APIModel400ETrainingManual

TRAINING MANUAL

MODEL 400EUV ABSORPTION OZONE ANALYZER

a TELEDYNE4 INSTRUMENTSAdvanced Pollufion /nsfrumenfafionA T e l e d y n e T e c h n o l o g i e s C o m p a n y

0 TELEDYNE ADVANCED POLLUTION INSTRUMENTATION(T-API)

9480 CARROLL PARK DRIVESAN DIEGO, CA 92121-5201

TOLL-FREE: 800-324-5190TEL: 858-657-9800FAX: 858-657-9816

E-MAIL: [email protected] SITE: www.teledyne-api.com

04592Rev. F

04/25/06

MODEL 400E OZONE ANALYZERTraining Manual

TABLE OF CONTENTS

1. PRINCIPLE OF OPERATION

2. PNEUMATICS AND SUBASSEMBLIES

3. MENU STRUCTURE

4. CALIBRATION PROCEDURE

5. MAINTENANCE

6.

7.

8.

TROUBLESHOOTING AND FAULTS

SPECIFICATIONS

MISC DIAGRAMS

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1. PRINCIPLE OF OPERATION

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MODEL 4OOE OZONE ANALYZERTraining Manual

Beer-Lambert’s LawThe basic principle by which the Model 400E Ozone Analyzer works is called Beer’s Law (alsoreferred to as the Beer-Lambert equation). It defines the how light of a specific wavelength isabsorbed by a particular gas molecule over a certain distance at a given temperature andpressure. The mathematical relationship between these three parameters for gasses atStandard Temperature and Pressure (STP) is:

/do emaLC a t S T P

Where:I, is the intensity of the light if there was no absorption.

1 is the intensity with absorption.

L is the absorption path, or the distance the light travels as it is being absorbed.

C is the concentration of the absorbing gas. In the case of the Model 400E, Ozone(03).

a is the absorption coefficient that tells how well O3 absorbs light at the specificwavelength of interest.

To solve this equation for C, the concentration of the absorbing Gas (in this case 03), theapplication of a little algebra is required to rearrange the equation as follows:

at STP

Unfortunately, both ambient temperature and pressure influence the density of the sample gasand therefore the number of ozone molecules present in the absorption tube thus changingthe amount of light absorbed.

In order to account for this effect the following addition is made to the equation:

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M O D E L 4 0 0 E O Z O N E A N A L Y Z E RT r a i n i n g M a n u a l

Where:T = sample temperature in Kelvin

P= sample pressure in inches of mercury

Finally, to convert the result into Parts per Billion (PPB), the following change is made:

In a nutshell the Model 400E Ozone Analyzer:cl Measures each of the above variables: Sample Temperature; Sample

Pressure; the Intensity of the UV light beam witJ and without O3 present,

0 Inserts known values for the Length of the Absorption Path and theAbsorption Coefficient, and calculates the concentration of O3 present inthe sample gas.

The Absorption Path

In the most basic terms, the Model 400E uses a high energy, mercury vapor lamp to generatea beam of UV light. This beam passes through a window of material specifically chosen to beboth non-reactive to O3 and transparent to UV radiation at 254nm and into an absorption tubefilled with Sample Gas.Because ozone is a very efficient absorber of UV radiation the Absorption Path Lengthrequired to create a measurable decrease in UV intensity is short enough (approximately 42cm) that the light beam is only required to make pass through the Absorption Tube. Thereforeno complex mirror system is needed to lengthen the effective path by bouncing the beam backand forth.Finally, the UV then passes through similar window at the other end of the Absorption Tubeand is detected by a specially designed vacuum diode that only detects radiation at or verynear a wavelength of 254nm. The specificity of the detector is high enough that no extraoptical filtering of the UV light is needed.The detector assembly reacts to the UV light and outputs a voltage that varies in directrelationship with the light’s intensity. This voltage is digitized and sent to the instrument’s CPUto be used in computing the concentration of O3 in the absorption tube.

Window Window\ UV Detector

Sample Gas OUTSample Gas OUT

\ ABSORPTION TUBE \

II ‘

Absorption Path Length = 42 cm -tI

03 Absorption Path

I.9

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The Reference / Measurement Cvcle

In order to solve the Beer-Lambert equation it is necessary to know the intensity of the lightpassing through the Absorption Path both when O3 is present and when it is not. The Model400E accomplishes this be alternately sending the Sample Gas directly to the Absorption tubeand passing it through a chemical Scrubber that removes any O3 present.

Particulate

F r o m S a m p l e

Valve switchesevery 3 seconds

T o

ABSORPTION TUBE

Reference / Measurement Gas Cycle

The Measurement / Reference Cycle consists of:Time Index

0 seconds

0 - 2 seconds

2 - 3 seconds

3 seconds

3 - 5 seconds

5 - 6 seconds

StatusMeasure/Reference Valve Opens to the Measure Path.

Wait Period. Ensures that the Absorption tube has been adequately flushed of any previouslyp resen t gasses .

Analyzer measures the average UV light intensity of 03 bearing Sample Gas (I) during thisper iod.

Measure/Reference Valve Opens to the Reference Path.

Wait Period. Ensures that the Absorption tube has been adequately flushed of 03 b3earingg a s .

Analyzer measures the average UV light intensity of Non-03 bearing Sample Gas (IO) duringthis period.

