temperatures between 5oC and 40oC. As
a first step in troubleshooting temperature problems, confirm the ambient temperature is within
this range and that the air inlets slots on the sides of the cover and the fan exhaust on the rear
panel are not obstructed.
The instrument monitors four temperatures:
1. Sample Temperature
2. Inside Chassis Temperature
3. Source Lamp Temperature
4. O3 GEN Lamp Temperature
The instrument controls the temperatures of two components by heating:
1. Source Lamp
2. O3 GEN Lamp
If any of the temperature readings appear to be incorrect, check for proper thermistor operation
by measuring the resistance of the thermistor(s). This resistance should be in the range of 7.6K
ohms to 95K ohms. If it is not, the thermistor is defective and should be replaced. Points for
measuring thermistor resistance are as follows:
Sample Temperature
Unplug the connector at Motherboard J2 and measure across the leads.
Source Lamp Temperature
Unplug the connector at Motherboard J4 and measure across the leads.
O3 GEN Lamp Temperature
Unplug the connector at Motherboard J6 and measure across the leads.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Chassis Temperature
Turn the analyzer off and remove the DC Power Supply Board. Measure across Motherboard J21
pins A30 and C30.
If thermistor resistance(s) are within the proper range, check the temperature linearization
circuits on the DC Power Supply Board as described in Section 9.6.4.
If temperature sensor readings appear accurate but control temperatures are not being maintained
at their proper value, check the operation of the heaters as follows:
1. Observe the indicator LED's on the Power Supply Module and confirm that the red (right-
most) LED is lit, and that the "CEL HTR" and "O3 GEN HTR" LED's are lit or cycling
(turning off and on). If these indicators are not correct, it is probably that the Power Supply
Module, or the V/F Board is at fault. Check as described in Sections 9.2 and 9.6.3.
2. Unplug the heater element from Power Supply Module and confirm that 115VAC is present.
If 115VAC is present, the heater element has failed and should be replaced.
WARNING
Hazardous voltage present - use caution.
9.6.3 Checking The V/F Card
A schematic and physical diagram of the V/F card are shown on Drawings 00514 and 00515 in
Appendix D. Proper operation of the V/F board can be confirmed by performing an ADC
calibration procedure as described in Section 8.2. If this calibration procedure can be performed
correctly, it is probable that the V/F card is functioning properly. If the V/F does not function
properly, check the following:
1. Confirm the presence of appropriate power by checking for:
+5V between TP 4 and TP 5
+15V at TP 1 and TP 3
-15V at TP 2 and TP 3
If any of these voltages are incorrect, check the DC Power Supply as described in Section 9.6.4.
NOTE
Do not disconnect CPU or other digital cards while under power.
9-11
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
2. Confirm that all jumpers on the V/F board are set properly, as follows:
Table 9-3: V/F Board Jumpers - Factory Settings
Factory Set Jumpers
Jumper Setting
B1 1
B2 1-2
B12 3-4 (0-5V)
B14 2-3 (Enabled)
B15 Set to match power line frequency
JP1 1-2
JP2 1-2
Table 9-4: V/F Board Dip Switches - Ranges For Analog Output
User Set DIP Switches
Switch 100 mV
Full Scale 1 V
Full Scale 5 V
Full Scale 10 V
Full Scale
S1(DAC 0)= “REC” 1,6 = ON 1,5 = ON 1,4 = ON 1,3 = ON
S2(DAC 1)= “DAS” 1,6 = ON 1,5 = ON 1,4 = ON 1,3 = ON
S3(DAC 2)=”TEST” 1,6,7 = ON 1,5,7 = ON 1,4,7 = ON 1,3,7 = ON
S3(DAC 2)=”O3 GEN” N/A N/A 1,4,7 = ON N/A
3. If Voltages and Jumper settings are correct, the V/F card is faulty and should be replaced.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
9.6.4 Checking The DC Power Supply Board
A schematic and physical diagram of the DC Power Supply Board are shown on Drawings
00015 and 00016 in Appendix D.
