Teledyne Car Video System 460L User Manual
INSTRUCTION MANUAL  
MODEL 460L  
Nema Ozone Monitor  
9480 CARROLL PARK DRIVE  
SAN DIEGO, CA 92121-5201  
USA  
Toll-free Phone: 800-324-5190  
Phone: 858-657-9800  
Fax: 858-657-9816  
Email: [email protected]  
Website: http://www.teledyne-api.com/  
05012 REV. D  
DCN 5164  
© 2008 T-API  
22 January 2009  
PRINT DATE: 19 February 2009  
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TELEDYNE INSTRUMENTS  
460L Instruction Manual  
Safety Messages  
SAFETY MESSAGES  
Your safety and the safety of others is very important. We have provided many important safety  
messages in this manual. Please read these messages carefully.  
A safety message alerts you to potential hazards that could hurt you or others. Each safety  
message is associated with a safety alert symbol. These symbols may be found in the manual and  
inside the monitor. The definition of these symbols is described below:  
GENERAL SAFETY HAZARD: Refer to the instructions for details on the  
specific hazard.  
CAUTION: Hot Surface Warning  
CAUTION: Electrical Shock Hazard  
TECHNICIAN SYMBOL: All operations marked with this symbol are to  
be performed by qualified maintenance personnel only.  
CAUTION  
The monitor should only be used for the purpose and in the manner described in this  
manual. If you use the monitor in a manner other than that for which it was intended,  
unpredictable behavior could ensue with possible hazardous consequences.  
NOTE  
Technical Assistance regarding the use and maintenance of the Model 460L Nema Ozone  
Monitor or any other Teledyne Instruments product can be obtained by:  
Contacting Teledyne Instruments’ Customer Service Department at 800-324-5190  
or  
Via the internet at http://www.teledyne-api.com/inquiries.asp  
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460L Instruction Manual  
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TELEDYNE INSTRUMENTS  
460L Instruction Manual  
Table of Contents  
TABLE OF CONTENTS  
1. INTRODUCTION........................................................................................................................... 1  
1.1. Preface ..................................................................................................................................1  
1.2. 460L Documentation................................................................................................................1  
1.3. Using This Manual ...................................................................................................................2  
2. SPECIFICATIONS AND WARRANTY .............................................................................................. 5  
2.1. Specifications .........................................................................................................................5  
2.2. Warranty................................................................................................................................6  
3. GETTING STARTED....................................................................................................................... 7  
3.1. Unpacking..............................................................................................................................7  
3.2. Mechanical Installation.............................................................................................................9  
3.3. Pneumatic Connections ..........................................................................................................10  
3.4. Electrical Connections ............................................................................................................12  
3.4.1. AC Power Connection.......................................................................................................12  
3.5. Signal I/O Connections...........................................................................................................13  
3.5.1. Analog Output ................................................................................................................13  
3.5.2. Digital Status Outputs......................................................................................................14  
3.5.3. Control Inputs ................................................................................................................15  
3.5.4. Relay Outputs.................................................................................................................15  
3.6. Initial Startup .......................................................................................................................17  
3.7. Setting up the Serial Communications Port................................................................................17  
3.7.1. Physical Serial Port Configuration ......................................................................................18  
3.7.2. Software Setup for Serial Port Communications...................................................................19  
4. FREQUENTLY ASKED QUESTIONS................................................................................................21  
5. OPTIONAL HARDWARE AND SOFTWARE .....................................................................................23  
5.1. Sample Conditioning System...................................................................................................23  
5.2. Current Loop Analog Output....................................................................................................23  
5.3. Ozone Destruct Option...........................................................................................................23  
6. OPERATING INSTRUCTIONS .......................................................................................................25  
6.1. Front Panel Display................................................................................................................25  
6.1.1. O readout ....................................................................................................................25  
3
6.1.2. Zero Point Calibration......................................................................................................25  
6.1.3. Status LED’s...................................................................................................................25  
6.2. Concentration Alarms.............................................................................................................26  
6.2.1.1. Concentration Alarm Configuration..............................................................................26  
6.2.1.2. Remotely Sensing the Status of the Alarm....................................................................26  
6.2.1.3. Clearing Alarms........................................................................................................26  
7. SERIAL COMMUNICATIONS.........................................................................................................27  
7.1. Serial Port Command Syntax...................................................................................................27  
7.2. Serial Port Command Summary...............................................................................................28  
7.3. Serial Port Command Reference ..............................................................................................29  
7.3.1. ALMACK.........................................................................................................................29  
7.3.2. ALMSTAT.......................................................................................................................30  
7.3.3. CZERO ..........................................................................................................................31  
7.3.4. DACSTEP.......................................................................................................................32  
7.3.5. O3.................................................................................................................................33  
7.3.6. SETADDR.......................................................................................................................34  
7.3.7. TDUMP ..........................................................................................................................35  
7.3.8. TLIST............................................................................................................................36  
7.3.9. VGET ............................................................................................................................37  
7.3.10. VLIST..........................................................................................................................38  
7.3.11. VSET...........................................................................................................................39  
8. CALIBRATION.............................................................................................................................41  
8.1. Zero Point calibration.............................................................................................................41  
8.2. Span Point Calibration............................................................................................................41  
8.3. Adjusting the Optional Current Loop Output ..............................................................................43  
9. MAINTENANCE:...........................................................................................................................45  
9.1. Replacing the Particulate Filter Element ....................................................................................45  
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460L Instruction Manual  
9.1.1. Filter Replacement Procedure............................................................................................45  
9.1.2. Mounting the Particulate Filter Externally............................................................................46  
9.2. Maintaining the Optional H2O Coalescing Filter...........................................................................47  
9.2.1. Draining the Optional Coalescing Filter ...............................................................................47  
9.2.2. Replacing the Coalescing Membrane ..................................................................................48  
9.3. UV Lamp Replacement ...........................................................................................................49  
9.4. Cleaning Exterior Surfaces of the 460L .....................................................................................50  
9.5. Degree of Protection..............................................................................................................50  
10. THEORY OF OPERATION............................................................................................................51  
10.1. Basic O3 Measurement Principle .............................................................................................51  
10.1.1. (Beer’s Law).................................................................................................................51  
10.1.2. The Absorption Path ......................................................................................................52  
10.1.3. The Reference / Measurement Cycle ................................................................................53  
10.1.4. Digital Noise Filter.........................................................................................................54  
10.2. Pneumatic Theory of Operation..............................................................................................55  
10.2.1. Basic Pneumatic Flow And Flow Control ............................................................................55  
10.2.2. Internal Pump and Flow Control.......................................................................................55  
10.2.3. Optional Sample Conditioning .........................................................................................56  
10.2.3.1. H2O Coalescing Filter...............................................................................................56  
10.2.3.2. H2O Vapor Dryer.....................................................................................................56  
10.2.3.3. Ozone Destruct Scrubber .........................................................................................57  
10.3. Electronic Theory of Operation...............................................................................................58  
10.3.1. Main Board...................................................................................................................58  
10.3.2. O3 Sensor Module..........................................................................................................59  
10.3.2.1. O3 Sensor Components............................................................................................59  
10.3.2.2. Sensor Module PCA .................................................................................................60  
10.3.3. CPU Board....................................................................................................................61  
10.3.3.1. I/O Functions .........................................................................................................61  
10.3.3.2. Status and Alarm Functions......................................................................................61  
10.3.4. Display Driver and Keyboard Assembly.............................................................................62  
10.3.4.1. Keyboard...............................................................................................................62  
10.3.4.2. Display..................................................................................................................62  
10.3.4.3. Display Driver ........................................................................................................62  
10.3.5. Power Distribution.........................................................................................................63  
11. TROUBLESHOOTING..................................................................................................................65  
11.1. Status Output Summary.......................................................................................................65  
11.2. Troubleshooting Using Status Outputs ....................................................................................65  
11.2.1. Sensor OK....................................................................................................................65  
11.2.2. Invalid Reading.............................................................................................................66  
11.2.3. Lamp Low ....................................................................................................................66  
11.2.4. Status LED / Status Output Troubleshooting Summary .......................................................66  
11.3. Concentration Alarm Outputs.................................................................................................67  
11.4. Technical Assistance ............................................................................................................68  
12. A PRIMER ON ELECTRO-STATIC DISCHARGE.............................................................................69  
12.1. How Static Charges are Created.............................................................................................69  
12.2. How Electro-Static Charges Cause Damage .............................................................................70  
12.3. Common Myths About ESD Damage .......................................................................................71  
12.4. Basic Principles of Static Control ............................................................................................72  
12.4.1. General Rules ...............................................................................................................72  
12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ..........................................73  
12.4.2.1. Working at the Instrument Rack................................................................................73  
12.4.2.2. Working at an Anti-ESD Work Bench..........................................................................73  
12.4.2.3. Transferring Components from Rack to Bench and Back................................................74  
12.4.2.4. Opening Shipments from Teledyne Instruments’ Customer Service.................................75  
12.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service ...................76  
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460L Instruction Manual  
Table of Contents  
List of Figures  
Figure 3-1  
Figure 3-2  
Figure 3-3  
Figure 3-4  
Figure 3-5  
Figure 3-6  
Figure 3-7  
Figure 3-8  
Figure 3-9  
Figure 3-10  
Figure 3-11  
Figure 3-12  
Figure 8-1  
Figure 8-2  
Figure 9-1  
Figure 9-2  
Figure 9-3  
Figure 9-4  
Figure 9-5  
Figure 10-1  
Figure 10-2  
Figure 10-3  
Figure 10-4  
Figure 10-5  
Figure 10-6  
Figure 12-1  
Figure 12-2  
M460L Front Cover Layout.............................................................................7  
460L Layout ................................................................................................8  
460L Sensor Module Layout ...........................................................................9  
460L Mounting Hole Locations and Dimensions ............................................... 10  
460L Pneumatic Connections........................................................................ 11  
Location of Electrical Connectors................................................................... 12  
Signal I/O Connector Pin Assignments........................................................... 13  
Digital Status Output Connections................................................................. 14  
Control Input Connections ........................................................................... 15  
Alarm Output Relays................................................................................... 16  
RS-232/RS-485 Jumper Location and Settings................................................ 18  
Typical RS-232 and RS-485 Connections........................................................ 19  
Setup for Measuring Current Output Signal Level ............................................ 43  
Location Current Output Adjustment Potentiometers ....................................... 44  
Changing the Particulate Filter...................................................................... 45  
Changing the Particulate Filter...................................................................... 46  
Draining the Optional H2O Coalescing filter..................................................... 47  
Replacing the Membrane of the Optional H2O Coalescing filter........................... 48  
UV Lamp Set Screws and Calibration Test Points............................................. 49  
O3 Absorption Path ..................................................................................... 53  
Reference / Measurement Gas Cycle ............................................................. 53  
460L Internal Pneumatic Diagram – Basic Configuration................................... 55  
460L Internal Pneumatic Diagram with Optional Sample Conditioning ................ 56  
460L Electronic Block Diagram ..................................................................... 58  
460L Power Distribution Block Diagram ......................................................... 63  
Triboelectric Charging ................................................................................. 69  
Basic anti-ESD Workbench........................................................................... 72  
LIST OF TABLES  
Table 2-1  
Table 3-1  
Table 3-2  
Table 3-3  
Table 3-4  
Table 3-5  
Table 3-6  
Table 6-1  
Table 6-2  
Table 7-1  
Table 7-2  
Table 7-3  
Table 10-1  
Table 11-1  
Table 11-2  
Table 11-3  
Table 12-1  
Table 12-2  
460L Specifications.......................................................................................5  
460L Ventilation Clearances......................................................................... 10  
Digital Status Output Descriptions................................................................. 14  
Control Inputs............................................................................................ 15  
Relay Output Operation............................................................................... 16  
Serial I/O Port Connection ........................................................................... 17  
Serial Port Configuration.............................................................................. 20  
Status LED’s.............................................................................................. 25  
Concentration Alarm Default Settings............................................................ 26  
Serial Port Command Summary.................................................................... 28  
VAR_INDEX List for VGET Command ............................................................. 37  
VAR_INDEX List for VSET Command.............................................................. 39  
Measurement / Reference Cycle.................................................................... 54  
Digital Status Outputs Definitions ................................................................. 65  
Status LED / Output Trouble shooting Truth Table........................................... 67  
Alarm Output Troubleshooting...................................................................... 67  
Static Generation Voltages for Typical Activities.............................................. 70  
Sensitivity of Electronic Devices to Damage by ESD......................................... 70  
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TELEDYNE INSTRUMENTS  
Table of Contents  
460L Instruction Manual  
LIST OF APPENDICES  
Appendix A – Spare Parts List  
Appendix B – List of Schematics  
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TELEDYNE INSTRUMENTS  
460L Instruction Manual  
Introduction  
1. INTRODUCTION  
1.1. Preface  
Teledyne Instruments is pleased that you have purchased the Model 460L NEMA Ozone Monitor.  