CYCLE REPEATS EVERY 6 SECONDS

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MODEL 400E OZONE ANALYZERTrainina Manual

Interferant Rejection

The detection of O3 is subject to interference from a number of sources including, SOZ, NO*,NO, H20, aromatic hydrocarbons such as meta-xylene and Mercury vapor. The Model 400E’sbasic method or operation successfully rejects interference from most of these interferents.The O3 Scrubber located on the Reference Path is specifically designed to ONLY remove O3from the Sample Gas. Thus the variation in intensities of the UV light detected during theinstrument’s Measurement Phase versus the Reference Phase is ONLY due to the presenceor absence of OX. Thus the effect of interferents on the detected UV Light intensity is ignoredby the instrument.Even if the concentration of interfering gases were to fluctuate so wildly as to be significantlydifferent during consecutive Reference and Measurement Phases, this would only cause theO3 concentration reported by the instrument to become noisy. The average of such noisyreadings would still be a relatively accurate representation of the O3 concentration in theSample Gas.Interference from SOa, NO*, NO and HZ0 are very effectively rejected by the model 400E. Thetwo types of interferents that may cause problems for the Model 400E are aromatichydrocarbons and mercury vapor.

Aromatic Hydrocarbons

While the instrument effectively rejected interference from meta-xylene, it should be noted thatthere are a very large number of volatile aromatic hydrocarbons that could potentially interferewith ozone detection. This is particularly true of hydrocarbons with higher molecular weights. Ifthe Model 400E is installed in an environment where high aromatic hydrocarbonconcentrations are suspected, specific tests should be conducted to reveal the amount ofinterference these compounds may be causing.

Mercury Vapor

Mercury Vapor absorbs radiation in the 254nm wavelength so efficiently that its presence,even in small amounts, will reduce the intensity of UV light to almost zero during both theMeasurement and Reference Phases rendering the analyzer useless for detecting OS-

If the Model 400E is installed in an environment where the presence of Mercury vapor issuspected, specific steps MUST be taken to remove the Mercury Vapor from the Sample Gasbefore it enters the analyzer.

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USER NOTES:

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2. PNEUMATICS AND SUB-ASSEMBLIES

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ABSOR?TION T U B E

M E A S U R E / R E F E R E N C E N

V A L V E

*Flow

Transducer

b PressureTransducer

P U M P

O Z O N E

SCRUBBER

r-F I L T E R

REAR

- I -

- - - - -PANEL

EXHAUST

--- ---SAMPLE

M400E Pneumatic Diagram (no options)

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r - - - A B S O R P T I O N T U B E


-------j

/FlowFlow

TransducerTransducerI I

PressurePressure- Transducer- Transducer

PUMP

EXHAUST

04592F

O Z O N E

SCRUBBER

bFILTER

SAMPLE/CALVALVE

SAMPLE

M400E Pneumatic Diagram (12s)

of 63

IZSO Z O N E

G E N E R A T O R

-I

CHARCOAL DFU

FILTER

DESSICANT D R Y E R

CARTRIDGE

ROOM

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r - -From Sample

Reference/Measure Valve

Temperature Senso

Pressure Sensor(Sample Pressure)

ABSORPTION TUBE

To Exhaust Port

Model 400E Pneumatic Operation

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The Sample Particulate Filter

The particulate filter should be inspected often for signs of plugging or excess dirt. It should bereplaced regularly even without obvious signs of dirt. Filters with lprn and 5pm pore size canclog up while retaining a clean look. We recommend handling the filter and the wettedsurfaces of the filter housing with gloves and tweezers. We recommend to not touch any partof the housing, filter element, PTFE retaining ring, glass cover or the O-ring with bare hands,as this may cause the pores to clog quicker and surfaces to become dirty due to possible oilsfrom your hands.

-01628 Retaining Ring./’

/,-024310100 C-Ring. PTFE. Notches

- FTFF Metn brane Ftlf er Flam -+._ ._._. -.-_.- _- La’-IIlk*IIi=i’IS- ljm: FL6 - 5 pm

-OR 58 Viton O-Ring

- FT-13 Teflon Fitting

. ‘ L‘-....- FF-13 Teflon Fitting

UP

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Ozone Scrubber and Reference Valve

The Ozone Reference scrubber contains Manganese Dioxide screens inside. These screensact as a catalytic converter that react the O3 into Oz. This chemical equations is 2033302.This is an exothermic reaction, meaning it releases heat. Theoretically the scrubber will lastforever, but what happens is over time the screens degrade or become dirty. Eventually thescrubber will no longer be able to scrub ozone. There will then be ozone breakthrough andwill cause your spans to drop and read lower then they should. This same effect can be seenif the valve develops a cross-port leak. Please see the Unable to Span section in theTroubleshooting Tree s.

OS Scrubber and Measure/Reference Switching Valve

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The Critical Flow OrificeCritical flow orifices are a remarkably simple way to regulate stable gas flow rates. Theyoperate without moving parts by taking advantage of the laws of fluid dynamics. By restrictingthe flow of gas though the orifice, a pressure differential is created. This pressure differentialcombined with the action of the analyzer’s pump draws the gas through the orifice.