The overall performance of the DC Power Supply Board can be checked by observing the value
of the DCPS test functions. If this value, a composite of five regulator outputs, deviates by more
than 10% from the value recorded in Table 1-1 of this manual under Test Values, the outputs of
the individual regulators should be checked by measuring for the following voltages:
1. Remove Plugs J8, J6, and J13 from the front of the Power Supply Module. Verify that the
following voltages are present:
+24 VDC between J8 pins 2 and 4
+24 VDC between J6 pins 12 and 13
25 VAC between J13 pins 4 and 5
15 VAC between J13 pins 3 and 2
38VAC between J13 pins 6 and 7
WARNING
Hazardous voltage present on the power supply module.
If any of these voltages is not present, the Power Supply Module is defective and should be
replaced.
2. Confirm that the following voltages are present on the V/F Board:
+5V between V/F TP 4 and V/F TP 5
+15V between V/F TP 1 and V/F TP 3
-15V between V/F TP 2 and V/F TP 3
+12V between Mother Board Pad J13,6 and J13,7
If any of these voltages is incorrect, it is probable that the DC Power Supply Board is faulty and
should be replaced.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Four Temperature linearization circuits are contained on the DC Power Supply board. The
outputs of these circuits can be checked by measuring the voltages at test points on the board as
follows:
TP1 Sample Temp 30° C=2.5V, ± 0.125V/°C
TP2 Source Lamp Temp 50° C=2.5V, ± 0.125V/°C
TP3 IZS Lamp Temp 50° C=2.5V, ± 0.125V/°C
TP4 Chassis Temp 20° C=2.5V, ± 0.125V/°C
If any of these voltages is incorrect, check thermistor operation as described in Section 9.6.2. If
thermistors are operating correctly, it is probable the DC Power Supply Board is defective and
should be replaced.
9.6.5 Checking The Pneumatic Sensor Board
A schematic and physical diagram of the Pneumatic Sensor Board are shown on Drawings 00402
and 00403 in Appendix D. Proper operation of the pneumatic sensor board can best be
determined by comparing the values of Flow and Pressure Test functions to measurements
obtained with independent flow and pressure meters. Flow and pressure readings can be adjusted
as described in Section 8.5.
If it is not possible to adjust the pneumatic sensor board to agree with independent flow and
pressure measurements, confirm the presence of +15 V at connector J1 pin 6. If this voltage is
not present, check the DC Power Supply Board as described in Section 9.6.4. If +15 V is present,
it is probable that the Pneumatic Sensor Board is defective and should be replaced.
9.6.6 Checking The Source Lamp And Detector
Basic operation of the source lamp and detector can be determined by observing the value of the
O3 REF test function. After the analyzer is warmed-up (15 min to 30 min after power-on), this
value will give a good indication of the state of Lamp and Detector operation as follows.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Table 9-5: UV Source Lamp And Detector Diagnostics
UV Source Lamp and Detector Diagnostics
O3 REF Value Meaning
4700 mV to 5000 mV The Source Lamp and Detector are operating, but
adjustment is required.
4000 mV to 4700 mV The Source Lamp and Detector are operating
properly; no adjustment is needed.
2500 mV to 4000 mV The Source Lamp and Detector are operating.
Adjustment is useful but not required.
175 mV to 2500 mV The Source Lamp and Detector are operating, but
adjustment is required.
75 mV to 175 mV Either the Source Lamp or the UV detector is not
functioning.
Less than 75 mV The Detector Pre-Amp or V/F Board has failed or is
disconnected.
WARNING
UV light present. Do not look directly at the UV lamp since UV
light could cause eye damage. Always use safety glasses or view
through glass.
Adjustment Required or Adjustment Useful
Adjust the Lamp and Detector Preamp as described in Section 8.8. If it is not possible to achieve
an acceptable O3 REF test value by means of adjustment, it is possible that the lamp has
deteriorated beyond its useful range and should be replaced.
Lamp or Detector Failure
The O3 REF value of approximately 125 mV usually indicates a total failure of either the source
lamp or the detector. To determine which component is at fault, remove the top cover of the
optical bench and observe the "lamp end" of the glass absorption tube. If a blue-white light is
visible, the lamp is operating and the detector is at fault and should be replaced. If no light is
visible, the lamp power supply should be checked as described in Section 9.6.8. If the Lamp
Power Supply check is satisfactory, then the lamp has failed and should be replaced.
