TELEDYNE API 465M User manual

USER MANUAL
MODEL 465M
OZONE MONITOR
Teledyne API (TAPI)
9970 Carroll Canyon Road
San Diego, CA 92131-1106
Toll-free: 800-324-5190
Phone: [phone]
FAX: [phone]
Email: api-[email protected]
Website: http://www.teledyne-api.com/
© 2007-2018 TAPI 06160K DCN8017
Teledyne API 31 October 2018

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06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual i
SAFETY MESSAGES
Important safety messages are provided throughout this manual for the purpose of avoiding
personal injury or instrument damage. Please read these messages carefully.Each safety
message is associated with a safety alert symbol and placed throughout this manual and inside the
instrument. The symbols with messages are defined as follows:
WARNING: Electrical Shock Hazard
HAZARD: Strong oxidizer
GENERAL WARNING/CAUTION: Read the accompanying message
for specific information.
CAUTION: Hot Surface Warning
Do Not Touch: Touching some parts of the instrument without
protection or proper tools could result in damage to the part(s) and/or
the instrument.
Technician Symbol: All operations marked with this symbol are to be
performed by qualified maintenance personnel only.
Electrical Ground: This symbol inside the instrument marks the central
safety grounding point for the instrument.
CAUTION
GENERAL SAFETY HAZARD
This instrument should only be used for the purpose and in the
manner described in this manual. If you use it in a manner other
than that for which it was intended, unpredictable behavior could
ensue with possible hazardous consequences.
NEVER use any gas analyzer to sample combustible gas(es).

ii Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
CONSIGNES DE SÉCURITÉ
Des consignes de sécurité importantes sont fournies tout au long du présent manuel dans le but
d’éviter des blessures corporelles ou d’endommager les instruments. Veuillez lire attentivement
ces consignes. Chaque consigne de sécurité est représentée par un pictogramme d’alerte de
sécurité; ces pictogrammes se retrouvent dans ce manuel et à l’intérieur des instruments. Les
symboles correspondent aux consignes suivantes :
AVERTISSEMENT : Risque de choc électrique
DANGER : Oxydant puissant
AVERTISSEMENT GÉNÉRAL / MISE EN GARDE : Lire la consigne
complémentaire pour des renseignements spécifiques
MISE EN GARDE : Surface chaude
Ne pas toucher : Toucher à certaines parties de l’instrument sans
protection ou sans les outils appropriés pourrait entraîner des dommages
aux pièces ou à l’instrument.
Pictogramme « technicien » : Toutes les opérations portant ce symbole
doivent être effectuées uniquement par du personnel de maintenance
qualifié.
Mise à la terre : Ce symbole à l’intérieur de l’instrument détermine le
point central de la mise à la terre sécuritaire de l’instrument.
MISE EN GARDE
Cet instrument doit être utilisé aux fins décrites et de la manière décrite
dans ce manuel. Si vous utilisez cet instrument d’une autre manière que
celle pour laquelle il a été prévu, l’instrument pourrait se comporter de
façon imprévisible et entraîner des conséquences dangereuses.
NE JAMAIS utiliser un analyseur de gaz pour échantillonner des gaz
combustibles!

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual iii
WARRANTY
WARRANTY POLICY (02024J)
Teledyne API (TAPI), a business unit of Teledyne Instruments, Inc.,
provides that:
Prior to shipment, TAPI equipment is thoroughly inspected and tested.
Should equipment failure occur, TAPI assures its customers that prompt
service and support will be available. (For the instrument-specific warranty
period, please refer to the “Limited Warranty” section in the Terms and
Conditions of Sale on our website at the following link:
http://www.teledyne-api.com/terms_and_conditions.asp).
COVERAGE
After the warranty period and throughout the equipment lifetime, TAPI
stands ready to provide on-site or in-plant service at reasonable rates similar
to those of other manufacturers in the industry. All maintenance and the first
level of field troubleshooting are to be performed by the customer.
NON-TAPI MANUFACTURED EQUIPMENT
Equipment provided but not manufactured by TAPI is warranted and will be
repaired to the extent and according to the current terms and conditions of
the respective equipment manufacturer’s warranty.
Product Return
All units or components returned to Teledyne API should be properly
packed for handling and returned freight prepaid to the nearest
designated Service Center. After the repair, the equipment will be
returned, freight prepaid.
The complete Terms and Conditions of Sale can be reviewed at
http://www.teledyne-api.com/terms_and_conditions.asp
CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti-Electro-Static Discharge (ESD) handling
and packing instructions and Return Merchandise Authorization (RMA)
procedures when returning parts for repair or calibration may void your
warranty. For anti-ESD handling and packing instructions please refer to the
manual, Fundamentals of ESD, PN 04786, in its “Packing Components for
Return to Teledyne API’s Customer Service”
section. The manual can be
downloaded from our website at http://www.teledyne-api.com. RMA
procedures can also be found on our website.