As the pressure on the downstream side of the orifice (the pump side) continues to drop, thespeed that the gas flows though the orifice continues to rise. Once the ratio of upstreampressure to downstream pressure is greater than 2:1, the velocity of the gas through theorifice reaches the speed of sound. As long as that ratio stays at least 2:i the gas flow rate isunaffected by any fluctuations, surges, or changes in downstream pressure because suchvariations only travel at the speed of sound themselves and are therefore cancelled out by thesonic shockwave at the downstream exit of the critical flow orifice

The Orifice itself is made out of a ruby or sapphire gemstone and then a small hole is laser cutto the desired diameter in the center of the gemstone. A gemstone is used due to its hightolerance to thermal expansion.

CRITICALFLOW

ORIFICE

AREA OFHIGH

PRESSUREI

AREA OFLOW

PRESSURE

S h o c k w a v e

FILTER

Flow Control Assembly & Critical Flow Orifice

The actual flow rate of gas through the orifice (volume of gas per unit of time), depends on thesize and shape of the aperture in the orifice. The larger the hole, the more gas molecules,moving at the speed of sound, pass through the orifice. Because the flow rate of gas throughthe orifice is only related to the minimum 2:l pressure differential and not absolute pressure,the flow rate of the gas is also unaffected by degradations in pump efficiency due to age. Thisis true until the pump degrades to the point where the 2:l pressure ratio is no longermaintained, normally around 14”-15”. The critical flow orifice used in the Model 400E isdesigned to provide a flow rate of 800 cm3/min.

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USER NOTES:

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3. MENU STRUCTURE

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-

L

% 1- I

I -

-2P


USER NOTES:

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4. CALIBRATION PROCEDURE

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MODEL 400E OZONE ANALYZERTrainina Manual

Manual Calibration & Calibration without Zero/SpanValve or IZS Options

This is the basic method for manually calibrating the Model 400E O3 Analyzer.

ZERO/SPAN CALIBRATION VS. ZERO/SPAN CHECKPressing the ENTR key during the following procedureresets the stored values for OFFSET and SLOPE and

alters the instrument’s Calibration.

STEP ONE: Connect the Sources of Zero Air and Span Gas as shown below.

MODEL 700Gas Dilution Calibrator(w/ P h o t o m e t e r O p t i o n )

MODO:L 401Ozone Generator

Source ofSAMPLE GAS

I--mm

III~

Removed duringcalibration

Sample

[ Exhaust

[ Span

MODEL400E

[ Zero Air

Dry Air

Pneumatic Connections for Manual Calibration without Z/S Valve or ES Options

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STEP TWO: Set the expected O3 Span Gas concentration:

‘33 :xxx.x

SETUPM400E to prompt for the

expected 03 spanconcentration.

M-P CAL

< TST TST z ZERO CONC E X I TThe 03 span concentration value automaticall)

defaults to400.0 Cone

M-P CAL 03 SPAN CONC:400.0 Cone

0 0 4 0 0 .o ENTR EXIT

Make sure that you input theACTUALconcentration value of the SPAN Gas.

To change this value to meet the actualconcentration of the SPAN Gas, enter the

number sequence bypressing the key undereach digit until the expected value is set.

NOTEFor this Initial Calibration it is important to independently verify the

PRECISE O3 Concentration Value of the SPAN gas.

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MODEL 400E OZONE ANAL YZERTraining Manual

STEP THREE: Perform the Zero/Span Calibration Procedure:

/

WAMINUTES

Or until the

I readingstabilizes and

the ZERO button

FiP.l'it = 500 0 r’f’Y T3 =YXX x. d,

.: ‘ST TST :. ENTR tY9.c EXIT

I Press ZERO onlv I fperforming a&Q

CAI IBRATION

NOTE:In Cerialn Instances where low span gas

concentrmons are present,both the Zero 8 SPAN buttons may appear

simultaneously

If either the ZERO or SPAN buttons fail toappear see the Troubleshooting Trees for help.

If the ZERO or SPAN keys are not displayed, this means that the measurement madeduring that part of the procedure is too far out of the allowable range to do allow areliable calibration. The reason for this must be determined before the analyzer can becalibrated.

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PRESSURE CALIBRATION

To calibrate the pressure in the analyzer the first thing you will want to do is find out thecurrent atmospheric pressure. This can be found from a barometer or contacting yourlocal airport or weather station.

Next, disconnect the pump. You can either do this pneumatically or electrically. Alsodisconnect any tubing connected to the sample inlet or exhaust ports on the back of theanalyzer. This will put the analyzer at atmospheric pressure.

From the front panel of the analyzer press cSETUPXMOREXDIAG> and enter 929 forthe password when ever it asks for it. Once in the DIAG menu press next until you getPressure Calibration and hit ENTER. Now enter the actual atmospheric pressure andpress ENTER.

Exit back out to the main menu and scroll over to sample pressure. This should beequal to the atmospheric pressure now. Reconnect the pump and the pressure shoulddrop a few inches, Reconnect the sample inlet and exhaust and the pressure shouldremain the same +- 0.2”Hg. If the pressure changes more than this when you reconnectthe sample and exhaust lines, you will have to troubleshoot the system as the analyzeris being pressurized or being put under a vacuum.

FLOW CALIBRATION

With the analyzer on and the pump connected, connect an external flow meter to thesample inlet port on the back of the analyzer. Record the flow rate. Then from the frontpanel hit &ETUP><MORE><DIAG> enter 929 for the password when it asks you for it.