Included is a full one-year warranty (see Section 2.2) and we at Teledyne Instruments will be  
pleased to provide you with any support required so that you may utilize our equipment to the  
fullest extent.  
The Model 460L is a microprocessor based low range ozone monitor for safety monitoring of ozone  
levels in a variety of applications such as water treatment, food processing, and research. The  
design has been specifically optimized for applications requiring the measurement of ozone at the  
typically low concentration levels encountered when tracking ambient conditions. The Model 460L  
has been designed to give accurate and stable readings over long time periods with little or no  
maintenance or calibration.  
The flexibility of the software as well as the analog and digital I/O allow the Model 460L to  
interface with a broad range of devices for process control and data logging.  
We hope you will not experience any problems with the Teledyne Instruments Model 460L but if  
you do, our full time customer service department is always available to answer your questions.  
1.2. 460L Documentation  
The documentation for this monitor is available in several different formats:  
Printed format, part number 050120100  
Electronic format on a CD-ROM, part number 050120200  
The electronic manual is in Adobe® Systems Inc. “Portable Document Format”. The Adobe®  
Acrobat Reader® software, which is necessary to view these files, can be downloaded for free from  
the Internet at http://www.adobe.com/.  
The electronic version of the manual has many advantages:  
Keyword and phrase search feature  
Figures, tables and internet addresses are linked so that clicking on the item will display  
the associated feature or open the website.  
A list of chapters and sections as well as thumbnails of each page are displayed to the left  
of the text.  
Entries in the table of contents are linked to the corresponding locations in the manual.  
Ability to print sections (or all) of the manual  
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TELEDYNE INSTRUMENTS  
Introduction  
460L Instruction Manual  
1.3. Using This Manual  
This manual has the following data structures:  
1.0 Table of Contents:  
Outlines the contents of the manual in the order the information is presented. This is a good  
overview of the topics covered in the manual. There is also a list of tables, a list of figures and a  
list of appendices. In the electronic version of the manual, clicking on any of these table entries  
automatically views that section.  
2.0 Specifications and Warranty  
This section contains a list of the monitor’s performance specifications, a description of the  
conditions and configuration under which Teledyne Instruments Incorporated warranty statement  
applies.  
3.0 Getting Started:  
A concise set of instructions for setting up, installing and starting your monitor for the first time.  
This includes unpacking; mechanical installation; attaching all pneumatic lines; attaching all  
electrical and electronic connections and the physical configuration the RS-232/RS-485 port.  
4.0 FAQ:  
Answers to the most frequently asked questions about operating the monitor.  
5.0 Optional Hardware & Software  
A description of optional equipment to add functionality to your monitor.  
6.0 Operation Instructions  
Instructions for operating the monitor and using its basic features and functions.  
7.0 Serial Communications  
Information regarding the syntax and command definitions for the monitor’s serial I/O interface.  
8.0 Calibration Procedures  
General information and step-by-step instructions for manually calibrating your monitor.  
9.0 Monitor Maintenance  
Description of certain preventative maintenance procedures that should be regularly performed on  
your monitor to keep it in good operating condition.  
10.0 Theory of Operation  
An in-depth look at the various principals by which your monitor operates as well as a description  
of how the various electronic, mechanical and pneumatic components of the monitor work and  
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460L Instruction Manual  
Introduction  
interact with each other. A close reading of this section is invaluable for understanding the  
monitor’s operation.  
11.0 Troubleshooting Section:  
This section includes pointers and instructions for diagnosing problems with the monitor, such as  
excessive noise or drift, as well as instructions on performing repairs of the monitor’s major  
subsystems.  
12.0 Electro-Static Discharge (ESD) Primer:  
This section describes how static electricity occurs; why it is a significant concern and how to  
avoid it and; how to avoid allowing ESD to affect the reliable and accurate operation of your  
monitor.  
USER NOTES:  
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Introduction  
460L Instruction Manual  
USER NOTES:  
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460L Instruction Manual  
Specifications and Warranty  
2. SPECIFICATIONS AND WARRANTY  
2.1. Specifications  
Table 2-1 460L Specifications  
Measurement Principle  
Ranges  
UV Absorption (Beer Lambert Law)  
1ppm to 500 ppm: User selectable  
ppm; ppb  
Measurement Units  
Accuracy  
1% of Full Scale  
Zero Noise  
< 0.0015 ppm (rms)  
Span Noise  
< 0.5% of reading (rms) (above 0.1 ppm)  
< 0.003 ppm (rms)  
Lower Detectable Limit  
Linearity  
Better than 1% of selected range  
<30 sec  
Response Time (95%)  
Repeatability  
0.5% of selected range  
0001 ppm, 1 ppb  
Display Resolution  
Gas Flow Rate  
1.0-2.0 LPM  
Compensation  
Pressure, Temperature (NTP = 273.15K, 760mmHg)  
11.0 – 16.0 psia  
Gas Inlet Pressure Range  
Temperature Range  
Humidity Range  
Dimensions (H x W x D)  
5-45 ˚C  
10-90% RH, Non-Condensing  
12.64" x 11.19" x 6.08"  
(321mm x 284mm x 154mm)  
Weight  
9.40lb (4.27kg)  
Power  
110-240V~, 50/60Hz, 200 VA  
Environmental Conditions  
Installation Category (Over Voltage Category) II  
Pollution Degree 2  
Maximum Operating Altitude  
Analog Voltage Output  
2000 meters  
Single output: 0-5V,  
Option available converting voltage output to 4-20mA output  
with maximum voltage between outputs and ground 60V peak  
Relay Outputs  
3 relay outputs: Sensor OK and two concentration alarms (HI &  
Hi-Hi)  
Relay type & Output Rating  
SPDT: 250V AC, 3A  
IP65 (NEMA 4X)  
Degree of Protection (IP Code)  
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Specifications and Warranty  
460L Instruction Manual  
2.2. Warranty  
WARRANTY POLICY (02024D)  
Prior to shipment, T-API equipment is thoroughly inspected and tested. Should equipment failure  
occur, T-API assures its customers that prompt service and support will be available.  
COVERAGE  
After the warranty period and throughout the equipment lifetime, T-API stands ready to provide  
on-site or in-plant service at reasonable rates similar to those of other manufacturers in the  
industry. All maintenance and the first level of field troubleshooting is to be performed by the  
customer.  
NON-API MANUFACTURED EQUIPMENT  
Equipment provided but not manufactured by T-API is warranted and will be repaired to the  
extent and according to the current terms and conditions of the respective equipment  
manufacturers warranty.  
GENERAL  
During the warranty period, T-API warrants each Product manufactured by T-API to be free from  
defects in material and workmanship under normal use and service. Expendable parts are  
excluded.  
If a Product fails to conform to its specifications within the warranty period, API shall correct such  
defect by, in API's discretion, repairing or replacing such defective Product or refunding the  
purchase price of such Product.  
The warranties set forth in this section shall be of no force or effect with respect to any Product:  
(i) that has been altered or subjected to misuse, negligence or accident, or (ii) that has been used  
in any manner other than in accordance with the instruction provided by T-API, or (iii) not  
properly maintained.  
THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE  
EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR  
PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED.  
THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF  
ANY WARRANTY CONTAINED HEREIN. API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR  
CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF T-API'S  
PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE  
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460L Instruction Manual  
Getting Started  
3. GETTING STARTED  
3.1. Unpacking  
1. Inspect the received packages for external shipping damage. If damaged, please advise  
the shipper first, then Teledyne Instruments.  
2. Loosen the 2 setscrews located in the top and bottom left corners of the front and swing  
open the cover.  
Set Screw  
O3 Concentration  
Display  
SYSTEM OK  
Status  
INVALID READING  
LAMP LOW  
LED’s  
ALARM ACTIVE  
ZERO  
Buttons  
Ozone Monitor – Model 460L  
Alarm  
Acknowledge  
Key  
Gas  
Flowmeter  
&
Control  
Set Screw  
Figure 3-1 M460L Front Cover Layout  
3. Inspect the interior of the monitor to make sure all circuit boards and other components  
are in good shape and properly seated.  
NOTE  
Printed circuit assemblies (PCAs) are static sensitive. Electro-static discharges (ESD),  
too small to be felt by the human nervous system, are large enough to destroy sensitive  
circuits.  
Before touching PCAs, read Chapter 12 of this manual and follow the procedure  
described there for avoiding damage to your monitor due to ESD.  
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Getting Started  
460L Instruction Manual  
CAUTION  
Never disconnect electronic circuit boards, wiring harnesses or  
electronic subassemblies while the unit is under power.  
4. Check the connectors of the various internal wiring harnesses and pneumatic hoses to  
make sure they are firmly and properly seated (see Figure 3-2).  
5. Verify that all of the optional hardware ordered with the unit has been installed. These are  
listed on the paperwork accompanying the monitor.  
CPU  
Board  
Analog Relay H2O Vapor Dryer  
(optional)  
Outputs  
Optional  
Ozone  
Scrubber  
Not Shown  
Signal I/O  
Connector  
Main  
Board  
AC Power  
Input  
Connector  
Display  
Board  
Flow Meter  
Sensor Module  
H2O  
Coalescing  
Filter  
(optional)  
Main  
Power  
Supply  
Particulate  
Filter  
Pump  
Ozone  
Inlet  
Exhaust  
Outlet  
Figure 3-2 460L Layout  
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460L Instruction Manual  
Getting Started  
UV  
Lamp  
UV Lamp  
Housing  
UV Lamp  
Power Connector  
Ozone Outlet  
Manifold  
UV Lamp  
Power Supply  
Reference  
Scrubber  
Absorption  
Tube  
Sensor  
Module PCA  
Ozone Intlet  
Manifold  
Measure / Reference  
Valve  
UV  
Detector  
Figure 3-3 460L Sensor Module Layout  
3.2. Mechanical Installation  
Mount the enclosure securely to a vertical surface.  
Figure 3-4 below shows the locations of the four mounting holes.  
All four mounting holes should be used to secure the monitor.  
Use stainless steel, 5/16” diameter bolts.  
VENTILATION CLEARANCE:  
When installing the monitor be sure to leave sufficient ventilation clearance.  
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Getting Started  
460L Instruction Manual  
Table 3-1  
460L Ventilation Clearances  
AREA  
MINIMUM REQUIRED CLEARANCE  
1 inch  
1 inch  
Sides of the monitor  
Above and below the monitor.  
Figure 3-4 460L Mounting Hole Locations and Dimensions  
3.3. Pneumatic Connections  
1. Connect a ¼” exhaust line to the fitting labeled ‘Exhaust.’  
CAUTION  
If using the 460L to measure O3 levels that are ≥100 ppb exhaust gas  
from the MODEL 460L may contain dangerous levels of ozone!  
The optional ozone destruct (see Section 5.3) should be installed  
and  
Make sure that the exhaust line is vented to an outside area.  
2. Connect the ozone delivery line to the ¼” inlet fitting labeled “Ozone Inlet” on the bottom  
face of the enclosure (See Figure 3-5.)  