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Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
NOTE
In cold, ambient conditions, it may require 5 to 15 minutes of warm-
up before the source lamp initially fires. Be sure to wait for this
period before troubleshooting the lamp/detector.
Detector Pre-Amp or V/F Failure
The O3 REF test value of less than 75 MV usually indicates a failure of the Detector Pre-Amp.
Confirm that the V/F is operating properly as described in Section 9.6.3. If the V/F check is
successful, the Detector pre-amp has failed and should be replaced.
9.6.7 Checking Main Switching Valve
Proper operation of the main Switching Valve can be determined by performing the following
procedure:
1. Press Zero to generate the Zero gas and allow the analyzer to stabilize.
2. Observe the O3 REF Test Function and make a note of its value.
3. Press span to generate approximately 400 ppb concentration and allow the analyzer to
stabilize.
4. Observe the O3 REF Test Function and note its value.
If the O3 REF value has decreased by more than 5 MV from its value with Zero-gas, then there is
a "cross-port" leak in the main switching valve. (NOTE: If desired, this check can be performed
using Ozone concentrations higher than 400 ppb. In this case, the drop in O3 REF (in MV)
should be no greater than 5 x Actual Concentration/400.)
9.6.8 Checking The Lamp Power Supply
A schematic and physical diagram of the Lamp Power Supply are shown on drawings 01217 and
01218 in Appendix D.
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.
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9-17
WARNING
Hazardous voltage present - use caution.
1. Unplug the cable connector at J1 on the Lamp Power Supply and confirm that +24VDC is
present between Pins 1 and 2 on the cable connector. If this voltage is incorrect, check the
Power Supply Module as described in Section 9.6.4.
2. Remove the cover of the Lamp Power Supply and check for the presence of the following
voltages:
+15VDC between TP14 and TP2
+20VDC +/-2VDC between TP14 and TP7
If these voltages are incorrect, the Lamp Power Supply is faulty and should be replaced.
If the above checks are successful, 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.
Teledyne API Model 401 O3
Photometric Calibrator Instruction
Manual, 01124, Rev. J2
Warranty/Repair
Questionnaire TELEDYNE
INSTRUMENTS
Advanced Pollution Instrumentatio
n
Model 401
A Teledyne Technologies Company
9.7 Warranty/Repair Questionnaire
CUSTOMER: PHONE: __________________________________________
CONTACT NAME: FAX NO. __________________________________________
SITE ADDRESS: ______________________________________________________________________________________
MODEL 401 SERIAL NO.: FIRMWARE REVISION: _____________________________
1. ARE THERE ANY FAILURE MESSAGES? ____________________________________________________________
_____________________________________________________________________________________________________
_____________________________________________________________________________________________________
PLEASE COMPLETE THE FOLLOWING TABLE: (NOTE: DEPENDING ON OPTIONS INSTALLED, NOT ALL
TEST PARAMETERS SHOWN BELOW WILL BE AVAILABEL IN YOUR INSTRUMENT.)
Parameter Observed Value Units Normal Range
DCPS MV 2300-2700mV
BOX TEMP DEG C Ambient +3-5° C
O3 OFFSET PPB -10 - +20PPB
O3 SLOPE - 1.0 ± .15
REG PRESSURE IN-HG-A 10 – 21”-Hg-A
O3 GEN TMP DEG C 48 ±1° C
O3 GEN FLOW L/MIN 2 – 5 LPM
ANA LAMP TMP DEG C 52 ±1° C
SAMPLE TEMP DEG C 10 - 50° C
SAMPLE FLOW SCC/MIN 700-900 cc./min
SAMPLE PRESS IN-HG-A Ambient +0-2”-Hg-A
O3 DRIVE MV 0-5000mV
O3 GEN REF MV 120-5000mV
O3 REF MV 2500-4700mV
O3 MEAS MV 2500-4700 mV
O3 SET PPB/PPM .05 PPM –1 PPM
2. HAS THE UNIT BEEN LEAK CHECKED? YES NO
3. WHAT ARE THE FAILURE SYMPTOMS?____________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________________________
____________________________________________________________________________________
IF POSSIBLE, PLEASE INCLUDE A PORTION OF A STRIP CHART PERTAINING TO THE PROBLEM. CIRCLE
PERTINENT DATA.