Once in the DIAG menu press next until you get Flow Calibration and hitcENTER>eCAL>. Now enter the value you measured with the external flow meter andhit Enter. This will calibrate the flow meter in the analyzer. Exit back out to the mainmenu and scroll through the TST values till you get Sample Flow. It will be reading closeto the measured value.

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IZS Ozone Generator Lamp

The procedure adjusts the lamp for optimum operation of the IZS and its feedbackcircuit.

1. Enter the Adjustment menu by pressing SETUP-MORE-03-ADJ. This causesthe lamp drive circuit to output a constant 2.5 V.

2 . If you are installing a new lamp, allow approximately 30 min for lampto stabilize.

output

3. Select the “03 GEN” Test function on the front panel display. Loosen the IZSlamp and rotate until the reading on the display is 2500 mV & 500 mV.

CAUTIONUV light present. Do not pull the lamp from the IZS assembly.

‘

4. Re-tighten the sealing ring, securing the ozone lamp to the IZS generatorassembly.

5. Adjust the reference potentiometer on the IZS UV detector board to refine thefront panel reading to 2500 mV 4 25.

6. The IZS lamp and feedback circuit are now set up. Now perform an IZS ozonegenerator calibration, located in the DIAG menu. This procedure is automated and willtake about 1 hour to complete.

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TELEDYNEINSTRUMENTSAdvanced Pollufion lnstrumenfafionA Teledyne Technologies Company

9480 Carroll Park Drive, San Diego, CA 92121-2251Phone (858) 657-9800 Fax: ( 8 5 8 ) 657-9818 Toll Free 1 8 0 0 324-5190E-mail: aDi-customerserviceQteledvne.com httD://www.teiedvne-aDi.com

03-020A9 September, 2003

HOW TO PERFORM A MANUAL DAC CALIBRATION ON“E” SERIES MACHINES

I. PURPOSE:The purpose of this service note is to give instructions on how to perform a manual Digitalto Analog Calibration (D/A Calibration) on “E” series analyzers.

II. TOOLS:Digital Voltmeter

Ill. PARTS:None

IV. PROCEDURE:

Please follow the appropriate procedure below for either VOLTAGE or CURRENT output.

VOLTAGE OUTPUT1. From the main menu press SETUP-MORE-DIAG-ENTR-NEXT until ANALOG I/O

CONFIGURATION press ENTR.2. Press SET> 5 times.3. The top line should read A/IN CALIBRATED: YES4. Press CAL to calibrate the analog inputs.5. Press &ET 4 times.6. The top line should read CONC-OUT-l: RANGE 5V

a. If this is the output voltage you desire then go to step 7b. If this voltage is incorrect press EDIT and change to the output voltage

desired, press ENTR and go to step 7.7. Press EDIT, Press SET>. The top line should read CONC-OUT-l: REC

OFFSET: Omva. If you don’t want a recorder offset go to step 8.b. If you want a recorder offset press EDIT. Enter the OFFSET value and

press ENTR. Go to step 8.8. Press SET>. The top line should read CONC-OUT-l: AUTO CAL: ON

a. If this says AUTO CAL ON press EDIT and turn it OFF.b. If this says AUTO CALL OFF go to step 9.

9. Press SET>. The top line should read CONC-OUT-l: CALIBRATED: YES10. Now place your meter on pins 1 and 2 on the rear panel analog output connector

and set your meter to read mvDC.11. Press CAL on the front panel.

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12. You should have some DN and UP buttons. And the top line should be sayZERO ADJUST or something similar.

13. The output on the meter should be as close as possible to OmV rt0.3mV.a. If it is not then press DN or UP until the meter reads as close as possible

to Omvb. If it does go to step 14

14. Press ENTR.15. The top line should now say GAIN ADJUST and you should have DN and UP

buttons again. The meter should now read 90% of your full-scale voltage (i.e.lV, W, 1OV) you will have to change the range on the meter to read Voltsinstead of Milkvolts. If you are on the 1OV scale you will be adjusting to 4.5Vsinstead of 90% of full scale.

16. Press the DN and UP buttons until the output on the meter reads 90% of yourfull-scale voltage it mV.

17. Press ENTR18. That channel is now calibrated.19. Do this for all channels and ensure that you move the meter on the output

connector to the proper pins.

CURRENT OUTPUT

04592F

1. From the main menu press SETUP-MORE-DIAG-ENTR-NEXT until ANALOG I/OCONFIGURATION press ENTR.

1. Press SET> 5 times.2. The top line should read A/IN CALIBRATED: YES3. Press CAL to calibrate the analog inputs.4. Press &ET 4 times.5. The top line should read CONC-OUT-l: CURRENT

a . If you desire Current output then go to step 7b. If you do not desire Current output press EDIT and change to the output

voltage desired, press ENTR and follow the steps in the Voltage Outputprocedure.

6. Press EDIT, Press SET>. The top line should read CONC-OUT-l: AUTO CAL:ON

a . If this says AUTO CAL ON press EDIT and turn it OFF.b. If this says AUTO CALL OFF go to step 8.