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NOTE  
The ozone delivery pressure should be at ambient pressure +/- 5 PSIG.  
All tubing used should be made of ozone resistant material such as Stainless Steel, PTFE  
(Teflon) or FEP. API can supply appropriate tubing for connecting the ozone supply  
line.  
Display  
Ozone  
Scrubber  
(optional)  
Gas  
Flowmeter  
&
Coalescence  
Control  
Filter  
(optional)  
OZONE INLET  
EXHAUST  
OUTLET  
Install AC  
Power Cord  
Through Here  
Figure 3-5 460L Pneumatic Connections  
The gas flow rate through the monitor should be established between 1.0 and 2.0 L/min.  
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3.4. Electrical Connections  
NOTE  
It is recommended that if multi-strand wires are used for the following electrical  
connections. To ensure a reliable connection the wires should be:  
“Tinned” with solder or;  
Terminated with insulated crimped ferrules, such as Entrelec® P/N 304.456.02  
(18 gauge) or 304.558.10 (22 gauge)  
3.4.1. AC Power Connection  
CAUTION  
Disconnect power to the AC mains before making or removing any  
electrical connections to the 460L.  
CAUTION  
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  
Connect AC power to the monitor.  
3. Install a ½” conduit fitting for routing the electrical wiring into the monitor through the  
hole provided (see Figure 3-5). In order to maintain the IP (NEMA4X) rating of the  
enclosure, an appropriate sealed conduit connector should be used.  
4. Attach the leads of the power line to the AC power connector (see Figure 3-6)  
Analog and  
Digital I/O  
Connector  
Relay  
Outputs &  
Connectors  
Ground  
AC Line  
AC Neutral  
AC POWER  
Connector  
Figure 3-6 Location of Electrical Connectors  
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3.5. Signal I/O Connections  
All digital and analog signal I/O connections are made via a 16-pin connector on the main board  
(See Figure 3-6 for the location of the connector.)  
This connector can be unplugged from the header on the main board for easier access when  
wiring. To disconnect from main board, loosen the two retaining screws at either end of the  
connector.  
Retaining Screw  
Analog Out +  
Analog Out -  
Zero Input  
Aux Input  
Gnd  
Status Out 1  
Status Out 2  
Status Out 3  
Status Out 4  
Status Com  
Serial TX  
Serial RX  
Serial GND  
Status Out 5  
Status Out 6  
Retaining Screw  
Figure 3-7 Signal I/O Connector Pin Assignments  
3.5.1. Analog Output  
The 460L is equipped with one analog output that is factory configurable as either a 0-5 VDC  
signal or a 4-20 mA signal. You may verify how your 460L is set up by checking the information  
on the monitor’s serial number tag.  
The analog output requires two connections: ANALOG +, the signal line, and ANALOG–, the  
ground connection. See Figure 3-7 for the locations of the ANALOG OUT + and ANALOG OUT–  
pins.  
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3.5.2. Digital Status Outputs  
The 460L has six assigned digital status outputs for indicating error and operational status  
conditions of the monitor as well as the status of its O3 concentration alarms (see Table 3-2).  
These outputs are in the form of opto-isolated open-collector transistors. They can be used to  
drive status LED’s on a display panel or interface to a digital device such as a Programmable Logic  
Controller (PLC). Several of the status outputs are useful tools for diagnosing sensor and system  
level malfunctions (see Section 11.2 for more information).  
Table 3-2 Digital Status Output Descriptions  
LABEL1  
NAME  
Sensor O.K.  
OPERATION  
Normally On  
Normally Off  
Normally Off  
Normally Off  
Normally Off  
Normally Off  
N/A  
STATUS OUT 12  
STATUS OUT 22  
STATUS OUT 32  
STATUS OUT 4  
STATUS OUT 5  
STATUS OUT 6  
STATUS COM  
Invalid Reading  
Lamp Low  
Alarm Active  
HI Alarm Status  
HI-HI Alarm Status  
Common Pin for all Status Outputs  
1
2
See Figure 3-7 for pin locations of the these output lines on the monitor’s 16-pin I/O  
connector  
See Section 11-2 for definitions and interpretations of these output.  
Figure 3-8 shows the most common way of connecting the digital outputs to an external device  
such as PLC.  
460M  
PLC OR OTHER DEVICE  
+5V  
Status Outputs 1-6 (Collector)  
STATUS COM (Emitter)  
Digital Input  
Opto-Isolator  
Figure 3-8 Digital Status Output Connections  
Note  
Most devices, such as PLC’s, have internal provision for limiting the current that the  
input will draw from an external device.  
When connecting to a unit that does not have this feature, external dropping-resistors  
must be used to limit the current through the transistor output to 50mA or less.  
At 50 mA, the transistor will drop approximately 0.2V from its collector to emitter.  
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3.5.3. Control Inputs  
Two digital control inputs are also available for use on the 460L. The control inputs are used for  
remote control of the 460L by a device such as a PLC. They are labeled ZERO INPUT and AUX  
INPUT (see Figure 3-9).  
Table 3-3 Control Inputs  
INPUT  
DESCRIPTION  
ZERO INPUT  
AUX INPUT  
This input performs exactly the same function as the ‘Zero’ buttons on the front panel.  
This input can be used to clear active concentration alarms in similar fashion as the serial  
communications ALMACK.  
Signal I/O  
Connector  
Analog Out +  
Analog Out -  
Zero Input  
Aux Input (AlmAck)  
Gnd  
Figure 3-9 Control Input Connections  
NOTE:  
Never connect a voltage level output from another device to these contacts.  
3.5.4. Relay Outputs  
The 460L is equipped with three SPDT relays. They are located at the top right hand side of the  
main board and are labeled RELAY 1, RELAY 2 & RELAY 3.  
RELAY 1 corresponds to the Sensor OK status output and LED;  
RELAY 2 corresponds to the HI concentration alarm, and;  
RELAY 3 corresponds to the HI-HI concentration alarm  
See Section 11.2.1 for more information on the Sensor OK status output.  
See Section 6.2 for more information on these alarms.  
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Below each relay is a 3-pin connector that allows the relay to be connected for either  
normally open or normally closed operation.  
Table 3-4 describes how to connect the alarm relays.  
NOTE  
The relay contacts are rated to 3A at 240VAC. Do not exceed these ratings when  
connecting equipment to the instrument.  
RELAY 1  
RELAY 2  
RELAY 3  
D6  
D7  
D8  
STATUS LEDS  
Figure 3-10 Alarm Output Relays  
Table 3-4 Relay Output Operation  
RELAY PIN  
STATE2  
STATUS  
RELAY  
FUNCTION  
COMMENTS  
LED1  
C
O
M
N.  
O.  
N.  
C.  
D6 ON  
460L is operating normally  
SENSOR OK ON  
1
Problem with the O3 sensor module.  
See Section 11.2.  
D6 OFF  
SENSOR OK OFF  
D7 ON  
O3 concentration > HI alarm limit  
O3 concentration < HI alarm limit  
HI Alarm ON  
2
3
D7 OFF  
HI Alarm OFF  
D8 ON  
O3 concentration > HI-HI alarm limit  
O3 concentration < HI-HI alarm limit  
HI-HI Alarm ON  
D8 OFF  
HI-HI Alarm OFF  
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1
Located just below each relay connector (see Figure 3-10)  
N.O. = Normally Open operation.  
2
N.C. = Normally Closed operation.  
3.6. Initial Startup  
Perform the following steps when initially starting up the 460L or when bringing the monitor back  
into service it has been shut down for repair or maintenance.  
1. Turn on power to the monitor.  
The display will briefly display the “API” logo followed by the software version.  
The display will then begin showing ozone concentration.  
2. Establish a flow of ozone to the monitor.  
Flow rate through the monitor should be between 0.5 – 2.0 LPM (Liters per minute.)  
Adjust as needed using the needle valve of the flow meter on the front panel  
(see Figure 3-1).  
3. Let the monitor warm up for a minimum of 5 minutes.  
4. Check Status LED’s on front panel;  
Sensor OK LED should be ON.  
All other LED’s should be OFF.  
If the Status LED’s are not in this state, refer to Chapter 11 for troubleshooting  
information.  
5. Observe the monitor for several more minutes at zero to ensure that it is stable.  
THE MONITOR IS NOW READY TO MEASURE OZONE.  
3.7. Setting up the Serial Communications Port  
The 460L’s bi-directional RS-232/485 Serial Port Interface allows the user to communicate with  
the monitor via a computer over that computer’s serial communications port (COM port). A  
terminal emulation program such as HyperTerminal is required to be installed and running on the  
host computer.  
The following three pins are provided on the I/O connector for serial communications (see Figure  
3-12).  
Table 3-5 Serial I/O Port Connection  
LABEL  
DESCRIPTION  
Serial Transmit (RS-485 – A)  
Serial Receive (RS-485 – B)  
Serial Ground (RS-232 Only)  
SERIAL TX  
SERIAL RX  
SERIAL GND  
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While the standard factory configuration is for RS-232, the monitor’s serial port can be configured  
for either RS-232 or RS-485 (see Section 3.7.1 for the procedure).  
Use RS-232 for direct connection to a nearby (no more than 6-8 feet cable length) PC or  
Laptop, RS-232 should be used.  
Use RS-485 for permanent connection to continuously operating data acquisition systems  
or connections over greater distances.  
3.7.1. Physical Serial Port Configuration  
6. To configure the com port for RS-232 or RS-485, move the 4 shunts on JP3 of the CPU PCA  
(P/N #03492) to the proper position as shown in below.  
The jumpers may already be in this position but this still needs to be verified.  
Also make sure that JP1 is jumpered. It may be hanging off of one pin, make sure it is  
jumpered together as in Figure 3-11.  
JP2 can either be jumpered or not as it is already shorted on the board.  
Reset Button  
Micro-Controller  
Connector for  
Optional 4-20 mA  
output  
JP2  
JP1  
JP3 set for RS-232  
JP3 set for RS-485  
Figure 3-11 RS-232/RS-485 Jumper Location and Settings  
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7. Connect the appropriate type of cable to the 16 pin Signal I/O connector inside the  
analyzer.  
8. A cable may be included with you instrument. If not, Figure 3-12 below illustrates how to  
construct wiring for both RS-232 and RS-485 connections.  
DB9 Female  
RS-232  
1
6
Serial TXD  
2
7
Serial RXD  
3
8
4
9
Serial GND  
5
RS-485  
Twisted Pair  
Serial TXD  
Serial RXD  
RS-485-A  
RS-485-B  
Figure 3-12 Typical RS-232 and RS-485 Connections  
3.7.2. Software Setup for Serial Port Communications  
NOTE  
This section refers to various serial communication commands for the M460M. For  
detailed information regarding these commands see Chapter 7.  
1. Connect the other end of the cable to your serial Com port on your computer  
2. Open up Hyper-terminal or another terminal program and set up a connection with the  
settings below. Your com port is most likely COM1.  
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The Serial Port of the device being used to communicate with the 460L should be  
configured as follows:  
Table 3-6 Serial Port Configuration  
PARAMETER  
Baud Rate  
Data Bits  
Stop Bits  
Parity  
VALUE  
9600 bps  
8
1
None  
3. Find the address of the 460L.  
This can be accomplished by repeating the O3 command (see Section 7.3.5) for each  
possible address (0-9) until the M460M responds:  
EXAMPLE: 0O3<CR>  
1O3<CR>  
2O3<CR>  
…
9O3<<CR>  
When the instrument responds record the first number in the response line  
This is the address of the analyzer.  
4. To determine if the M460L is operating correctly type:  
1TLIST<CR>  
This analyzer will respond with a list of the current values of its test functions. See Section  
7.3.8 for a list of the nominal values for these functions  
5. Check the analyzer’s operation variables (VARS). These describe certain application  
specific conditions such as units of measure, measurement ranges, etc.  