iv Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
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06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual v
TABLE OF CONTENTS
1. INTRODUCTION..........................................................................................................9
2. SPECIFICATIONS AND AGENCY APPROVALS ................................................11
2.1. MODEL 465M SPECIFICATIONS ..........................................................................................................11
2.2. APPROVALS .......................................................................................................................................12
2.2.1. Safety ..........................................................................................................................................12
2.2.2. EMC............................................................................................................................................12
2.2.3. Other Type Certifications ...........................................................................................................12
3. PRINCIPLE OF OPERATION..................................................................................13
4. GETTING STARTED.................................................................................................15
4.1. MECHANICAL INSTALLATION (FOR NEMA 4X ENCLOSURE) .............................................................15
4.1.1. Ventilation Clearance.................................................................................................................15
4.2. MECHANICAL INSTALLATION (19” RACK VERSION) ..........................................................................16
4.2.1. Ventilation Clearance.................................................................................................................16
4.3. AC POWER CONNECTION (FOR MONITORS IN NEMA 4X ENCLOSURES) ...........................................17
4.3.1. Wiring Requirements for NEMA Enclosures ..............................................................................17
4.3.2. Wiring Instructions .....................................................................................................................17
4.4. PNEUMATIC CONNECTIONS................................................................................................................19
4.4.1. Ozone Inlet Connection ..............................................................................................................20
4.4.2. Exhaust Connection....................................................................................................................20
4.5. ELECTRICAL I/O CONNECTIONS.........................................................................................................23
4.5.1. Location of I/O Connectors in the NEMA Configuration ...........................................................23
4.5.2. Analog Output.............................................................................................................................24
4.5.3. Status Outputs.............................................................................................................................24
4.5.4. Hi-Current Relay Outputs...........................................................................................................25
4.5.5. Digital Serial Interfaces..............................................................................................................25
5. FREQUENTLY ASKED QUESTIONS.....................................................................27
6. OPTIONS......................................................................................................................29
6.1. RACK MOUNT SLIDES ........................................................................................................................29
6.2. LOW FLOW ALARM............................................................................................................................29
6.3. NO SAMPLE CONDITIONER.................................................................................................................29
7. OPERATION ...............................................................................................................31
7.1. FRONT PANEL OVERVIEW..................................................................................................................31
7.1.1. Ozone Concentration Display.....................................................................................................31
7.1.2. Menu Navigation Keypad ...........................................................................................................31
7.1.3. Concentration Alarm Status/Reset..............................................................................................32
7.1.4. Status LED’s ...............................................................................................................................32
7.2. FRONT PANEL MENUS .......................................................................................................................33
7.2.1. Menu Navigation Basics.............................................................................................................33
7.2.2. Editing Numeric Values..............................................................................................................33
7.2.3. DIAG Menu.................................................................................................................................36
7.2.4. VIEW Menu.................................................................................................................................39
7.2.5. SETUP-VARS Menu....................................................................................................................40
7.2.6. SETUP-ALARM Menu ................................................................................................................41
7.2.7. CONFIG Menu ...........................................................................................................................41

