TELEDYNE API 480M User manual

User Manual
Model 480M
OZONE MONITOR
©Teledyne API (TAPI)
9970 Carroll Canyon Road
San Diego, CA 92131-1106
Toll-Free:
[phone]
Phone:
[phone]
Fax
[phone]
Email:
[e-mail]
Website:
http://www.teledyne-api.com
Copyright 2023 09420B DCN8501
Teledyne API 10 April 2023

THIS PAGE IS INTENTIONALLY LEFT BLANK

09420B DCN8501 Teledyne API Model 480M 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.

ii Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
CAUTION
This product should only be installed, commissioned, and used strictly for the
purpose and in the manner described in this manual. If you improperly install,
commission, or use this instrument in any manner other than as instructed in this
manual or by our Technical Support team, unpredictable behavior could ensue
with possible hazardous consequences.
Such risks, whether during installation and commission or caused by improper
installation/commissioning/use, and their possible hazardous outcomes include
but are not limited to:
RISK
HAZARD
Liquid or dust/debris ingress
Electrical shock hazard
Improper or worn power cable
Electrical shock or fire hazard
Excessive pressure from improper gas
bottle connections
Explosion and projectile hazard
Sampling combustible gas(es)
Explosion and fire hazard
Improper lift & carry techniques
Personal injury
Note that the safety of a system that may incorporate this product is the end
user’s responsibility.

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual iii
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.

iv Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
MISE EN GARDE
Ce produit ne doit être installé, mis en service et utilisé qu’aux fins et de la
manière décrites dans le présent manuel. Si vous installez, mettez en service ou
utilisez cet instrument de manière incorrecte autre que celle indiquée dans ce
manuel ou sous la direction de notre équipe de soutien technique, un
comportement imprévisible pourrait entraîner des conséquences potentiellement
dangereuses.
Ce qui suit est une liste, non exhaustive, des risques et résultats dangereux
possibles associés avec une mauvaise utilisation, une mise en service incorrecte,
ou causés mauvaise commission.
RISQUE
DANGER
Pénétration de liquide ou de
poussière/débris
Risque de choc électrique
Câble d’alimentation incorrect,
endommagés ou usé
Choc électrique ou risque d’incendie
Pression excessive due à des
connexions de bouteilles de gaz
incorrectes
Risque d’explosion et d’émission de
projectile
Échantillonnage de gaz combustibles
Risque d’explosion et d’incendie
Techniques de manutention,
soulevage et de transport
inappropriées
Blessure corporelle
Notez que la sécurité d’un système qui peut incorporer ce produit est la
responsabilité de l’utilisateur final.

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual v
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
www.teledyne-api.com).
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 on our website.
CAUTION – Avoid Warranty Invalidation
Failure to comply with proper anti
-Electro-Static Discharge (ESD)
handl
ing and packing instructions and Retu
rn Merchandise
Authorization (RMA) procedures when returning parts for repair or
calibration may void your warranty. For anti
-ESD handling and
packi
ng instructions please refer to the manual, Fundamentals of
ESD, PN 047
86, 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.

vi Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
ABOUT THIS MANUAL
We recommend that all users read this manual in its entirety before operating the
instrument.
CONVENTIONS USED
In addition to the safety symbols as presented in the Safety Messages page, this
manual provides special notices related to the careful and effective use of the
instrument and related, pertinent information.
ATTENTION COULD DAMAGE INSTRUMENT AND VOID WARRANTY
This special notice provides information to avoid damage
to your instrument and possibly invalidate the warranty.
Important IMPACT ON READINGS OR DATA
Provides information about that which could either affect
accuracy of instrument readings or cause loss of data.
Note
Provides information pertinent to the proper care,
operation or maintenance of the instrument or its parts.