To check the current state of the VARS, type:  
1VLIST<CR>  
This analyzer will respond with a list of the current values of its VARS. See Section 7.3.10  
for a list of the nominal values for these functions  
6. If you need to change one of the VARS settings, see the VSET command (see Table 7-3 of  
Section 7.3.11)  
7. After viewing the data you can return the analyzer to normal operation.  
After changing the value of any of the VARS return the analyzer to normal operation.  
The simplest way to do this is to turn the analyzer off and back on. User Notes:  
USER NOTES:  
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4. FREQUENTLY ASKED QUESTIONS  
Q: What do I do if I smell Ozone and suspect a leak?  
A: Ensure that all the fittings are tight. If the fittings are tight and ozone is still detected send  
the monitor back for repair to Teledyne Instruments’ customer service for repair.  
Q: What do I do if my CPU status light stops flashing?  
A: The CPU has stopped working. This is a major malfunction of the monitor. Return it to  
Teledyne Instruments’ customer service for repair.  
Q: What do I do if the Status OK light turns off or doesn't turn on after 30 min.?  
A: If the status ok light is off and the Lamp low light is on then the monitor’s UV lamp needs to  
be adjusted.  
If the status ok light is off and the Lamp Low light is off then most likely the UV lamp output  
has drifted to >5000mv and needs to be adjusted.  
Q: What does it mean if the Invalid Reading light turns on?  
A: This will happen if the:  
Ozone supply pressure exceeds 14.9 psia.  
Ozone concentration exceeds the Range of the monitor then this light will turn on.  
Ozone concentration goes excessively negative.  
Q: What do I do if my Lamp Low light turns on?  
A: If the Lamp Low light turns on and the Status OK light is ON, the UV reference value has  
dropped to < 1000mv. The monitor will continue to run with no problems until the UV  
reference drops below 500mv.  
If the Lamp low light turns on and the Status OK light is OFF, the UV reference has dropped  
below acceptable limits and will have to be adjusted.  
Q: When should I change the Particulate Filter and how do I change it?  
A: The Particulate filter should be changed monthly. See Section 9.1 for instructions on  
performing this replacement.  
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460L Instruction Manual  
5. OPTIONAL HARDWARE AND SOFTWARE  
This section includes descriptions of the hardware and software options available for the 460L  
monitor. For assistance with ordering these options please contact the sales department of  
Teledyne Instruments at:  
TOLL-FREE: 800-324-5190  
TEL: +1 858-657-9800  
FAX: +1 858-657-9816  
E-MAIL: [email protected]  
WEB SITE: http://www.teledyne-api.com/  
5.1. Sample Conditioning System  
This option is required for 460L’s that will be used in applications where the sample gas includes  
liquid or vaporous water. This option includes two major components:  
A coalescing water drop-out filter, and;  
A permeation tube dryer.  
5.2. Current Loop Analog Output  
This option adds isolated, voltage-to-current conversion circuitry to the monitor’s CPU card. This  
option be installed at the factory or added later. Call Teledyne Instruments sales for pricing and  
availability.  
The standard configuration of the current loop option is 4 – 20 mA. 0-20 mA is also available.  
5.3. Ozone Destruct Option  
An externally mounted scrubber (see Figure 3-5) is available for the 460L monitor for use when  
measuring O3 levels that are ≥100 ppb. Ozone levels this high will damage several of the  
components of the monitor downstream of the sensor module such as the flow meter and the  
pump. High levels of O3 are hazardous and should be removed from the gas stream exhaust.  
CAUTION  
Make sure that the exhaust line is vented to an outside area.  
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6. OPERATING INSTRUCTIONS  
The 460L has been designed for simple and trouble-free operation. The sections below detail the  
operational features of the 460L.  
6.1. Front Panel Display  
6.1.1. O readout  
3
The current ozone concentration is displayed in the 4-digit readout in the center of the display.  
The concentration is displayed in the currently selected units either: wt%, g/Nm3 or ppm, ppb.  
6.1.2. Zero Point Calibration  
The 460L needs little or no calibration in the field; however sometimes minor measurement  
offsets can occur. To compensate for this a zero point calibration can be initiated by using the  
two ZERO buttons. See Section 8.1 for more information.  
6.1.3. Status LED’s  
The four status LED’s to the right of the display indicate the general status of the 460L Monitor.  
During normal operation, after the monitor has warmed up, the green ‘Sensor OK’ LED should be  
on and all other Status LED’s should be off. For information on troubleshooting using the Status  
LED’s, see Sections 11.2.4.  
Table 6-1 Status LED’s  
NAME  
ON STATE  
OFF STATE  
OFF when  
Reference or Measure > 4995mV;  
SENSOR O.K.  
Normal State is STEADY GLOW  
Reference < 1000mV  
STEADY GLOW if:  
Ozone Pressure > 14.9 psia,  
Negative Ozone Concentration,  
Concentration Over-Range  
INVALID  
READING  
Normal State  
STEADY GLOW if Reference  
Detector<2500mV  
LAMP LOW  
Normal State  
Normal State  
BLINKS whenever the measured O3  
concentration exceeds either the alarm  
limits.  
ALARM  
ACTIVE  
Definitions for these four LED’s correspond to the definitions of the monitor’s four digital status  
outputs with identical names. See Sections 11.2 and 11.3 for more detailed information.  
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6.2. Concentration Alarms  
There are two O3 concentration alarms, HI and HI-HI. Both alarms are triggered when the  
measured O3 concentration equals or rises above the set limit for that alarm. The set limit for  
HI alarm must always be a lower value than that of the HI-HI alarm. If the O3 concentration is  
between the HI limit and the HI-HI limit, the HI alarm will be active, but the HI-HI alarm will be  
inactive.  
When either the HI or the HI-HI alarms are active the ALARM ACTIVE status LED on the front  
panel (see Figure 3-1) will blink. In addition when the HI alarm is active alarm trigger LED D7 (on  
the main PCA, see Figure 3-12) will glow and when the HI-HI alarm is active alarm trigger LED  
D8 will glow.  
6.2.1.1. Concentration Alarm Configuration  
Either of the concentration alarms can be independently configured via the 460L’s serial  
communication port (see Section 7.3.11).  
The user can set the alarms to operate in either the latching or non-latching as well as  
independently adjust the trigger levels of the alarm limits.  
In non-latching mode, the alarms will be triggered when O3 concentration equals or exceeds the  
associated limit is reached and will automatically return to an inactive state if the O3 concentration  
falls below the limit level. In latching mode once an alarm is triggered it will stay active until  
cleared by the user regardless of how the O3 concentration measurement changes.  
6.2.1.2. Remotely Sensing the Status of the Alarm  
Besides the LEDs located on the front panel and on the monitor’s main PCA, the status of each  
alarm can be sensed externally via a single-pull, double-throw relay (see Section 3.5.4) or  
determined from a remote location via the monitor’s serial communication port (See Chapter 7).  
6.2.1.3. Clearing Alarms  
When set for non-latching mode the alarms will only clear when the alarm condition disappears  
and will do so automatically. When in latching mode, the concentration alarms may be cleared in  
several ways:  
FRONT PANEL: Pressing the ALARM ACKNOWLEDGE key on the monitor’s front panel  
will clear all active alarms.  
SERIAL COMMUNICATION PORT: The ALMACK command to clear all active alarms (see  
Section 7.3.1)  
Table 6-2 Concentration Alarm Default Settings  
ALARM  
HI  
CONDITION  
MODE  
TRIGGER LIMIT  
100 ppb  
Enabled  
Latching  
HI-HI  
300 ppb  
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7. SERIAL COMMUNICATIONS  
The 460L comes equipped with a powerful digital Serial Communications Port that can be used for  
Data Acquisition and for changing the monitor’s configuration. This port can be configured for  
either RS-232 or RS-485 (half-duplex) operation. See Section 3.7.1 for details on configuring the  
port and connecting it to a computer or data acquisition system.  
7.1. Serial Port Command Syntax  
All characters sent and received are standard ASCII characters and all numbers are decimal  
numbers converted to ASCII text.  
All commands are sent using the following syntax:  
<address><command>:<data1>,<data2>#<checksum (optional)><CR>  
Where:  
address  
is the monitor address (default =1)  
command is the command string being sent  
: (colon)  
is the data separator and is only included if data is being sent as part of the  
command (See Command Details below to see if a command requires data or  
not)  
data1  
data2  
#  
is the first data parameter, if required.  
is the second data parameter, if required.  
is the Checksum separator, sent only if optional checksum is included  
The checksum is an ASCII checksum of all characters up to the # character.  
The checksum is optional. Commands sent without the checksum (and  
checksum separator,) are also valid.  
CR  
is a carriage return, ASCII 13.  
Examples  
Valid Commands with no data:  
Checksum Included: 1ALMACK#474<CR>  
No Checksum: 1ALMACK<CR>  
Valid Commands with data:  
Checksum Included: 1VSET:1,20#620<CR>  
No Checksum: 1VSET:1,20<CR>  
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7.2. Serial Port Command Summary  
Table 7-1 below lists the commands available and a summary of their function.  
Table 7-1 Serial Port Command Summary  
COMMAND  
DESCRIPTION  
ALMACK  
Acknowledges and clears any active concentration  
alarms  
ALMSTAT  
CZERO  
Returns the current state of the concentration  
alarms  
Perform a manual zero calibration. The CZERO  
does not activate the zero-gas solenoid valve,  
therefore the calibration is calculated based on the  
current ozone content of the measurement cell.  
DACSTEP  
O3  
Analog Output Test Mode, Step Function  
Returns O3 concentration currently being  
measured  
SETADDR  
TDUMP  
TLIST  
Sets communication address for this 460L to a  
specific value  
Returns the current values of a set of  
measurement parameters as a single data string  
Returns list of measurement parameters and their  
current values as a formatted list.  
VGET  
VLIST  
VSET  
Returns the current value of a single VAR  
Lists all VARS and their current values  
Sets value of internal VAR  
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Serial Communications  
7.3. Serial Port Command Reference  
7.3.1. ALMACK  
SYNTAX  
<address>ALMACK<CR>  
DESCRIPTION  
Acknowledges any active concentration alarm and clears them if possible For more information  
see Section 6.2.  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<success_flag>#<checksum><CR>  
EXAMPLE  
Command:  
1ALMACK<CR>  
Response:  
1:OK#261<CR>  
- Command successfully received. All alarms capable of being cleared  
have been.  
NOTE  
The alarm(s) will only clear if the condition causing the alarm no longer exists,  
EXAMPLE  
If the current O3 concentration rises above the trigger levels for both the HI and HI-HI alarms,  
both alarms will activate. If the O3 level falls below the HI-HI alarm limit, but is still above the  
is still above the HI limit, the ALMACK command will only clear the HI-HI alarm.  
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7.3.2. ALMSTAT  
SYNTAX  
<address>ALSTAT<CR>  
DESCRIPTION  
Returns the current status of both of the concentration alarms.  
0= Inactive  
1= Active  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<HI alarm state>,<HI-HI alarm state>#<checksum><CR>  
EXAMPLE  
Command:  
1ALMSTAT<CR>  
Response:  
1:0,0#247<CR>  
1:1,0#248<CR>  
1:1,1#249<CR>  
- Both concentration alarms are INACTIVE  
- The HI alarm is ACTIVE and the HI-HI alarm is INACTIVE  
- Both concentration alarms are ACTIVE  
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Serial Communications  
7.3.3. CZERO  
SYNTAX  
<address>CZERO<CR>  
DESCRIPTION  
Performs a zero calibration using gas sourced from the ozone gas inlet.  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<success_flag>#<checksum><CR>  
EXAMPLE  
Command:  
1CZERO<CR>  
Response:  
1:OK#261<CR>  
- Calibration Successful  
- Calibration Failed  
1:FAIL#391<CR>  
NOTE  
Once the CZERO function is activated the monitor will briefly display dashes (‘----‘) after which  
the concentration should quickly go to zero.  
The CZERO does not activate the zero-gas solenoid valve, therefore the gas flowing through the  
monitor is sourced from the ozone inlet and the zero calibration is calculated based on the current  
ozone content of that gas source.  