vi Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
8. DIGITAL COMMUNICATIONS ..............................................................................43
8.1. DIGITAL COMMUNICATIONS OVERVIEW.............................................................................................43
8.2. CHANGING COM PORT HARDWARE CONFIGURATION ........................................................................43
8.3. RS-232 CONFIGURATION ...................................................................................................................45
8.4. RS-485 CONFIGURATION ...................................................................................................................46
8.5. ETHERNET CONFIGURATION...............................................................................................................47
8.5.1. Hardware Setup for Configuring the Ethernet Module...............................................................47
8.5.2. Verifying Network Hardware Connection...................................................................................47
8.5.3. Determining a Dynamically Assigned IP Address (DHCP Mode)..............................................48
8.5.4. Manually Assigning a Static IP Address.....................................................................................48
8.6. MODBUS REGISTER MAPS ...............................................................................................................50
8.6.1. Notes on MODBUS registers ......................................................................................................50
8.6.2. Real-Time Concentration and Status Registers (Read Only)......................................................50
8.6.3. Instrument Setup and Configuration Registers (Read / Write)....................................................50
9. MAINTENANCE.........................................................................................................51
9.1. MAINTENANCE SCHEDULE .................................................................................................................51
9.2. INSTRUMENT LAYOUT........................................................................................................................52
9.3. REPLACING INTERNAL PARTICULATE FILTER .....................................................................................53
9.4. UV LAMP ADJUSTMENT.....................................................................................................................56
9.5. UV LAMP REPLACEMENT ..................................................................................................................57
9.6. SAMPLE PUMP REPLACEMENT ...........................................................................................................57
9.7. AUTO-ZERO VALVE REPLACEMENT...................................................................................................58
9.8. CONFIGURING THE ANALOG OUTPUT .................................................................................................58
9.9. CLEANING EXTERIOR SURFACES OF THE 465M..................................................................................59
9.10. BOOT LOADER OPERATION ..............................................................................................................60
9.10.1. Boot Loader – Hardware Setup ................................................................................................60
9.10.2. Boot Loader – Software Setup ..................................................................................................60
10. TROUBLESHOOTING ............................................................................................63
10.1.1. Pneumatic Diagram ..................................................................................................................63
10.1.2. Interconnect Diagram...............................................................................................................64
10.2. TROUBLESHOOTING USING FRONT PANEL STATUS LED’S OR STATUS OUTPUTS .............................65
10.2.1. Sensor OK .................................................................................................................................66
10.2.2. Invalid Reading.........................................................................................................................66
10.2.3. Check Lamp ..............................................................................................................................66
10.2.4. Pneumatic Error .......................................................................................................................66
11. CALIBRATION.........................................................................................................69
11.1. FACTORY CALIBRATION ...................................................................................................................69
12. TECHNICAL ASSISTANCE ...................................................................................71

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual vii
FIGURES
Figure 4-1: 465M Mounting Hole Locations and Dimensions .....................................................................16
Figure 4-2. NEMA AC Power Connection to Monitor.................................................................................18
Figure 4-3: Pneumatic Connections, Rack Mount Configuration.................................................................19
Figure 4-4: Pneumatic Connections, NEMA Configuration .........................................................................20
Figure 4-5: Rear Panel Electrical I/O Connections.......................................................................................21
Figure 4-6: NEMA Electrical I/O Connections ............................................................................................22
Figure 4-7: NEMA I/O Label .......................................................................................................................23
Figure 4-8: Status Output Schematic ............................................................................................................24
Figure 6-1: Pneumatic Diagram with Sample Conditioner Removed...........................................................29
Figure 7-1: Front Panel Display ...................................................................................................................31
Figure 7-2: Front Panel Menu Diagram........................................................................................................34
Figure 7-3: Front Panel Menu Diagram........................................................................................................35
Figure 7-4: Span Cal Menu ..........................................................................................................................39
Figure 8-1: Com Configuration Jumper Settings (SW2) ..............................................................................44
Figure 9-1: Instrument Layout, Rack Mount Configuration .........................................................................52
Figure 9-2: Instrument Layout, NEMA Configuration .................................................................................53
Figure 9-3: Internal Particulate Filter Replacement......................................................................................55
Figure 9-4: Mainboard – Analog Output Configuration ...............................................................................59
Figure 10-1: Pneumatic Diagram (Rack Mount and NEMA) .......................................................................63
Figure 10-2: Interconnect Diagram ..............................................................................................................64

viii Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
TABLES
Table 4-1: 465M Ventilation Clearances, NEMA Version............................................................................15
Table 4-2: 465M Ventilation Clearances, Rack Mount Version....................................................................16
Table 4-3: Status Output Definitions ............................................................................................................24
Table 4-4: Relay Functions...........................................................................................................................25
Table 7-1: Alarm LED’s ...............................................................................................................................32
Table 7-2: Status LED’s ...............................................................................................................................32
Table 7-3: Analog Step Test Values .............................................................................................................36
Table 7-4: Signal I/O List .............................................................................................................................37
Table 7-5: VIEW Menu Parameters .............................................................................................................39
Table 7-6: VARS List...................................................................................................................................40
Table 7-7: Alarm Configuration Settings......................................................................................................41
Table 8-1: RS-232 Connector Details...........................................................................................................45
Table 8-2: RS-232 Port Setup.......................................................................................................................45
Table 8-3: RS-485 Connector Details...........................................................................................................46
Table 8-4: RS-485 Port Setup.......................................................................................................................46
Table 8-5: Ethernet LED Definitions............................................................................................................47
Table 9-1: Maintenance Schedule.................................................................................................................51
Table 9-2: Required Software.......................................................................................................................60
Table 10-1: Status LED/Output Definitions .................................................................................................65