4. THANK YOU FOR PROVIDING THIS INFORMATION. YOUR ASSISTANCE ENABLES TELEDYNE API TO RESPOND
FASTER TO THE PROBLEM THAT YOU ARE ENCOUNTERING
TELEDYNE API CUSTOMER SERVICE
EMAIL: api-customerservice@teledyne.com
PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 FAX: (858) 657-9816
9-18
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
10 ROUTINE MAINTENANCE
NOTE
The operations outlined in this chapter are to be
performed by qualified maintenance personnel only.
10.1 Maintenance Schedule
Table 10-1 shows a typical maintenance schedule for the Model 401. 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.
Table 10-1: Maintenance Schedule
Date Instrument Was Recieved: ___________________
Item Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Recommended
Action
Zero Air
Scrubber Replace charcoal
quarterly.
Pump
Diaphragms Replace every 6
months.
DFU
particulate
filter for
zero air
Replace
annually.
Sample Cell
Inspect quarterly.
Clean as
necessary.
(Section 10.3)
Sample
Flow Check annually
800 cc/min ± 80.
Leak Check
Check annually
(Section 10.2)
leak check after
any maintenance.
10-1
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
10.2 Leak Checking
There are two methods of leak checking:
1. By vacuum: This is the simplest method but it does not show the location of a leak.
2. By pressure: By using bubble solution, this method shows a leak location.
NOTE
Be careful using the bubble solution. There is no internal pressure,
the solution may enter and contaminate the cell. Use only bubbles,
not liquid.
If you know you have a leak, use pressure.
If you want to confirm that you do not have a leak, use vacuum.
10.3 Cleaning Of Sample Cell
1. Remove the center cover from the optical bench.
2. Loosen the screws that hold the retaining rings at each end of the glass tube.
3. Using both hands, rotate the tube to free it, then slide the tube towards the back of the
instrument (towards the lamp housing). The front of the tube can now be slid past the
detector block and out of the instrument.
CAUTION
Do not cause the tube to bind against the metal housings. The glass
tube may break and cause serious injury.
4. Clean the tube with soapy water by running a swab from end-to-end. Rinse with de- ionized
water, then isopropyl alcohol, then air dry. Check the cleaning job by looking down the bore
of the tube. It should be free from dirt and lint.
5. Re-assemble the tube into the lamp housing and leak check the instrument.
10-2
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
10.4 Changing The Prom
1. Locate the CPU card by referring to Figure 1-7.
2. Remove the screws that hold the CPU card (SBC40 printed on the lever) top corner to the
V/F card, then remove the card from the STD-BUS backplane.
3. Remove the two cables attached to the SBC40, taking note of the polarity.
4. Remove the card, laying it down on an insulating surface such that the card edge pins on the
PCB are on the left. The PROM chip should be at the top center. The current chip should be
labeled with something like "M401 411A0 - - -". Gently pry the chip from its socket and
replace it with the new chip. Install the chip in the left end of the socket with the notch facing
to the right. Make sure that all of the legs insert into the socket correctly.
5. Replace the CPU board and re-attach the connectors, making sure to observe the polarity.
6. Re-attach the CPU card to the STD-BUS.
7. Move the power switch to the "ON" position and observe the front panel display. As the
analyzer goes through the setup the version number will be displayed on the front panel. It
should read the same as the version number that was located on the top right corner of the
label on the PROM.
8. Re-enter any non-default settings such as RANGE or AUTOCAL. Check all settings to make
sure that expected setup parameters are present.
Re-calibrate the analyzer so that the default slope and intercept are overwritten with the correct
values.
Perform Dark Calibration (see Section 8.11).
10-3
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
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10-4
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
11 MODEL 401 SPARE PARTS AND
EXPENDABLES KITS
11.1 Spare Parts For CE Mark Units
NOTE
Use of replacement parts other than those supplied by Teledyne API
may result in non-compliance with European Standard EN 61010-1.