Care must be taken to ensure that all ozone is purged from the monitor before activating the  
CZERO function. Before activating the CZERO function, disconnect the O3 supply line from the  
monitor and allow room air to flow through the monitor for several minutes.  
Use a shutoff valve to make sure that the O3 source does not continue to feed O3 into the supply  
line while it is disconnected  
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Serial Communications  
460L Instruction Manual  
7.3.4. DACSTEP  
SYNTAX  
<address>DACSTEP<CR>  
DESCRIPTION  
Puts the monitor into Analog Output setup mode. The Analog Output steps from zero to full-scale  
in 25% increments, pausing for 10 seconds at each level. This repeats 5 times, after which the  
monitor returns to normal operation. This mode is useful for testing the Analog Output and the  
operation of any equipment measuring the Analog Output.  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<success_flag>#<checksum><CR>  
EXAMPLE  
Command:  
1DACSTEP<CR>  
Response:  
1:OK#261<CR>  
NOTES  
- DACSTEP command acknowledged and initiated  
The DACSTEP function takes some time to complete.  
When the command is sent to the monitor, it will immediately respond with the <address> and  
colon ‘:’ as an acknowledgement that the message was received. After the function is complete  
the rest of the response will be sent.  
No additional commands should be issued to the monitor until the function completes.  
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Serial Communications  
7.3.5. O3  
SYNTAX  
<address>O3<CR>  
DESCRIPTION  
Returns the current ozone concentration measured by the monitor.  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<o3_conc>#<checksum><CR>  
EXAMPLE  
Command:  
1O3<CR>  
Response:  
1:250.1898#522<CR> - Current O3 Concentration (reading 250.2 ppb)  
NOTES  
While the concentration value returned shows more digits after the decimal than the front panel  
(in the example above, 250.1898) display it is only valid to 4 significant digits (in the example  
above, 250.2).  
The returned value will be in whichever units of measure for which the monitor is set.  
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7.3.6. SETADDR  
SYNTAX  
<address>SETADDR:<new_address><CR>  
DESCRIPTION  
Changes the communications address to a new value.  
DATA PARAMETERS SENT  
new_address is the new address for the monitor; Range for new_address is 1-9.  
RESPONSE  
<address>:<success_flag>#<checksum><CR>  
EXAMPLE  
Command:  
1SETADDR:2<CR>  
Response:  
- Change address from 1 to 2  
1:OK#261<CR>  
- Change Address Successful  
- Change Address Failed  
1:FAIL#391<CR>  
NOTES  
The monitor response is from the previous address (1 in the example shown above), but any  
further commands must be at new address (2 in the example shown above).  
If the address change was successful, after sending back the OK response, the monitor will no  
longer respond to commands with address 1.  
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Serial Communications  
7.3.7. TDUMP  
SYNTAX  
<address>TDUMP<CR>  
DESCRIPTION  
This command is best used if the response is intended as input for a database program or data  
acquisition system  
It returns a string made up of the current values of the following parameters in the following  
order: O3 Concentration, Cell Pressure (psia), Cell Temperature (K,) Lamp Temperature (K,)  
Measure Detector (mV,) Calibrated Reference Detector (mV,) Reference Detector (mV).  
DATA PARAMETERS SENT  
None  
RESPONSE  
<address>:<o3_conc>,<pressure>,<cell_temp>,<lamp_temp>,<measure>,<cal_ref>,<referenc  
e>,<al-hi-stat>,<al-hi-hi-stat>#<checksum><CR>  
EXAMPLE  
Command:  
1TDUMP<CR>  
Response:  
1:0.0282144,14.77461,300.7179,324.7713,2881.437,2940.903,4412.52,1,0#3413  
<CR>  
NOTES  
While the concentration value returned shows more digits after the decimal than the front panel  
display (in the example above, 0.0282144), it is only valid to 4 significant digits (in the example  
above, 0.028).  
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7.3.8. TLIST  
SYNTAX  
<address>TLIST<CR>  
DESCRIPTION  
Returns a formatted, easy to read list of the parameters by name with the current values for  
each.  
DATA PARAMETERS SENT  
None  
RESPONSE  
Test Parameter List (See Below)  
EXAMPLE  
Command:  
1TLIST<CR>  
Response:  
O3 = 0.0226168  
Press = 14.7753  
Cell Temp = 300.7116  
Lamp Temp = 324.7965  
Ref = 2881.52  
Meas = 2941.092  
Raw Ref = 4412.646  
HI Alarm = ON  
HI-HI Alarm = OFF  
NOTES  
The set of parameters is not the same as those returned by the TDUMP command.  
While the concentration value returned shows more digits after the decimal than the front panel  
display (in the example above, 0.0226168), it is only valid to 4 significant digits (in the example  
above, 0.022).  
No checksum is sent in the response to the TLIST command.  
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Serial Communications  
7.3.9. VGET  
SYNTAX  
<address>VGET:<var_index><CR>  
DESCRIPTION  
Returns value of an internal configuration variable (VAR.)  
DATA PARAMETERS SENT  
var_index  
is index number for internal VAR as follows:  
Table 7-2 VAR_INDEX List for VGET Command  
var_index  
Name  
Description  
ANALOG_RANGE  
Full-Scale concentration range for Analog Output scaling  
0
1
0 = disabled  
1 = enabled  
ALARM_ENABLE  
ALARM_MODE  
0 = latching  
1 =non-latching  
2
Molecular weight of carrier gas(e.g. 32.0 = O2). Only used by  
460L’s with ppmw capability  
CARRIER_WEIGHT  
COMM_MODE  
IIR_FILT  
3
4
5
Not Used  
The sensitivity of the software filter used by the monitor to reduce  
noise and hysteresis in the reported O3 concentration reading.  
2 =ppb  
3 = ppm  
CONC_UNITS  
6
HI_ALARM_LEVEL  
Sets the trigger limit of the HI alarm  
Sets the trigger limit of the HI-HI alarm  
7
8
HI-HI_ALARM_LEVEL  
NOTE: Only one yar_index is allowed per iteration of the VGET command  
RESPONSE  
<address>:<var_value>#<checksum><CR>  
EXAMPLE  
Command:  
1VGET:8<CR> - Request limit value for HI concentration Alarm  
Response:  
1:300.0#348<CR>  
NOTE  
- HI alarm limit is 300.0 ppb  
Response is in units of measure for which the monitor is set.  
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7.3.10. VLIST  
SYNTAX  
<address>VLIST<CR>  
DESCRIPTION  
Returns a formatted, easy to read list of an internal configuration variables (VAR’s) and their  
current values.  
DATA PARAMETERS SENT  
None  
RESPONSE  
VAR List (See Below)  
EXAMPLE  
Command:  
1VLIST<CR>  
Response:  
#0 analog_range = 1000.0  
#1 alarm_enable = 1.0  
#2 alarm_mode = 0.0  
#3 carrier_weight =32.0  
#4 comm_mode = 0.0  
#5 iir_filt = 0.25  
#6 conc_units = 2.0  
#7 hi_al_level = 100.0  
#8 hihi_al_level = 300.0  
NOTES  
No checksum is sent in the response to the VLIST command.  
The 460L does not use the comm_mode VAR, so its value will always be 0.  
hi_al_level and hihi_al_level are returned in the units of measure for which the monitor is set.  
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7.3.11. VSET  
SYNTAX  
<address>VSET:<var_index>,<new_value><CR>  
DESCRIPTION  
Sets value of an internal configuration variable (VAR.)  
DATA PARAMETERS SENT  
var_index  
new_value  
index number for internal VAR (See VGET for index list)  
new value for VAR.  
RESPONSE  
<address>:<var_value>#<checksum><CR>  
Table 7-3 VAR_INDEX List for VSET Command  
var_index  
Name  
Description  
Allowable Range  
Sets the full-scale concentration range for  
Analog Output scaling  
1 ppb – 1000 ppb  
0.001 ppm – 1.000 ppm  
ANALOG_RANGE  
0
0 = disabled  
1 = enabled  
ALARM_ENABLE  
ALARM_MODE  
Enables or disables the Concentration alarms  
1
2
Selects latching mode or non-latching mode for  
both alarms.  
0 = latching  
1 =non-latching  
Sets the molecular weight of carrier gas for  
wt% calculations (e.g. 32.0 = O2)  
CARRIER_WEIGHT  
COMM_MODE  
27.0 – 32.0  
N/A  
3
4
Not Used  
Sets the sensitivity of the software filter used  
by the monitor to reduce noise and hysteresis  
in the reported O3 concentration reading.  
0.05 – 1.0  
IIR_FILT  
5
2 =ppb  
3 = ppm  
CONC_UNITS  
HI_AL_LEVEL  
HIHI_AL_LEVEL  
O3 concentration measurement units  
Sets the trigger limit of the HI alarm  
Sets the trigger limit of the HI-HI alarm  
6
7
8
10 ppb < x < 1000 ppb  
0.010 ppm < x < 1.000 ppm  
10 ppb < x < 1000 ppb  
0.010 ppm < x < 1.000 ppm  
NOTE: Only one yar_index is allowed per iteration of the VSET command  
EXAMPLE1  
Command:  
1VSET:8,275.0<CR> - Set HI-HI concentration alarm to 275.0 ppb  
Response:  
1:OK#261<CR>  
- VSET Successful  
1:FAIL#391<CR>  
- VSET Failed  
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EXAMPLE2  
Command:  
1VSET:6,1<CR>  
Response:  
- Set CONC_UNITS VAR to ppm  
1:OK#261<CR>  
- VSET Successful  
1:FAIL#391<CR>  
- VSET Failed  
NOTES  
ANALOG_RANGE: Setting is in whatever units selected by the CONC_UNITS VAR  
ALARM_ENABLE: The concentration alarms cannot be enable/disabled independently.  
ALARM_MODE: The mode of the concentration alarms cannot be set independently.  
CARRIER_WEIGHT: This variable is only used by 460L’s with ppm by weight capability (ppmw).  
The molecular weight of pure O2 is 32.  
The nominal molecular weight of ambient air is 28.96  
COM_MODE: The 460L does not use the comm_mode VAR, so its value will always be 0.  
IIR_FILT: The lower the setting value the more significant the effect of the filter; 1.0 = No  
filtering; 0.05 = Maximum filtering. 0.0 is not allowed.  
HIHI_AL_LEVEL must be greater than HI_AL_LEVEL. New_value should be in the units of  
measure the monitor for which the monitor is set.  
EXAMPLE:  
1VSET:8,275.0<CR>  
1VSET:8,0.275<CR>  
- Set HI-HI concentration alarm to 275.0 ppb  
- Set HI-HI concentration alarm to 0.275 ppm  
USER NOTES:  
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460L Instruction Manual  
Calibration  
8. CALIBRATION  
8.1. Zero Point calibration  
Variations in ambient conditions, most notably changes in ambient humidity, and minor changes  
in the performance of certain electronic components over time may cause slight offsets in the zero  
point measurement of the monitor. To check for and compensate for these minor offsets use the  
following procedure.  
1. Supply zero air to the monitor by inserting a O3 scrubber filled with activated charcoal into  
the ozone supply gas line just before it enters the monitor.  
A scrubber of this type is available from Teledyne Instruments  
(Carbon Filter, DAU, 000 Grade; P/N FL0000020).  
NOTE  
Since variations in humidity is a common cause of these types of offsets, use of bottled  
O2, which is extremely dry, as zero air is not recommended particularly in areas where  
the ambient humidity is high.  
2. Once the scrubber is installed, allow the monitor to operate until the O3 reading stabilizes.  
This may take approximately 15 minutes  
3. Check the O3 reading.  
If the reading is within the repeatability specification of the monitor (see Section 2.1),  
no adjustment is needed.  
If the reading is higher than the repeatability specification of the monitor but still  
relatively minor (10 to 20 ppb for example), press the two ZERO keys on the front  
panel and hold them for 3 seconds.  