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual 9
1. INTRODUCTION
Teledyne API’s Model 465M Ozone Monitor is a medium range ozone monitor that
measures process ozone concentrations; this microprocessor-controlled instrument
provides fast response times with minimal zero drift, and has built in tests and diagnostics
to allow maximum uptime.
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. Our full time technical support
department is always available to answer your questions.
Teledyne API, Technical Support,
9970 Carroll Canyon Road
San Diego, California 92131-1106 USA
Toll-free: 800-324-5190
Phone: [phone]
Fax:
[phone]
Email:
api-[email protected]
Website:
http://www.Teledyne-API.com

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06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual 11
2. SPECIFICATIONS AND AGENCY
APPROVALS
2.1. Model 465M Specifications
Measuring Principle UV absorption (Beer Lambert Law)
Ranges
User selectable to any full scale range from:
0-1000 PPM to 0-10,000 PPM
0-5 g/Nm3 to 0-50 g/Nm3
0-1 wt% to 0-3 wt%
Measurement Units PPM, wt%, g/Nm3
Accuracy
±1% of Full Scale
Precision/Repeatability
±0.5% of Full Scale
Display Resolution
1 PPM, 0.001 wt%, 0.01 g/Nm3
Response Time (95%)
<45 seconds to 95%
Compensation
Pressure, Temperature (NTP = 273.15K, 760
mmHg)
Gas Inlet Pressure Range
11.0 – 16.0 psia
Sample Flow Rate
0.8 LPM
Humidity Range
10-90% RH, non-condensing
Temperature Range
5-45o C
Dimensions (H x W x D)
Rack Mount (3U Panel) - 5.22” (133 mm) x 19.0"
(483 mm) x 15.3" (388 mm)
With NEMA 4X enclosure, typical product envelope:
16.85" x 15.60 (±0.25)" x 6.65" (428mm x 396 (±6.35)mm
x 169mm)
Weight
Rack Mount – 13.6 lbs (6.17 kg)
With NEMA 4X enclosure– 16.5 lbs (7.5 kg)
Power
100-240 V~, 47-63 Hz, 74 W
Environmental
Installation Category II
Pollution Degree 2
For Indoor Use Only
Maximum Operating Altitude 2000 meters
Analog Output
0 – 5 V or 4-20 mA isolated output
Status Outputs
System OK, Invalid Reading, UV Lamp Fault,
Pneumatic Error
RS-232 (optional RS-485)
57.6 Kbaud, DB-9 connector

12 Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
2.2. Approvals
This section presents Safety and Electromagnetic Compatibility (EMC) compliance
approvals for the Model 465M monitor.
2.2.1. Safety
IEC/EN 61010-1:2010 (3rd Edition), Safety requirements for
electrical equipment for measurement, control, and laboratory use.
CE: 2006/95/EC, Low-Voltage Directive
2.2.2. EMC
EN 61326-1 (IEC 61326-1), Class A Emissions/Industrial
Immunity
EN 55011 (CISPR 11), Group 1, Class A Emissions
FCC 47 CFR Part 15B, Class A Emissions
CE: 2004/108/EC, Electromagnetic Compatibility Directive
2.2.3. Other Type Certifications
For additional certifications, please contact Technical Support:
Toll-free: 800-324-5190
Phone: [phone]
Fax: [phone]
Email: [e-mail]

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual 13
3. PRINCIPLE OF OPERATION
The detection of ozone molecules is based on absorption of 254 nm UV light due to an
internal electronic resonance of the O3molecule. The 465M uses a mercury lamp
constructed so that a large majority of the light emitted is at the 254nm wavelength. Light
from the lamp shines through an absorption cell through which the sample gas is passed.
The ratio of the intensity of light passing through the absorption cell and the intensity of
light measured by a reference detector forms a ratio I/Io. This ratio forms the basis for the
calculation of the ozone concentration.
The Beer-Lambert equation, shown below, calculates the concentration of ozone from the
ratio of light intensities.
o
On
psi
L
CΙ
Ι
×
Ρ
×
Κ
Τ
×
×
−= 
695.14
273
106
3
α
Where:
I = Intensity of light passed through the sample
Io= Intensity of light through sample free of ozone
α
= absorption coefficient
L = path length
3
O
C
= concentration of ozone in parts per million
T
= sample temperature in Kelvin
P
= pressure in pounds per square inch (absolute)
As can be seen the concentration of ozone depends on more than the intensity ratio.
Temperature and pressure influence the density of the sample. The density changes the
number of ozone molecules in the absorption path 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 path length
determines how many molecules are present in the column of gas in the absorption tube.