7 . Press SET>. The top line should read CONC-OUT-l: CALIBRATED: YES8. Now place your meter on pins 1 and 2 on the rear panel analog output connector

and set your meter to read mA.9. Press CAL on the front panel.10. You should have some DN and UP buttons. And the top line should be say

ZERO ADJUST or something similar.11. The output on the meter should be as close as possible to Oma eO.01 ma (if O-

20ma output), 4ma *O.Ol ma (if 4-20ma output).a. If not then press DN or UP until the meter reads as close as possible to

Oma or 4ma.b. If it does go to step 13

12. Press ENTR.13. The top line should now say GAIN ADJUST and you should have DN and UP

buttons again. The meter should now read your full-scale current output 20ma.14. If it doesn’t press the DN and UP buttons until the output on the meter reads your

full-scale current output of 20ma 20.01 ma.15. Press ENTR16. That channel is now calibrated.

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Do this for all remaining channels that contain the Current option and ensure that you move themeter on the output connector to the proper pins for that channel.

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USER NOTES:

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5. MAINTENANCE

I t e m Action Priority Frequency Date Performed

Particulate Filter Replace MandatoryWeekly or as

needed Yes

Orings &Sintered Filters Replace Mandatory Annually Yes

PumpDiaphragm Replace Mandatory Annually Yes

IZS zero airscrubber Replace Mandatory Annually No

03 Scrubber (RefScrubber)

Replace Mandatory Every two years Yes

Verify TestFunctions

Perform FlowCheck

Record &Analyze

Check Flow

Recommend

Recommend

Weekly or after anymaintenance or

repair

Every 6 months

No

No

Perform Annually or afterVerify Leak Tight Leak Check Recommend any maintenance Yes

or repair

Examineand Recommend As needed

Yes ifPneumatic Lines

Replacereplaced

Absorption Tube Clean Recommend As needed Yes

BenchCalibration

Calibrate RecommendAnnually as

needed N/A

IZS OzoneCalibration Calibrate Recommend

Annually asneeded N/A

M400E Preventative Maintenance Schedule

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Vacuum Leak Check and Pump Check

This method is easy and fast. It detects, but does not locate most leaks, it also verifiesthat the sample pump is in good condition.

1. Turn the analyzer ON, and allow enough time for flows to stabilize.

2. Cap the sample inlet port.3. After 2 minutes, when the pressures have stabilized, note the SAMP FL and

PRES test function readings on the front panel.

4. If SAMP FL < 10 CC/M then the analyzer is free of any large leaks.

5. If PRES c 10 IN-HG-A then the sample pump diaphragm is in good condition.

Pressure Leak CheckIf you can’t locate the leak by the above procedure, obtain a leak checker similar to theT-API part number 01960, which contains a small pump, shut-off valve, and pressuregauge. Alternatively, a tank of pressurized gas, with the two stage regulator adjusted to5 15 psi; a shutoff valve and pressure gauge may be used.

A

CAUTION

1Once the fittings have been wetted with soap solution, DO NOT apply /

‘a re-apply vacuum as this will cause soap solution to be drawn into theinstrument, contaminating it.

DO NOT exceed 15 psi pressure.1. Turn OFF power to the instrument.

2. Install a leak checker or tank of gas as described above on the sample inletat the rear panel.

3 . Install a cap on the Exhaust fitting on the rear panel.

4. Remove the instrument cover and locate the sample pump. Disconnect thetwo fittings on the sample pump and install a union fitting in place of thepump. The analyzer cannot be leak checked with the pump in line due tointernal leakage that normally occurs in the pump.

5. Pressurize the instrument with the leak checker, allowing enough time tofully pressurize the instrument through the critical flow orifice. Check eachfitting with soap bubble solution, looking for bubbles. Once the fittings havebeen wetted with soap solution, do not re-apply vacuum, as it will draw soapsolution into the instrument and contaminate it. Do not exceed 15 psipressure.

6. If the instrument has one of the zero and span valve options, the normallyclosed ports on each valve should also be separately checked. Connect theleak checker to the normally closed ports and check with soap bubblesolution.

7. If the analyzer is equipped with an IZS Option Connect the leak checker tothe Dry Air inlet and check with soap bubble solution.

8. Once the leak has been located and repaired, the leak-down rate should be< 1 in-Hg (0.4 psi) in 5 minutes after the pressure is shut off.


Cleaninq the Absorption Tube

1. Remove the cover from the optical bench.

2 . Unscrew the knurled nuts from the absorption tube at both ends of theabsorption tube.

3. Using both hands, rotate the tube to free it, and then carefully slide thetube towards the lamp housing. The tube can now be slid past the detectorblock and out of the instrument.

CAUTIONDo not cause the tube to bind against the metal housings. The tube may

break and cause serious injury.

4 . Clean the tube with distilled water, then use dry air or nitrogen to dry thetube. Check the cleaning job by looking down the bore of the tube. It shouldbe free from dirt and lint.

5. Inspect the o-rings that seal the ends of the optical tube (these o-ringsmay stay seated in the manifolds when the tube is removed.) If there is anynoticeable damage to these o-rings, they should be replaced.

6. Re-assemble the tube into the lamp housing and leak check theinstrument. Note: It is important for proper optical alignment that the tube bepushed all the way towards the detector end of the optical bench when it isre-assembled.

7. Leak check the analyzer. If it leaks check o-rings on tubes.

a . Flow check analyzer.