If the offset is greater than 30 ppb or pressing the zero key has no effect, contact  
Teledyne Instruments’ customer service department.  
8.2. Span Point Calibration  
1. Connect the M40M to a computer running a terminal emulation program such as Hyper-  
terminal. See Section 3.7 for instructions.  
2. Flow zero air, or pure O2 through the analyzer and wait 15minutes.  
3. After the analyzer has stabilized, perform a zero calibration by pressing both zero buttons  
on the front panel at the same time.  
4. Type:  
<address>LOGIN:929<CR>  
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Where  
<address> is the network address of the M460M being calibrated.  
929 is a special password allowing you to calibrate the analyzer.  
5. List the current values of the M460M’s VARS. Type:  
<address>VLIST<CR>  
Look through the list for one with the a special VARS named either O3 SLOPE, or O3  
SPAN SLOPE. This VAR is only available using the 929 password.  
Record both the slope value and the VAR Number it corresponds with.  
6. Make sure your ozone standard and analyzer are both reading the same span gas or ozone  
concentration.  
7. Calculate the slope using the following equations:  
Equation 8-1  
(O3 concentration on analyzer) ÷ (O3 Slope) = (True O3 value of analyzer)  
Equation 8-2  
(O3 concentration on standard) ÷ (True O3 value of analyzer) = (New slope)  
EXAMPLE  
Where:  
Slope of analyzer = 1.013  
Current O3 reading of analyzer = 8.70%  
Current O3 reading of standard = 9.00%  
a) (O3 concentration on analyzer) ÷ (O3 Slope) = (True O3 value of analyzer  
8.70% 1.013 8.59%  
b) (O3 concentration on standard) ÷ (True O3 value of analyzer) = (New slope)  
9.00% 8.59% 1.048  
1.048 would be the New Slope Value that needs to be entered in the next step.  
÷
=
÷
=
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Calibration  
8. Enter the New Slope into the M460M’s memory enter it in. Type:  
<address>VSET:<VAR Number>,<New Slope Value><CR>  
EXAMPLE  
3VSET:16,1.048<CR>  
Where:  
The address of the M460M is 3  
The O3 SLOPE VAR is number 16  
The New Slope is = 1.013  
8.3. Adjusting the Optional Current Loop Output  
If your monitor includes the option current loop output you may need to check or adjust the  
actual current levels of the output to ensure that it matches the input requirements of your  
recording device. See Section 3.5.1 for details on making connections to the 4-20mA output.  
To manually adjust the zero and span points of the 4-20mA analog output:  
1. Disconnect the monitor from AC power.  
2. Connect current measuring meter in series with the 4-20mA output. For best results, the  
4-20mA output should be calibrated with the actual load (measuring device) attached. If  
this cannot be done, then a 250 – 500 ohm resistor should be placed in series with the  
current meter to simulate a load.  
See Figure 3-6 for  
pin assignments of  
mA  
the signal I/O  
connector on the  
rear panel.  
IN  
OUT  
ANALOG OUT  
I IN +  
I IN -  
ANALOG OUT -  
Recording  
Device  
Monitor  
Figure 8-1 Setup for Measuring Current Output Signal Level  
3. While reconnecting the monitor to AC power, press and hold the “Alarm Reset” button on  
the front panel. This will cause the monitor to enter the analog output step mode. The  
display on the monitor will display “A 0” indicating that it is in the analog output step  
mode and at the 0% point (see Section 7.3.4).  
4. At this point the analog output should read somewhere near 4.0mA. Adjust the “Zero”  
potentiometer on the 4-20mA PCA (See Figure 8-2) as necessary.  
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5. The monitor will automatically generate the nominal signal level by producing a 25%  
increment output level on the current loop.  
EXAMPLE  
OUTPUT LEVEL  
NOMINAL SIGNAL  
LEVEL  
0%  
25%  
50%  
75%  
100%  
4mA  
8mA  
12mA  
16mA  
20mA  
6. The display will then show “A100” (four times). Adjust the “Span” potentiometer (See  
Figure 8.2) as necessary.  
Figure 8-2 Location Current Output Adjustment Potentiometers  
7. Note that the zero and span adjustments are not completely independent and adjusting  
one point may slightly affect on the other. Therefore steps 4-6 may need to be repeated  
several times in order to properly adjusted both points.  
8. When the adjustment process is complete, the monitor will automatically restart in  
standard measurement after 5 cycles.  
USER NOTES:  
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Maintenance  
9. MAINTENANCE:  
9.1. Replacing the Particulate Filter Element  
The 460L is equipped with a particulate filter on the ozone inlet. Only Teledyne Instruments filter  
elements should be used. When the monitor is first installed, the sample filters should be checked  
at least once a week for particulate loading and replaced if necessary. Once the replacement  
frequency is determined, a regular schedule for filter replacement should be instituted.  
For replacement filter, please contact Teledyne Instruments’ sales department and request part  
number 05017.  
9.1.1. Filter Replacement Procedure  
1. Turn the Monitor off and ensure that the gas delivery line is not under pressure  
2. Purge the gas delivery line of ozone.  
3. Unscrew the pressure fitting at the top of the filter (Fitting B in Figure 9-1) from the union  
fitting.  
4. Unscrew the pressure fitting at the bottom of the filter (Fitting C in Figure 9-1) from the  
ozone Inlet.  
5. Discard the filter.  
6. Attach the new filter using the fittings supplied with it.  
7. After reassembly, the gas line should be pressurized with oxygen or dry air and checked  
for leaks using a bubble solution.  
Pressure Fitting A  
Pressure  
Fitting B  
Union  
Fitting  
Pressure  
Fitting C  
Filter  
Ozone Inlet  
Figure 9-1 Changing the Particulate Filter  
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460L Instruction Manual  
9.1.2. Mounting the Particulate Filter Externally  
In applications where the 460L is sampling ambient air at its own location and no inlet gas line is  
being used, the particulate filter can be mounted on the outside of the instrument so that it may  
be replaced without turning off the monitor or opening the case.  
To mount the particulate filter outside the monitor enclosure:  
1. Turn the monitor off and ensure that the gas delivery line is not under pressure  
2. Purge the gas delivery line of ozone.  
3. Unscrew the pressure attached to the internal gas line (Fitting A in Figure 9-2) from the  
union fitting.  
4. Unscrew the union fitting from the fitting at the top of the filter (fitting B in Figure 9-2).  
Although the union fitting is no longer needed, save it in case you wish to return the  
particulate filter to the inside of the monitor at a later date.  
5. Unscrew the pressure fitting at the bottom of the filter (Fitting C in Figure 9-2) from the  
ozone inlet.  
6. Reattach the filter to the external side of the ozone inlet.  
7. Attach the internal gas line to the internal side of the ozone inlet using Fitting A.  
8. After reassembly, the gas line should be pressurized with oxygen or dry air and checked  
for leaks using a bubble solution.  
AFTER  
BEFORE  
Pressure  
Fitting A  
Union  
Fitting  
Pressure  
Fitting B  
Pressure  
Fitting C  
Pressure  
Fitting A  
Filter  
Pressure  
Fitting B  
Ozone Inlet  
Ozone Inlet  
Inlet Gas Line  
Filter  
Pressure  
Fitting C  
No Inlet Gas Line  
Figure 9-2 Changing the Particulate Filter  
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Maintenance  
9.2. Maintaining the Optional H2O Coalescing Filter  
9.2.1. Draining the Optional Coalescing Filter  
The coalescing filter component of the optional sample conditioning system may accumulate with  
water (see Figure 9-3 for filter location). It must be checked periodically and drained.  
It is recommended that the filter be checked every 2 hours for the first several days of the  
monitor’s operation to determine the fill rate of the filter’s reservoir.  
To drain the filter:  
1. Disconnect ozone supply line from monitor and shut off flow to the monitor using needle  
valve on front panel.  
2. Remove the cap from the fitting on the bottom of the coalescing filter and allow the filter to  
drain.  
3. Replace cap.  
4. Reconnect the O3 supply line and adjust flow to the monitor.  
5. Open the flow meter valve and adjust the gas flow to the appropriate rate.  
Coalescence  
Filter  
(optional)  
Coalescence  
Filter Drain  
Figure 9-3 Draining the Optional H2O Coalescing filter  
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9.2.2. Replacing the Coalescing Membrane  
The coalescing filter contains a replaceable Teflon® coalescing membrane. Under normal  
operating conditions, this membrane should last for a long time, however a significant reduction in  
the gas pressure measured in the O3 cell might indicate that this membrane needs replacement.  
To replace the filter membrane:  
1. Disconnect ozone supply line from the monitor and shut off flow to the monitor using  
needle valve on front panel.  
2. Remove inlet and exit fittings from scrubber body and cap.  
3. Remove the orange cap from the top of the coalescing filter.  
4. Remove the old membrane. It is located on the underside of the cap assembly  
(see Figure 9-4).  
5. Insert the new membrane into the cap assembly.  
6. Tightly secure the cap back on the filter.  
7. Reconnect the O3 supply line adjust flow to the monitor.  
8. Open the flowmeter valve and adjust the gas flow to the appropriate rate.  
Figure 9-4 Replacing the Membrane of the Optional H2O Coalescing filter  
Replacement filter elements can be ordered from TAPI (P/N 036750000).  
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460L Instruction Manual  
Maintenance  
9.3. UV Lamp Replacement  
1. Disconnect power from the monitor and open cover.  
2. Loosen, but do not remove, the two lamp set-screws (see Figure 9-5 below).  
3. Unplug lamp from the UV lamp power connector on Sensor Module PCA.  
4. Remove lamp from lamp housing. Dispose of lamp in accordance with local regulations  
regarding disposal of Mercury containing waste.  
5. Install new lamp in housing and plug into the UV lamp power connector.  
6. Connect the ground lead of a voltmeter to TP4.  
7. Connect the positive lead of voltmeter to TP10.  
8. Reconnect power to the monitor.  
9. The voltage on TP10 must read between –0.6 and –1.6Vdc. If this voltage is outside that  
range, slowly rotate the lamp until the proper voltage is achieved, then tighten the lamp  
set-screws.  
10.Connect the positive lead of a voltmeter to TP11 (Measure Detector Voltage).  
11.Adjust R26 until the voltage on TP11 is as high as possible within the range of 0.60 –1.00  
volts.  
UV Lamp Set Screws  
UV Lamp  
UV Lamp  
Power  
Connector  
Reset  
button  
Test Point  
4
Test Point  
11  
Test Point  
10  
R26  
Figure 9-5 UV Lamp Set Screws and Calibration Test Points  
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Maintenance  
460L Instruction Manual  
9.4. Cleaning Exterior Surfaces of the 460L  
If necessary, the exterior surfaces of the 460L can be cleaned with a damp cloth. Do not attempt  
to clean any of the other surfaces of the monitor. Do not submerge any part of the monitor in  
water or cleaning solution.  
9.5. Degree of Protection  
The Model 460L has a water ingress rating of IP65 which indicates that it can withstand strong  
jets of water and is totally protected against dust.  
USER NOTES:  
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460L Instruction Manual  
Theory of Operation  
10. THEORY OF OPERATION  
10.1. Basic O3 Measurement Principle  
10.1.1. (Beer’s Law)  
The detection of ozone molecules in a gas is based on the principle that ozone is a very strong  
absorber of UV light with a wavelength of 254 nm. If the distance that this light travels through  
the gas is always the same, the more ozone present in a gas, the more UV light is absorbed. If  
the distance the light travels through the gas, the intensity of light passing through the ozone  
containing gas, as well as the intensity of the light which does not pass through the gas are all  
known, the amount of ozone present can be calculated according to the following equation, called  
Beer’s Law (also referred to as the Beer-Lambert equation).  
I=IO e-  
LC  
Equation 10-1  
Where:  
Io  
I
is the intensity of the light if there was no absorption.  
is the intensity with absorption.  
L
is the absorption path, or the distance the light travels as it is being absorbed. This  
distance determines how many molecules are present in the column of gas in the  
absorption cell.  