14 Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
The intensity of light is converted into a voltage by the detector/preamp module. The
voltage is converted into a number by a high resolution A/D (analog-to-digital) converter.
The digitized signal, along with the other variables, is used by the CPU to compute the
concentration using the above formula.

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual 15
4. GETTING STARTED
WARNING! – RISK OF DEATH OR SERIOUS INJURY!
To reduce the risk of death or serious injury from a
chemical/combustion explosion hazard due to flammable
gases/vapors/liquids, never allow contaminants to enter
monitor during installation or use. The combination of ozone
and the catalytic ozone destruct media in the monitor can
produce strong oxidation reactions. Never allow organic
contaminants, including but not limited to peroxides and
chlorates, into monitor.
The 465M is shipped with the following standard equipment:
•Power cord (Rack mount version only)
•Instruction manual.
Upon receiving the 465M please do the following:
1. Verify that there is no apparent shipping damage. (If damage has occurred
please advise shipper first, then Teledyne API.)
4.1. Mechanical Installation (for NEMA 4X
Enclosure)
Mount the enclosure securely to a vertical surface.
•Figure 4-1 shows the locations of the four mounting holes, which are 0.32”
(8.128 mm) diameter.
•All four mounting holes should be used to secure the monitor.
•Use stainless steel, 5/16” (8 mm) diameter bolts.
4.1.1. Ventilation Clearance
When installing the 465M be sure to leave sufficient ventilation clearance.
Table 4-1: 465M Ventilation Clearances, NEMA Version
Area
Minimum required clearance
Back of the monitor
None
Sides of the monitor
1 inch
Above and below the monitor
1 inch

16 Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
Figure 4-1: 465M Mounting Hole Locations and Dimensions
4.2. Mechanical Installation (19” Rack Version)
The Rack Mount version of the 465M was designed to be operated as a bench-top
monitor or to be mounted in a standard 19” RETMA instrumentation rack. For rack
installations, the four mounting feet should be removed from the bottom of the monitor.
4.2.1. Ventilation Clearance
When installing the 465M be sure to leave sufficient ventilation clearance.
Table 4-2: 465M Ventilation Clearances, Rack Mount Version
Area
Minimum required clearance
Back of the monitor
3 inches
Sides of the monitor
1 inch
Above and below the monitor
1/2 inch

06160K DCN8017 Teledyne API Model 465M O3Monitor User Manual 17
4.3. AC Power Connection (for Monitors in
NEMA 4X Enclosures)
WARNING: Electrical Shock Hazard
Disconnect power to the AC mains before making or removing
any electrical connections to the 465M.
WARNING: Electrical Shock Hazard
A proper earth ground connection must be made to the
receptacle labeled “Earth Ground” on the 3 pin AC connector.
Failure to do so may result in a shock hazard and malfunction
of the monitor
4.3.1. Wiring Requirements for NEMA Enclosures
Use appropriate wiring rated for this type of equipment, ensuring that it meets local and
national safety and building requirements.
Ensure that overcurrent protection is used (a 5 A circuit breaker is recommended), and
that it fulfills the following requirements:
•be located as near to the instrument as possible
•quickly and easily accessible
•clearly labeled as the disconnecting device for this instrument
4.3.2. Wiring Instructions
1. Install a ½” conduit fitting for routing the electrical wiring into the monitor through
the hole provided in the bottom face of the NEMA enclosure; an appropriate sealed
conduit connector should be used.
2. Attach the leads of the power line to the AC power connector (see Figure 4-6).

18 Teledyne API Model 465M O3Monitor User Manual 06160K DCN8017
3. For the NEMA configuration, the electrical connection must be hard-wired to the 3-
pin connector on the mainboard labeled J23. AC power connection to the monitor
should be made with 12-14 AWG stranded copper wire, connected to the monitor as
follows:
a. Earth Ground (green):Connect the earth ground wire to the screw terminal lug on
the chassis as shown in the Figure below. Do not connect
the earth ground wire directly to the PCB connector on the
mainboard PCB.
b. Line (Black):Connect the Line wire to the connector on the mainboard
PCB labeled “Line”.
c. Neutral (White):Connect the Neutral wire to the connector on the
mainboard PCB labeled “Neutral”.
Figure 4-2. NEMA AC Power Connection to Monitor
4. Connect the power cord to an appropriate power outlet (see the serial number tag for
correct voltage and frequency).
WARNING: Electrical Shock Hazard
Verify that the instrument is set up for proper line voltage and
frequency. Observe local electrical codes when connecting
power to the monitor.