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual vii
TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................11
2. SPECIFICATIONS AND AGENCY APPROVALS ................................................13
2.1. MODEL 480M SPECIFICATIONS..........................................................................................................13
2.2. COMPLIANCE AND CERTIFICATIONS...................................................................................................14
3. GETTING STARTED.................................................................................................15
3.1. UNPACKING .......................................................................................................................................16
3.2. MECHANICAL INSTALLATION ............................................................................................................16
3.3. AC POWER CONNECTION...................................................................................................................18
3.3.1. Wiring Requirements...................................................................................................................18
3.3.2. Wiring Instructions .....................................................................................................................19
3.4. ELECTRICAL I/O CONNECTIONS.........................................................................................................20
3.4.1. Analog Output.............................................................................................................................22
3.4.2. Status Outputs .............................................................................................................................23
3.4.3. High-Current Relay Outputs .......................................................................................................24
3.4.4. FailSafe Operation Signal And Relay Outputs............................................................................24
3.4.5. Digital Communication Interfaces..............................................................................................25
3.5. PNEUMATIC CONNECTIONS................................................................................................................26
3.5.1. Sample Inlet Connection .............................................................................................................26
3.5.2. Exhaust Connection ....................................................................................................................27
3.6. PNEUMATIC FLOW DIAGRAM.............................................................................................................28
4. CALIBRATION...........................................................................................................29
4.1. FACTORY CALIBRATION ....................................................................................................................29
4.2. ZERO,SPAN,AND FLOW CALIBRATIONS ............................................................................................29
5. OPERATION ...............................................................................................................31
5.1. FRONT PANEL OVERVIEW ..................................................................................................................31
5.1.1. Display ........................................................................................................................................32
5.1.2. Control Keys ...............................................................................................................................32
5.1.3. Indicator LEDs............................................................................................................................32
5.2. FRONT PANEL MENUS........................................................................................................................33
5.2.1. Editing Settings ...........................................................................................................................33
5.2.2. Sensor Menu................................................................................................................................34
5.2.3. Diag Menu ..................................................................................................................................34
5.2.4. Setup Menu..................................................................................................................................36
5.2.5. Status Screen...............................................................................................................................38
6. DIGITAL COMMUNICATIONS..............................................................................39
6.1. ETHERNET CONFIGURATION ..............................................................................................................39
6.2. SERIAL CONFIGURATION -RS-232 AND RS-485................................................................................40
6.3. MODBUS REGISTER MAPS...............................................................................................................42
6.3.1. MODBUS Commands Supported................................................................................................42
6.3.2. Notes on MODBUS registers ......................................................................................................42
6.3.3. Real-Time Concentration and Status Registers (Read Only) ......................................................43
6.3.4. Instrument Setup and Configuration Registers (Read / Write)....................................................44
7. MAINTENANCE.........................................................................................................45
7.1. MAINTENANCE SCHEDULE.................................................................................................................45
7.2. INSTRUMENT LAYOUT .......................................................................................................................46

viii Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
7.3. PNEUMATIC LEAK CHECK..................................................................................................................47
7.4. PARTICULATE FILTER REPLACEMENT ................................................................................................47
7.5. SAMPLE PUMP REPLACEMENT ...........................................................................................................48
7.6. AUTO-ZERO VALVE REPLACEMENT ..................................................................................................49
7.7. UV LED REPLACEMENT ....................................................................................................................50
7.8. SENSOR MODULE REPLACEMENT ......................................................................................................51
7.9. DISPLAY ASSEMBLY REPLACEMENT..................................................................................................53
7.10. CLEANING EXTERIOR SURFACES .....................................................................................................54
7.11. REMOVING/INSTALLING RELAY EXPANSION BOARD .......................................................................54
7.12. BOOT LOADER OPERATION ..............................................................................................................56
7.12.1. Boot Loader – Full Instrument Update .....................................................................................56
7.12.2. Boot Loader – Recovery Option................................................................................................62
8. TROUBLESHOOTING ..............................................................................................63
8.1. REFERENCE DRAWINGS .....................................................................................................................63
8.2. TROUBLESHOOTING USING FRONT PANEL STATUS LEDAND STATUS OUTPUTS...............................63
8.2.1. Sensor OK ...................................................................................................................................65
8.2.2. Invalid Reading...........................................................................................................................65
8.2.3. Check Lamp.................................................................................................................................65
8.2.4. Pneumatic Error .........................................................................................................................65
8.2.5. Technical Assistance ...................................................................................................................66
9. PRINCIPLES OF OPERATION................................................................................67

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual ix
FIGURES
Figure 3-1. Model 480M Display and Control Panel.....................................................................................15
Figure 3-2: 480M Mounting Hole Locations and Dimensions ......................................................................18
Figure 3-3. AC Power Connection to Monitor ..............................................................................................19
Figure 3-4. Interior Location of I/O Connectors............................................................................................21
Figure 3-5. Mainboard – Analog Output Configuration................................................................................23
Figure 3-6. Pneumatic Connections...............................................................................................................26
Figure 3-7. Pneumatic Diagram.....................................................................................................................28
Figure 5-1. Front Panel Display and Controls ...............................................................................................31
Figure 5-2. Front Panel Selection and Control Buttons.................................................................................32
Figure 6-1. RS-232/RS-485 Signal Configurations.......................................................................................41
Figure 7-1. Instrument Layout.......................................................................................................................46
Figure 7-2. Particulate Filter (PN 02832) Replacement ................................................................................48
Figure 7-3. J9 Pump Connector on Mainboard..............................................................................................49
Figure 7-4. O3Sensor Module Board ............................................................................................................50
Figure 7-5. UV LED Access..........................................................................................................................51
Figure 7-6. Sensor Module Removal.............................................................................................................52
Figure 7-7. Display Assembly Removal........................................................................................................54
Figure 7-8. Relay Board Removal .................................................................................................................55
Figure 7-9. J7 Bootload Configuration..........................................................................................................56
Figure 8-1. Display and Control Panel ..........................................................................................................63
Figure 8-2. Status Outputs .............................................................................................................................64

x Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
TABLES
Table 3-1. Status Output Definitions .............................................................................................................24
Table 3-2. Relay Functions............................................................................................................................24
Table 5-1. Menu Structure.............................................................................................................................33
Table 5-2. Sensor Menu Parameters ..............................................................................................................34
Table 5-3. Analog Step Test Values ..............................................................................................................34
Table 5-4. VARS List ....................................................................................................................................36
Table 5-5. Alarm Configuration Settings ......................................................................................................37
Table 6-1. RS-232/RS-485 Port Setup...........................................................................................................40
Table 7-1. Maintenance Schedule..................................................................................................................45
Table 8-1. Status LED/Output Definitions ....................................................................................................64

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual 11
1. INTRODUCTION
Teledyne API’s Model 480M Ozone Monitor is a medium range ozone monitor that
measures process ozone concentrations and is specifically optimized for
applications requiring the ozone measurement at near-ambient pressure. This
microprocessor-controlled instrument provides fast response times with minimal
zero drift for accurate and stable readings, 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 team are always available to answer your questions.
Teledyne API, Technical Support,
9970 Carroll Canyon Road
San Diego, California 92131-1106 USA
Toll-free: [phone]
Phone:
[phone]
Fax: [phone]
Email:
[e-mail]
Website: http://www.teledyne-api.com

12 Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
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09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual 13
2. SPECIFICATIONS AND AGENCY APPROVALS
2.1. MODEL 480M SPECIFICATIONS
PARAMETER
SPECIFICATION
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/Nm
3
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)
NEMA 4X – 17.15” x 15.96” x 6.80”
(435.7 mm x 405.4 mm x 172.7 mm)
Weight
NEMA 4X – 17.6 lbs (8 kg)
Power
100-240 V~, 47-63 Hz, 74 W
Environmental
Installation Category II
Pollution Degree 2
For Indoor/Outdoor Use
Maximum Operating Altitude 2000 meters
Degree of Protection
IP65 (NEMA 4X)
Analog Output
0 – 5 V or 4-20 mA isolated output
Isolated Digital Status Outputs
Sensor OK, Invalid Reading, Check Lamp, Pneumatic
Error
24 VDC, 30mA per output Max
High Current Relay Outputs
SPDT (Form C) Dry Contact, 250VAC, 5A
(System OK, Global HI alarm, Global HI-HI alarm)
Communication Interface
Ethernet
RS-232 / RS-485

14 Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
2.2. COMPLIANCE AND CERTIFICATIONS
This product is CE compliant and adheres to the Low Voltage and ElectroMagnetic
Compatibility directives.
For any other certifications, please refer to this product’s specifications sheet on our
website.

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual 15
3. 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.
Figure 3-1. Model 480M Display and Control Panel

16 Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
3.1. UNPACKING
Upon receiving the 480M please verify that there is no apparent shipping damage.
(If damage has occurred please advise shipper first, then Teledyne API).
Check your packing slip for options that may be included, depending on your order,
e.g., disposable sample inlet filters.
3.2. MECHANICAL INSTALLATION
ATTENTION
COULD DAMAGE INSTRUMENT AND VOID WARRANTY
Locate the monitor in a suitable environment that protects
it from excessive heat, such as direct sunlight or near
heat-generating machinery.
When installing the monitor be sure to leave sufficient clearance on sides, top, and
bottom for adequate ventilation and for access to make/adjust all connections. The
monitor must be mounted securely with four (4) bolts or anchors to a vertical
structure or wall capable of supporting 80 lbs. The mounting bolts or anchors must
be capable of supporting 20 lbs each. If using wall anchors, they must be suitable
for the type of wall construction and installed per the manufacturer’s specifications.
•The illustrations in Figure 3-2 show the mounting dimensions and the sizes
and 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.
•If using bolts, ensure they are stainless steel, 5/16” (8 mm) diameter, capable
of supporting 20 lbs each.

09420B DCN8501 Teledyne API Model 480M O3Monitor User Manual 17

18 Teledyne API Model 480M O3Monitor User Manual 09420B DCN8501
Figure 3-2: 480M Mounting Hole Locations and Dimensions
3.3. AC POWER CONNECTION
WARNING – Electrical Shock Hazard
Disconnect power to the AC mains before making or removing any electrical
connections to the monitor.
A proper earth ground connection must be made to the copper lug with the
ground symbol on the chassis. Failure to do so may result in a shock hazard
and malfunction of the monitor.
3.3.1. WIRING REQUIREMENTS
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 on AC mains connections (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