Table 11-1: Spare Parts For CE Mark Units
Part No. Description
00015 Power Supply Board
00276-1401 CPU Board
00402-03 Sensor Board
00508 Absorption Tube
00514-03 V/F Board
00526-01 UV Lamp Assy, Source
00535 Pre-AMP Assy, M400 DET
00551-15 Power Supply Module - 230 V/50 Hz (EU)
00551-19 Power Supply Module - 230 V/50 Hz (UK)
00566-02 Assy, Optical Bench
00596 Activated Charcoal
00611 Assy, Bench Lamp Heater
00612-01 UV Lamp Assy, O3 Gen
00628 Assy, Heater, 50W (IZS)
00644 M400 Zero Air Scrubber Charcoal
00690-01 Scrubber Filter Pads
00728 Display
00815 M400 Valve Module
01061 M401 Pump
01111 M401 Level 1 Spares Kit
(table continued)
11-1
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Table 11-1: Spare Parts For CE Mark Units (Continued)
Part No. Description
01112 M401 Expendables Kit
01509 UV Lamp Power Supply
01916-01 Rear Panel Connector Board
01930 Keyboard
01934 Assy, Sample Thermistor
CB004 Fuse, 3 AG 3 AMP, 250 V
FA004 Fan
FL003 Filter, DFU (036-040180)
FM004 Flow Meter, 0-1000 CC
FM05 Flow Restrictor (O3 Generator)
FM06 Flow Restrictor (Zero Reference)
HW020 Spring, Flow Control
HW036 TFE Thread Tape (48 FT)
HW037 Tie, Cable
OP001 UV Detector
OR001 O-Ring, Flow Control
OR012 O-Ring, O3 Gen Lamp
OR014 O-Ring, Optical Bench, Lamp Window
OR021 O-Ring, Scrubber
OR026 O-Ring, Absorption Tube
OR028 O-Ring, O3 Gen Base
OR030 O-Ring, IZS Scrubber
OR048 O-Ring, UV Detector
SW006 Overheat SW, O3 GEN
SW008 Vacuum Sensor
TU001 Tubing: 6’, 1/8” Clr
TU002 Tubing: 6’, 1/8” Blk
TU009 Tubing: 6’, 1/4” Tygon
VA003 TFE, 24V, Sample/Ref. Valve
11-2
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
11.2 Spare Parts For Non-CE Mark Units
Table 11-2: Spare Parts For Non-CE Mark Units
Part No. Description
00015 Power Supply Board
00276-0401 CPU Board
00402-03 Sensor Board
00508 Absorption Tube
00514-03 V/F Board
00526-01 UV Lamp Assy, Source
00535 Pre-Amp Assy, M400 DET
00551-03 Power Supply Module - 115 V/60 Hz
00551-13 Power Supply Module - 220 V/50 Hz
00551-19 Power Supply Module - 240 V/50 Hz
00566-02 Assy, Optical Bench
00596 Activated Charcoal
00611 Assy, Heater/Thermistor
00612-01 UV Lamp Assy, IZS Gen
00628 Assy, Heater, 50 W (IZS)
00690-01 Scrubber Pads
00704 Keyboard
00728 Display
00815 M400 Valve Module
01061 M401 Pump
01111 M401 Level 1 Spares Kit
01112 M401 Expendables Kit
01509 UV Lamp Power Supply
01934 Assy, Sample Thermistor
CB004 Fuse, 3 AG 3 AMP, 250 V
FA004 Fan
FL003 Filter, DFU (036-040180)
(table continued)
11-3
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Table 11-2: Spare Parts For Non-CE Mark Units (Continued)
Part No. Description
FM004 Flow Meter, 0-1000 CC
FM05 Flow Restrictor (O3 Generator)
FM06 Flow Restrictor (Zero Reference)
HW020 Spring, Flow Control
HW036 TFE Thread Tape (48 FT)
HW037 Tie, Cable
OP001 UV Detector
OR001 O-Ring, Flow Control
OR012 O-Ring, O3 Gen Lamp
OR014 O-Ring, Optical Bench, Lamp Window
OR018 O-Ring, Sample Filter
OR021 O-Ring, Scrubber
OR026 O-Ring, Absorption Tube
OR028 O-Ring, O3 Gen Base
OR030 O-Ring, Zero Air Scrubber
OR048 O-Ring, UV Detector
SW006 Overheat SW, IZS OVEN
SW008 Vacuum Sensor
TU001 Tubing: 6’, 1/8” Clr
TU002 Tubing: 6’, 1/8” Blk
TU009 Tubing: 6’, 1/4” Tygon
VA003 TFE, 24 V, Sample/Ref. Valve
11-4
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Appendix A LIST OF AVAILABLE MODEL 401
OPTIONS
Table A-1: Available Model 401 Options
Option
1. RS-232
2. Status Outputs
3. Rack Mount and Slides
4. Rack Mount Only
A-1
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A-2
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Appendix B RECOMMENDED ZERO AIR
SYSTEM
The following is from the TECHNICAL ASSISTANCE DOCUMENT FOR THE
CALIBRATION OF AMBIENT OZONE MONITORS - Richard J. Paur and Frank F. McElroy
(1979).