C
is the concentration of the absorbing gas. In the case of the Model 460L, Ozone (O3).  
α
is the absorption coefficient absorption coefficient, a number that reflects the inherent  
ability of ozone to absorb 254 nm light. Most current measurements place this value at  
-1  
-1  
308 cm atm at Standard Temperature and Pressure (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.  
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460L Instruction Manual  
To solve this equation for C, the concentration of the absorbing gas (in this case O3), the  
application of a little algebra is required to rearrange the equation as follows:  
I
   
o
1
C ln  
   
I
L  
   
Equation 10-2  
Unfortunately, both ambient temperature and pressure influence the density of the sample gas  
and therefore the number of ozone molecules present in the absorption path thus changing the  
amount of light absorbed.  
In order to account for this effect the following addition is made to the equation:  
I
1
L  
Τ
14.695psi  
   
o
C ln  
   
   
   
273o   
I
Ρ
   
Equation 10-3  
Where:  
T
= sample ambient temperature in degrees Kelvin  
= ambient pressure in pound per square inch (psi),  
P
Finally, to convert the result into Parts per Million (PPM), the following change is made:  
6   
I
10  
14.695psi  
   
o
C ln  
   
273o   
I
L  
   
Equation 10-4  
10.1.2. The Absorption Path  
In the most basic terms, the Model 460L uses a high energy, mercury vapor lamp to generate a  
beam of UV light. This beam passes through a window of material specifically chosen to be both  
non-reactive to O3 and transparent to UV radiation at 254nm and into an absorption tube filled  
with Sample Gas.  
Because ozone is a very efficient absorber of UV radiation the Absorption Path Length required to  
create a measurable decrease in UV intensity is short enough (approximately 16 cm) that the light  
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Theory of Operation  
beam is only required to make pass through the Absorption Tube. Therefore no complex mirror  
system is needed to lengthen the effective path by bouncing the beam back and forth.  
Finally, the UV then passes through a similar window at the other end of the Absorption Tube and  
is detected by a specially designed vacuum diode that only detects radiation at or very near a  
wavelength of 254nm. The specificity of the detector is high enough that no extra optical filtering  
of the UV light is needed.  
The detector reacts to the UV light and outputs a voltage that varies in direct relationship with  
the light’s intensity. This voltage is digitized and sent to the instrument’s CPU to be used in  
computing the concentration of O3 in the absorption tube.  
Window  
Window  
UV Detector  
ABSORPTION TUBE  
Sample Gas IN  
Sample Gas OUT  
UV  
Source  
Absorption Path Length = 16 cm  
Figure 10-1 O3 Absorption Path  
10.1.3. The Reference / Measurement Cycle  
In order to solve the Beer-Lambert equation it is necessary to know the intensity of the light  
passing through the absorption path both when O3 is present and when it is not. The Model 460L  
accomplishes this by alternately passing the sample gas through a chemical scrubber that  
removes any O3 present and sending it directly to the absorption tube.  
Measure Path  
Reference/  
Measure  
Valve  
(I)  
Particulate  
Filter  
From Sample  
Port  
Reference Path  
O3  
Scrubber  
(I0)  
Valve switches  
every 3 seconds  
PUMP  
To Exhaust  
Port  
ABSORPTION TUBE  
Figure 10-2 Reference / Measurement Gas Cycle  
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The Measurement / Reference Cycle consists of:  
Table 10-1 Measurement / Reference Cycle  
CYCLE  
STATUS  
VALVE STATE  
(FIG. 10-3)  
DURATION  
- -  
ACTIVITY  
Measure/Reference Valve Opens to the Measure Path.  
Wait Period. Ensures that the Absorption tube has been adequately  
flushed of any previously present gasses.  
MEASURE  
PERIOD  
0.50 sec.  
1 3  
Analyzer measures the average UV light intensity of O3 bearing  
Sample Gas (I) during this period.  
0.15 sec.  
- -  
Measure/Reference Valve Opens to the Reference Path.  
Wait Period. Ensures that the Absorption tube has been adequately  
flushed of O3 bearing gas.  
REFERENCE  
PERIOD  
0.50 sec.  
2 3  
Analyzer measures the average UV light intensity of Non-O3 bearing  
Sample Gas (I0) during this period.  
0.15 sec.  
1 min 30 sec  
TOTAL CYCLE TIME  
10.1.4. Digital Noise Filter  
The 460L software processes sample gas concentration data through a noise filter that stabilizes  
the concentration value reported to the display and via the monitor’s analog outputs.  
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460L Instruction Manual  
Theory of Operation  
10.2. Pneumatic Theory of Operation  
10.2.1. Basic Pneumatic Flow And Flow Control  
Monitor Enclosure  
Flow Meter Valve  
PUMP  
Exhaust  
Out  
O3 Measurement Cell  
Reference Cycle Gas Path  
MEASURE  
REFERENCE  
VALVE  
O3  
Scrubber  
3
2
O3 IN  
1
Measure Cycle Gas Path  
Gas  
Pressure Sensor  
O3  
DESTRUCT  
(Optional)  
Figure 10-3 460L Internal Pneumatic Diagram – Basic Configuration  
10.2.2. Internal Pump and Flow Control  
Air flow through the M460L O3 Monitor is supplied by a single-diaphragm, brushless DC pump that  
pulls air though the monitor. Since diaphragm pumps necessarily heat and compress the air they  
are pumping and since both temperature and pressure fluctuations can effect the O3  
measurement, the pump is placed down stream from the measurement cell to avoid any  
inadvertent effects resulting from the pumping action.  
An adjustable needle-restrictor valve and flow gauge, located on the front panel of the monitor  
allow the user to manually adjust the gas flow rate through the monitor.  
Particulate Filter  
To remove particles in the sample gas which might clog airways or foul the measurement cell  
optics, the monitor is equipped with a glass-fiber membrane filter of 25 mm diameter with a pore  
size of 1.5 microns. The filter is located inside the black housing on the bottom of the monitor.  
See Section 9.1 for location and instruction for replacing the filter element.  
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460L Instruction Manual  
10.2.3. Optional Sample Conditioning  
The source air measured by the 460L needs to be as dry as possible. Significant amounts of liquid  
or vaporous water present in the source gas can foul the measurement cell optics. Also, water  
absorbs O3 and interferes with the 460L’s ability to accurately measure the O3 in the source gas.  
To counteract this problem, several optional components can be added to the 460L.  
Monitor Enclosure  
Flow Meter Valve  
PUMP  
Exhaust  
Out  
O3 Measurement Cell  
MEASURE  
REFERENCE  
VALVE  
O3  
Scrubber  
O3 IN  
3
2
1
Vapor  
Dryer  
Purge  
Line  
Gas  
Pressure Sensor  
O3  
DESTRUCT  
(Optional)  
H2O  
Coalescing  
Filter  
(Optional)  
Figure 10-4 460L Internal Pneumatic Diagram with Optional Sample Conditioning  
10.2.3.1. H2O Coalescing Filter  
The first step of this drying process is to remove any liquid water from the source gas. The 460L  
uses a Teflon® membrane, coalescing filter to accomplish this. This filter works in two ways. First,  
droplets of water that are large enough to precipitate out of the air on their own simply fall to the  
bottom of the filters container. Second, smaller droplets, small enough to stay combined and  
bourn along with the air encounter the Teflon® membrane (47 mm diameter; 20 micron pore size)  
at the top of the filter, and because Teflon® is inherently water repellent, these tiny droplets  
collect along the Teflon® fibers combining and growing until they are large enough to drip down  
into the reservoir.  
10.2.3.2. H2O Vapor Dryer  
Once all of the liquid water is removed from the source gas, a separate, Perma Pure® single tube  
permeation tube dryer removes any vaporous water still present. The dryer consists of a single  
tube of Nafion®, a co-polymer similar to Teflon® that absorbs water very well but not other  
chemicals. The Nafion® tube is mounted within an outer, flexible plastic tube. As gas flows  
through the inner Nafion® tube, water vapor is absorbed into the membrane walls. The absorbed  
water is transported through the membrane wall and evaporates into the dry purge gas flowing  
through the outer tube, countercurrent to the gas in the inner tube. This process is called  
pervaporation and is driven by the humidity gradient between the inner and outer tubes as well as  
the flow rates and pressure difference between inner and outer tubing.  
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Theory of Operation  
To provide a dry purge gas for the outer side of the Nafion® tube, the 460L returns the dried O3  
free air from the measurement cell and O3 destruct to the outer tube (see Figure 10-4). When the  
monitor is first started, the humidity gradient between the inner and outer tubes is not very large  
and the dryer’s efficiency is low at first but improves as this cycle reduces the moisture in the  
sample gas and settles at a minimum humidity.  
10.2.3.3. Ozone Destruct Scrubber  
The ozone destruct scrubber removes O3 from the exhaust gas stream of the monitor after it exits  
the instrument’s absorption tube but before it can damage the 460L’s flow meter and pump. It  
also prevents hazardously high levels of O3 from exiting the monitors exhaust outlet.  
When installed, the O3 scrubber is located outside the monitor’s NEMA housing, on the right side  
at the top (see Figure 3-5). It is filled with a special catalytic ozone scrubbing material that  
removes all of the O3 from the sample gas exiting the sensor module’s absorption tube. The  
catalyst used in the scrubber only converts ozone to oxygen and does not produce any toxic or  
hazardous gases.  
The catalyst is 100% efficient at scrubbing ozone at room temperature. It is a true catalytic  
converter, therefore there are no maintenance requirements such as changing the scrubbing  
material as is required for charcoal-based scrubbers.  
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10.3. Electronic Theory of Operation  
Front Panel  
Keyboard  
Status LED’s  
Sensor OK  
Display  
Driver  
Board  
Invalid Reading  
Lamp Low  
LED Display  
Alarm Active  
I2C Bus  
Sensor Module  
RS-485  
CPU Board  
UV Lamp  
UV Lamp  
Power  
Supply  
CPU  
Lamp  
Temperature  
Micro-processor  
Analog  
Ouput  
Sensor  
I2C Bus  
Measurement  
RS-232 / RS-485  
Port  
Cell  
Temperature  
Sensor  
Low  
Resolution  
A/D  
High  
Resolution  
A/D  
Optional 4-20 mA  
outpt  
Control  
Outputs  
Detector Assy  
Pre  
Amp  
Measurement  
Detector  
Amplifier  
Sensor OK  
Relay  
Status  
Output  
Drivers  
Sample Gas  
Pressure  
Sensor  
HI Alarm Relay  
M/R Valve  
Control  
Circuitry  
HI-HI Alarm  
Relay  
M/R Valve  
Relay  
M/R Valve  
Control  
Inputs  
Status  
Output  
Analog  
Outputs  
Serial I/O  
UV Lamp  
Heater  
Analog and Digital I/O Connector  
Main Board  
Figure 10-5 460L Electronic Block Diagram  
Electronically, the 460L is of modular design (see Figure 10-5). Each Sub-module performs a  
specific set of functions as described in Sections 10.3.1 through 10.3.5.  
10.3.1. Main Board  
This printed circuit assembly provides interconnection between the monitor’s other electronic  
modules; some opto-isolated signal buffers for the digital status outputs and control inputs and is  
the location of the three solid state output relays (see Section 3.5.5).  
The monitor’s main power supply (see Section 10.3.5) is also located on this assembly.  
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Theory of Operation  
10.3.2. O3 Sensor Module  
The heart of the 460 Monitor is the O3 sensor module. This electromechanical assembly located at  
the left hand side of the enclosure includes all of the pneumatic, mechanical and electronic  
components needed to gather the data required to calculate the O3 content of the source gas.  
10.3.2.1. O3 Sensor Components  
UV Lamp: The ultraviolet light needed to detect O3 is supplied by a mercury-vapor UV  
lamp. This lamp is coated in a material that optically screens the UV radiation output to  
remove the O3 producing 185nm radiation. Only light at 254nm is emitted.  