QCnfL=Q T)4/25/06


USER NOTES:

1)4/25/06


6. TROUBLESHOOTING AND FAULTS

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MODEL 4OOE OZONE ANALYZERTraining Manual

TAPI Service Repair Form

CUSTOMER:

PHONE:

CONTACT NAME:

FAX NO.

SITE ADDRESS:

MODEL 400E SERIAL NO.:

FIRMWARE REVISION:

1. ARE THERE ANY FAILURE MESSAGES?

PLEASE COMPLETE THE FOLLOWING TABLE: (NOTE: DEPENDlNG ON OPTlONS INSTALLED,ALL TESTS PARAMETERS BELOW WILL BE AVAILABLE IN YOUR INSTRUMENT)2. *IF OPTIONS ARE INSTALLED

Parameter Recorded Value Acceptable ValueRANGE PPB/PPM 1 - 10,000 PPBSTABIL <= 0.3 PPB WITH ZERO AIR

03 MEAS03 REF

03 GEN*03 DRIVE”

PRES

SAMPLE FLSAMPLE TEMPPHOTO LAMP03 GEN TMP*

BOX TEMP

mV 2 5 0 0 4 8 0 0 mV-mV 2 5 0 0 4 8 0 0 mV-mV 80 mV. 5000 mV.-mV 0 5 0 0 0 mV.-

IN-HG-A - - 2”AMBIENT ABSOLUTECM3/MIN 800 sf: 10%

“C lo-50°C“C 50 “C * 1 “C“C 48 ‘C f 3 “C“C lo-50°C

SLOPE 1.0 f .150.0 * 5.0 PPB

NOT

I,.. -..- ._.--- - - -..- - - -

mv I Ok 0.5 and Must be Stable

3. WHAT IS THE SAMPLE FLOW AND SAMPLE PRESSURE WITH THE SAMPLE INLET ON REAR OF MACHINECAPPED?

SAMPLE FLOW - CM3/MlN SAMPLE PRESSURE - IN-HG-A

04/25/06


4. WHAT ARE THE FAILURE SYMPTOMS?

5. IF POSSIBLE, PLEASE INCLUDE A PORTION OF A STRIP CHART PERTAINING TO THE PROBLEM. CIRCLETHE PERTINENT DATA.

6. THANK YOU FOR PROVIDING THIS INFORMATION. YOUR ASSISTANCE ENABLES TELEDYNE API TORESPOND FASTER TO THE PROBLEM THAT YOU ARE ENCOUNTERING

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Warning Messages

Message

LAMP DRIVER WARN

BOX TEMP WARNING

Meaning

CPU is unable to communicate with one of the 12C UV Lamp Drivers.

The temperature inside the M400E chassis is outside the specifiedlimits.

CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased.

DATA INITIALIZED iDAS data storage was erased.

FRONT PANEL WARN CPU is unable to communicate with the front panel.

PHOTO REF WARNING The 0s Reference value is outside of specified limits.

PHOTO TEMP WARNING The UV Lamp Temperature is outside of specified limits.

REAR BOARD NOT DET Motherboard was not de tec ted dur ing power up.

RELAY BOARD WARN CPU is unable to communicate with the relay board.

SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits.

SAMPLE PRESS WARN The pressure of the sample gas is outside the specified limits.

SAMPLE TEMP WARN The temperature of the sample gas is outside the specified limits.

SYSTEM RESET The computer has rebooted.

03 GEN LAMP WARNThe UV Lamp or Detector in the IZS module may be faulty or out ofad jus tmen t .

03 GEN REF WARNING IThe UV Lamp or Detector in the IZS module may be faulty or out ofad ius tmen t .

03 GEN TEMP WARNThe UV Lamp Heater or Temperature Sensor in the IZS module maybe faultv.

03 SCRUB TEMP WARNThe Heater or Temperature Sensor of the 03 Scrubber may be faulty(Optional Metal Wool Scrubber only.)

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Status LED’s

Eight LED’s are located on the Analyzer’s Relay board to show the current status on thevarious control functions performed by the Relay Board. They are:

Relay Board Status LED’s

LED

Dl

02

D3

D4

D5

D6

D7

D8

D9

DlO

Dll

D12

D13

D14D15

D16

Color Function Status When Lit Status When Unlit

RED Watchdog Circuit Cycles On/Off Every 3 Seconds under direct control of theanalyzer’s CPU.

YELLOW Metal Wool HEATING NOT HEATINGScrubber Heater

YELLOW Spare N/A N/AYELLOW Spare N/A N/A

YELLOW Spare N/A N/A

YELLOW Spare N/A N/A

GREEN Zero/Span Gas Valve Open to SPAN GAS Valve Open to ZERO GAS FLOWValve FLOW

GREEN Measure/Ref Valve Valve Open to REFERENCE Valve Open to MEASURE gas pathgas path

GREEN Sample/Cal Gas Valve Open to CAL GAS Valve Open to SAMPLE GASValve FLOW FLOW

GREEN Spare N/A N/A

GREEN Spare N/A N/A

GREEN Spare N/A N/A

GREEN Spare N/A N/A

GREEN Spare N/A N/A

GREEN Photometer UV HEATING NOT HEATINGLamp Heater

GREEN IZS 03 Generator HEATING NOT HEATINGUV Lamp Heater

Watch Doq Circuitry/

Special circuitry on the Relay Board watches the status of LED Dl . Should this LED everstay ON or OFF for 30 seconds, the Watchdog Circuit will automatically shut of all valvesas well as turn off the UV Source(s) and all heaters. The Sample Pump will still berunning.