Zero air must be free of ozone and any other substance that might react with ozone (e.g. NO,
NO2, various hydrocarbons, and particulates). Air from any source must be purified to remove
such substances. Very dirty air may require a pre-cleaning process to remove large particles, oil
mist, liquid water, etc. The primary purification process is based on mechanical and chemical
filtering. While various schemes may be acceptable, systems similar to the following have been
used successfully:
The air is first dried with a Perma-Pure type dryer followed by a column of indicating silica gel.
The air is then irradiated with a UV lamp to generate ozone that converts existing NO to NO2,
and a large column of activated charcoal removes NO2, O3, hydrocarbons, and various other
substances. If desired, molecular sieve can be included for good measure.
A final particulate filter removes particulates which can originate in the scrubber columns. The
removal of moisture may not be necessary, but fewer problems seem to be encountered when dry
air is used.
The particulars of air purification are not well known, so some experimentation may be
necessary to determine the appropriate size of volume for scrubber columns. Also, the capacity
of the scrubber materials may not be accurately known, so frequent replacement of renewal of
these materials is advisable. Additional information on air purification is available (APHA
Intersociety Committee 1977, Section 20, Part I).
A very important requirement in photometer operation is the need for the zero air supplied to the
photometer during the Io measurement to be obtained from the same source as that used for
generation of ozone. The impurities present in zero air from different sources can significantly
affect the transmittance of an air sample.
B-1
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B-2
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Appendix C 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/S4-80-050, 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.
12. Quality Assurance Handbook for Air Pollution Measurement Systems, Volume II,
(abbreviated Q.A. Handbook Volume II). Available through USEPA Center for
Environmental Research Information. Phone (513) 569-7562 EPA 600/4/77/027A.
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Appendix D SOFTWARE MENU TREES
Figure A-1: Model 401 Sample Software Menu Tree
ne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
D-2
Figure A-2: Model 401 Setup Software Menu Tree
Teledy
Teledyne API Model 401 O3 Photometric Calibrator Instruction Manual, 01124, Rev. J2
Appendix E ELECTRICAL SCHEMATIC INDEX
Table E-1: Electrical Schematic Index
Part No. Name
00015 Power Supply Board Assembly
00016 Power Supply Board Diagram
00402 Pneumatic Sensor Assembly
00403 Pneumatic Sensor Diagram
00514 V/F - I/O Card Assembly
00515 V/F - I/O Card Diagram
00517 Mother Board Assembly
00518 Mother Board Diagram
0053203 Power Supply PCA Assembly
0053303 Power Supply PCA Diagram
00535 UV Detector Assembly
00536 UV Detector Diagram
00704 Keyboard Assembly
00705 Keyboard Diagram
01217 UV Lamp Power Supply PCA
01218 UV Lamp Power Supply Diagram
01916 Rear Panel PCA Assembly
01917 Rear Panel PCA Diagram
02235 Transformer PTC Assembly
02236 Transformer PTC Diagram
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