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M400E Troubleshootinq Tree

Troubleshooting TreesNo PowerNo front panel or locking up DisplayUnstable Reading at Zero, Zero noiseUnstable Reading at Span, Span noiseUnable to Zero (No Zero Button)Unable to Span (No Span button or no response to Span gas)Non-Linear ResponseSlow Response to Zero or SpanNo FlowNo analog or incorrect analog outputPhoto Ref WarningAny Temperature Warning

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Incorrect voltage orpowering the analyzer

Verify that the correct voltage

I ,, . , . , , , , , , ” ,,.,,__ “.“... “ , . _..“. . .._..” . ..__... . - . , . , . . ^ -...

Check circuit breaker

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a9.s “iJtG,&& ?wmmq Perform a Leak check on the analyzer. Capm Leak in the analyzer {W sample inlet and make sure the pressure dropsxII -“l--l xI”““-. I”_x111”” 40” and the flow drops to clOcc/min

,-’ a em”& y%Internal Zero source fL Replace scrubber material and check with a

depleted known zero source“1

Dirty Sample tubing orI sample filter

4 Electronic noise detector simulator PN 051010000 to determine if

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4- Perform a Leak check on the analyzer. CapI Leak in the analyzer“~” . - - “-11 “-__I_--(

sample inlet and make sure the pressure drops~10” and the flow drops to <lOcc/min

depleted- -

Replace scrubber material and check with a4- known zero source;

Replace tubing or sample filter. Make sure notI sample filter -

,;to touch the Sample filter with your hands. Use

d gloves or soft tweezers““~1-11” 1

make sure it is stable to with imoving around more than that, change themotherboard, 5 year warranty part.

If the UV lamp doesn’t fix the problem, it iSeither caused by the UVPS or the Detector.Replace them one at a time to find the problem

e noise is fromcableslmotherboar

04/25/06

MODEL 4OOE OZONE ANAL YZERTraining Manual

o4592F

“_i ,“Ip %35!m%y Perform a Leak check on the analyzer. Capd Leak in the analyzer $7 sample inlet and make sure the pressure drops

‘L- ̂_ “-.... p m , - - ,_,- 40” and the flow drops to clOcc/min

internal Zero source j:jwReplace scrubber material and check with a

I depleted known zero sourcec :2zL-----. ,,.,,,, . ..--“-~--------~~

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SPAN BUTTON ORRESPONSE TO SP

il

Bad Reference 3Record the 03 Reference reading on Zero and

t1 scrubber, or bad M/R ; jjl- Span gas. It should not differ more than 1mV.

valve ;;g If it drops more than lmv when you go to span,4 replace the valve or the scrubber.

I..” ..-., _ -,,.- “‘..~.lll.” ..-.__ “_- . - . -“” ..,,,,,,,.. i

; Incorrect span gas in 4 Check the CONC menu in the calibration modeI C-J,JC menu &r and ensure it is the correct span gas value

t,j

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sample inlet and make sure

Check zero and span points again. Wait

i Improper zero/span f ”L lliminutes and make sure they are correct, this1 ” 3j( is the most important thing to ensure that theL Ozone analyzer is linear

zone source

Record the 03 Reference reading on Zero andSpan gas. It should not differ more than 1mV.If it drops more than lmv when you go to span,replace the valve or the scrubber.

1

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SLOW RESPONSE TOZERO OR SPAN

Perform a Leak check on the analyzer. Cap‘- sample inlet and make sure the pressure drops

- I -- ~“---“1_ X” I “-“--- ~10” and the flow drops to clOcc/min

i Measure the Flow with an external flow meter.- It should be 8OOcc +- 10%. If not replace filters

“” ” _ I.. ” -” “~“^ -I and look for restrictions.

Replace sample particulate filter. Make sure notto touch the Sample filter with your hands. Usegloves or soft tweezers

Analyzer needs 1 If this is a brand new analyzer, or has been out

-q condit ioning if-

of service for a while it may need to conditioni

$ the lines, either in the analyxer or from thef :t M calibrator to the analyzer

I -

II

c

Ii

J

Gas to the analyzer is 1taking too long to get to dL

the analyzer bx“4

Input spanhero gas and wait until the analyzeris stable. Disconnect the sample inlet to theanalyzer but let the cal gas keep flowing. Wait 5minutes. Reconnect the sample line. If it goesright to the concentration you expect or closerthan it was when you disconnected the tubing,the calibration system is the problem, or it justneeded to condition itself.

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Replace front panel particulate filter. Make surenot to touch the Sample filter with your hands.Use gloves or soft tweezers

Replace the sintered filter in front of the critical

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NO ANALOG ORINCORRECT ANALOG

Perform an analog output calibration. Refer to

Look at the motherboard on the rear panel andJ19, J21, and J23. Each connector that has asmall circuit board about 2” by 1” is configuredfor current. If it has two shunts across the twoleft pins, or a small %” by %” circuit board, it isconfigured for Voltage.

I I

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Look at the Reference value. If it is 4950mV orgreater, adjust it back down using theReference pot or physically adjusting the lamp

Adiust UV lamp. If the reference is readingardund 100mV; check to see if the lamp ispowered on. If it is, replace the detector. If it’snot, replace the UVPS or the lamp.

Reference too lowq

-,,,..-_-I__AJ

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12V DC. If the LED is turning on and off but thevoltage isn’t changing, the Relay is bad.

room temperature.

reads open or a short it is bad.

Measure the Resistance of the heater. It shouldI be less than 1 K ohms in most cases. If it is

open or shorted, it is badY”--- -Bad Heater g----ih.

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USER NOTES:

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7. SPECIFICA T/ONS

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Model 400E Basic Unit Specifications

Min/Max Range(Physical AnalogOutput)Measurement UnitsZero NoiseSpan NoiseLower Detectable LimitZero Drift (24 hours)Zero Drift (7 days)Span Drift (24 hours)Span Drift (7 days)LinearityPrecisionLag TimeRise/Fall TimeSample Flow RateTemperature RangeHumidity RangePressure RangeAltitude RangeTemp Coefficient

Min: O-100 PPBMax: O-10,000 PPB

ppb, ppm, pglm3, mg/m3 (user selectable)< 0.3 ppb RMS (EPA Definition)< 0.5% of reading above 100 PPB (EPA Definition)c 0.6 PPB (EPA Definition)c 1 .O ppb (at constant temperature and voltage)c 1 .O ppb (at constant temperature and voltage)c 1% of reading (at constant temperature and voltage)< 1% of reading (at constant temperature and voltage)c 1% of full scalec 0.5% of reading (EPA Definition)c 10 set (EPA Definition)< 20 set to 95% (EPA Definition)800 f 80 cc/min5 - 40°CO-90% RH, Non-Condensing25 - 31 “Hg-AO-2000mc 0.05% per deg C

Dimensions (H x W x D)WeightAC Power

Voltaae Coefficient 1 < 0.05% per Volt AC. . . ,. .,-, -....‘. IRM.SI n\/pr ranae of nominal + 10%

(2.5A)

-\ -,7” x 17” x 23.5”

Installation Category (Over voltage Category) II Pollution Degree 2

30.6lbs. (13.8Kg) with IZS Option1 OOV 50/60Hz (3.25A), 115V 60Hz (3.OA), 220 - 240 V 50/60 Hz

EnvironmentalConditionsAnalnn no h-u I

IFour (4) Outputs, Tr..,, \-I -----*--All Outputs: 100 mV, 1 V, 5 V, 10 V

Analog Wutpu- . -. It Ranges Two concentration outputs convertible to 4-20 mA isolated currentloop

Analog OutputResolutionStatus OutputsControl InputsSerial l/O

Certifications

All Ranges with 5% Under/Over Range1 part in 4096 of selected full-scale voltage

8 Status outputs from opto-isolators6 Control Inputs, 3 defined, 3 spareCOMl: RS-232; COM2: RS-232 or RS-485Baud Rate : 300 - 115200

USEPA: Equivalent Method Number EQOA-0992-087CE Mark

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Model 400E Internal 03 Generator Specifications

Maximum Concentration 1 .O PPMMinimum Concentration 0.050 PPMInitial AccuracyStability (7 Days)Repeatability (7 days)Response Time

+/- 5% of target concentration1% of reading1% of reading< 5 min to 95%

Resolution 1 0.5 ppb I

Specifications for Model 400E IZS Generator w/o Reference Feedback Option

Maximum ConcentrationMinimum Concentrationinitial AccuracyStability (7 Days)Repeatability (7 days)Response TimeResolution

1 .O PPM0.050 PPM+/- 10% of target concentration2% of reading2% of readingc 5 min to 95%0.5 ppb

NOTE

If at any time an illegal entry is selected (Example: Delta Days > 367) the ENTRkey will disappear from the display.

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8. M/SC DIAGRAMS

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I , Analog Outputs

COMM 0 COMMAFemale Male

r\l\

A4

control Inputs1-6

status outputs.1 -a

I

ExternalDigital I/O)

Analogoutputs -%

(D/A) ;

:,,., :

PC 104CPU Card

1 F lash Chip ]

Thermistor‘* x Interface Sensor IntWs

_-. “‘-““‘I

_ ,, :.A:,: i Zero/Span/Cal

- I V a l v e O p t i o n &iii-l

-I!-K e y b d &D i s p l a y-I

1; If.5 i r-m-----q

-t ReferenceI 1 IZS UV Lamp tJ

D e t e c t o r I I Power Supply ,_ I +I”“““‘-’I ----_--’ I-------d I IZS Sample/Cal 1

I I 1 I V a l v e II ------,---’““““II

t I Z S UVLamp t

I~~~~-~~

P H O T O M E T E RUV LAMP TEMP

3

d-

400E Electronic Block Diagram

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COMM AM a l e EM-=

COMM BF e m a l e r+

Status Outputs:l - 8

Analog OutputsAl t

1 1 - m - 1 1 1 11 Optional 1

M

rur-

4 - 2 0 mA 1I I-1-m-W

A3

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I

ns--zYZ VNLT

RS-232 or RS-485

Mother

PC/l04 BUS

I

CPU

KEYBPARD

I

I-- % II i

DISPLAY

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Basic Electronic Control Circuitry

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USER NOTES:

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USER NOTES:

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USER NOTES:

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APIModel400ETrainingManual

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