UV Lamp Heater : to operate efficiently the UV lamp must be kept at a temperature of  
52˚C or higher. While the heat created by the lamp itself is usually sufficient to cause this,  
under some ambient conditions additional heating is required. This additional heat is  
provided by a DC heater, controlled by the sensor microprocessor.  
Temperature Sensors: Two solid state temperature sensors are located in the O3 sensor  
module. They are:  
Measurement Cell Temperature Sensor: This sensor detects the temperature of the gas  
inside the measurement cell. This information is used by the CPU as part of the O3  
concentration calculation (see Formula 10-3 in Section 10.1).  
UV Lamp Temperature Sensor: This sensor, attached to the UV lamp reports the  
current temperature of the Lamp to the sensor microprocessor via the sensor module  
A/D converter.  
Both Sensors have built-in A/D converters and send digitized data directly to the monitors  
CPU.  
UV detector: A UV detector measures the two primary variables, I and I0 (See Section  
10.1.1) needed to compute the O3 concentration of the source gas. They are:  
The first measurement (I) is taken during the measure period of the measure/  
reference cycle (see Table 10-1) and records the intensity of the UV light passing  
through the O3 bearing source gas.  
The second measurement (I0) occurs during the reference period of the cycle and  
records the intensity of the light passing though gas from which the O3 has been  
removed.  
This detector is a specially designed vacuum diode that only reacts to radiation at or very  
near a wavelength of 254nm and outputs a voltage that varies in direct relationship with  
the light’s intensity. The wavelength specificity of the detector is high enough that no extra  
optical filtering of the UV light is needed.  
Two stages of the preamplifier are used to amplify the output signals of the detector to a  
level readable by the A/D Converter circuitry of the monitor’s sensor module. The first  
stage of amplification is located on the PCA’s on which the detector itself is mounted. The  
second stage of amplification is located on the sensor module PCA.  
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Gas Pressure Sensor: This absolute pressure sensor measures the gas pressure in the  
measurement cell upstream of the Pump. The sample pressure is used by the CPU to  
calculate O3 Concentration (see Formula 10-3 in Section 10.1). This sensor outputs an  
analog signal to the sensor microprocessor.  
Measure / Reference Valve: This valve alternates the O3 gas stream between a direct  
path to the absorption tube and a path that first passes it the O3 scrubber. The state of this  
valve is the Sensor Module PCA (see Section 10.3.2.2).  
10.3.2.2. Sensor Module PCA  
The sensor module PCA performs the real work of operating the O3 sensor module. It gathers the  
various measurements used to calculate the O3 concentration and performs all basic computations  
related to determining the O3 concentration of the source gas.  
It includes:  
Sensor Signal A/D Conversion: The output of the monitor’s O3 sensor and the pressure  
sensor are converted into digital signals that the CPU can understand by two analog to  
digital converters (A/D) located on the sensor PCA.  
LOW RESOLUTION A/D: A 12-bit, SAR converter that digitizes the output of the  
monitors pressure sensor.  
HIGH RESOLUTION A/D: This component digitizes the signal output by the UV detector  
of the monitor’s measurement detector. Since the reference detector output requires a  
large dynamic range and superior noise rejection, a Delta-Sigma type A/D Converter is  
used here.  
Sensor Microprocessor: This IC provides two important functions.  
A/D Converter Signal Selection: The A/D converter can only convert one signal at a time.  
The sensor microprocessor selects which of the sensor inputs is to be converted(pressure  
sensor or measurement detector), starts the conversion process, stops it and extracts the  
digital data.  
Data Output: The sensor microprocessor collects data from the various digital sensors as  
well as the data converted by its internal A/D and sends it to the main CPU via an internal  
RS-485 serial data bus.  
UV Lamp Heater Control: The sensor microprocessor also provides direct control of the UV  
lamp heater by turning it on and off via a transistor using high frequency pulse width  
modulation. The output of the UV Lamp sensor is converted by the micrprocessor’s A/D  
converter. Based on this digital value the sensor microprocessor sends out pulses that  
turn the heater ON/OFF. The more heat needed the longer the width of the ON (logic high)  
pulse and the shorter the width of the OFF (logic low) portion of the pulse.  
Measure / Reference Valve Control: The Measure/Reference valve is actuated by a 12  
VDC solenoid valve driver that is controlled by timing circuitry built into the sensor module  
board.  
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10.3.3. CPU Board  
In addition to being responsible for all I/O functions and managing the state of the monitors  
various status indicators and alarms (see below), the 460L’s CPU also calculates the monitor’s  
offset during zero point calibration (see Section 8.1) and converts O3 concentration data from ppb  
units into ppm units if necessary.  
10.3.3.1. I/O Functions  
Display Data: Two-way communications between the CPU and the Display driver module  
is handled via an I2C interface. I2C is a two-wire, clocked, bi-directional, digital serial I/O  
bus that is used widely in commercial and consumer electronic systems.  
Keyboard Input: The three keys/buttons on the front panel (two zero keys and the  
Alarm Resert key) are sensed directly by the CPU as simple digital contact closures.  
Analog Output: The 460L is equipped with one analog output which reports the current  
O3 concentration currently being measured by the monitor. During auto zero operation the  
last valid concentration value is held until the auto zero procedure is completed. This  
output is factory configurable as either a 0-5 VDC signal or a 4-20 mA signal.  
Serial I/O: A standard RS-232 or RS-485 serial communications port. Section 3.5.4  
describes how to configure and make connections to this port. Chapter 7 describes the  
syntax and commands available for use.  
Control Inputs: These inputs are used to initiate certain operations. (see Table 3-3).  
They are triggered by providing a contact closure or low impedance current path between  
the input and the ground pin (GND – see Figure 3-9). This can be done by using a  
mechanical switch or isolated transistor output from another device, such as a PLC.  
10.3.3.2. Status and Alarm Functions  
Relay Outputs: The 460L is equipped with three relay three SPDT relay. They are located  
at the top right hand side of the main board and are labeled RELAY 1, RELAY 2 & RELAY 3.  
RELAY 1 corresponds to the Sensor OK status output and LED;  
RELAY 2 corresponds to the HI concentration alarm, and;  
RELAY 3 corresponds to the HI-HI concentration alarm  
Status LED’s: Based on data received from the sensor module, it activates and  
deactivates the four status LED’s located on the monitor’s front panel (see Section 11.2.4).  
Status Outputs: Logic-Level voltages are output via optically isolated NPN transistors,  
which sink up to 50 mA of DC current. They are accessed through connector J2 on the  
main board. Several of these outputs convey good/bad information about key monitor  
operational conditions (see Section 11.2). Others reflect the status of the monitors O3  
concentration alarms.  
These outputs can be used to interface with devices that accept logic-level digital inputs,  
such as programmable logic controllers (PLC’s). Each Status bit is an open collector output  
that can withstand up to 40 VDC. All of the emitters of these transistors are tied together  
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and available at the STATUS COM pin of J2 on the main board (see Figure 3-7). This pin is  
normally connected to the input ground of the external device.  
NOTE  
Most PLC’s have internal provisions for limiting the current that the input will  
draw from an external device. When connecting to a unit that does not have this  
feature, an external dropping resistor must be used to limit the current through  
the transistor output to less than 50 mA. At 50 mA, the transistor will drop  
approximately 1.2V from its collector to emitter.  
10.3.4. Display Driver and Keyboard Assembly  
10.3.4.1. Keyboard  
The keyboard of the M460L is comprised of 3 contact closure button/keys that are directly sensed  
by the monitor’s CPU. These Switches are:  
Zero Switches: When pressed simultaneously, these switches activate the monitor’s auto  
zero calibration feature (see Section 8.1). Activating either switch independently has no  
affect on the monitor’s’ operation.  
Pressure Switch: Pressing and holding this switch causes the monitor to display the  
current gas pressure of the source gas as measured by the gas pressure sensor located on  
the measurement cell. Pressure is displayed in units of psia (pounds per square inch  
absolute).  
10.3.4.2. Display  
The main display of the monitor is a 4-digit, 7-segment LED display with decimal point. Under  
normal operation it displays the current O3 concentration of the source gas. It can also  
momentarily display the gas pressure of the source gas.  
10.3.4.3. Display Driver  
The circuitry on the display has driver several functions.  
Signal levels from the three front panel key/buttons are passed through the driver  
unaltered, directly to the CPU.  
Under command of the CPU a control chip located on this assembly turns the four status  
LED’s(see Section 112 & 11.3) ON/OFF  
A bipolar integrated circuit decodes the serial data sent by the CPU via an I2C bus and the  
individual segments of the display ON/OFF. The clock signal used to decode this data is  
supplied by the monitor’s main CPU.  
The four digits on the display are controlled by multiplexing between two pairs of 2 digits each.  
The display is operated in static mode. Each value sent by the CPU is held on the LED display  
until a new value is sent.  
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10.3.5. Power Distribution  
The 460L operates on 90 to 260 VAC power at either 50Hz or 60Hz. As illustrated in Figure 10-6  
below, power enters the monitor via a standard 3-conductor power cord through a hole provided  
in the bottom of the casing. In order to maintain the IP (NEMA4X) rating of the enclosure, an  
appropriate sealed conduit connector should be used.  
Serial I/O  
Port  
Analog  
Outputs  
Status I/O  
Measurement  
Detector  
Sensor Assembly  
Power Supply  
Status LEDS  
 Sensor OK  
 Invalid Reading  
 Lamp Low  
 Cell Dirty  
CPU  
Board  
± 9 VDC  
Pressure  
Sensor  
UV LAMP  
TEMPERATURE  
SENSOR  
+5 VDC  
Main Power Supply  
Main Power Supply  
+ 5 VDC  
MEASUREMENT CELL  
TEMPERATURE  
SENSOR  
Keyboard  
+ 12 VDC  
UV Lamp  
+ 15 VDC  
+ 12 VDC  
Power Supply  
200VAC 3kHz  
(1000VAC Peak)  
VAC IN  
UV Lamp  
Heater  
UV LAMP  
Vacuum  
Pump  
Output  
Relays  
Drivers  
M / R Valve  
Display  
Driver  
Board  
LED Display  
Output  
Relays  
Figure 10-6 460L Power Distribution Block Diagram  
MAIN POWER SUPPLY: AC line power is converted and stepped down to several DC  
voltages by the main power supply:  
+12 VDC: Powers the vacuum pump, the display driver and the alarm relay outputs.  
+5 VDC: The basic voltage on which the CPU and logic level circuitry operates.  
+15 VDC: Source voltage for the keyboard (where it is regulated down to +5 VDC),  
the UV lamp heater; the measure / reference valve a secondary power supply located  
on the sensor module assembly.  
SENSOR MODULE POWER SUPPLY: Using +15 VDC from the main power supply, this  
circuitry generates the +5, +12 & ±9 VDC supplies needed to operate its own on-board  
logic devices and the various components of the O3 sensor module.  
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UV LAMP POWER SUPPLY: Using +12 VDC supplied by the main power supply, this  
assembly generates the 30 kHz AC voltage for the monitor’s mercury vapor UV lamp. The  
output of this power supply is variable. At startup voltage level of this output can reach as  
high a 1000 VAC. Once the lamp is warmed up and operating at peak efficiency, the  
output should be around 200 VAC.  
The 460L has no onboard ON/OFF switch. A hardwired 2 Amp fuse is located on the main power  
supply assembly to provide over voltage/current protection.  
USER NOTES:  
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Troubleshooting  
11. TROUBLESHOOTING  
This chapter gives guidelines for diagnosing system and sensor malfunctions using the five digital  
Status Outputs provided by the 460L. All troubleshooting should be done after the 460L has been  
turned on and allowed to warm up for at least 15 minutes.  
11.1. Status Output Summary  
Table 11-1 below gives a summary of the operation of the Status Outputs on the 460L. See  
Section 3.5.2 Digital Status Outputs for information on connecting these outputs.  
Table 11-1 Digital Status Outputs Definitions  
LED on  
FRONT  
PANEL  
OUTPUT  
NAME  
ON STATE  
OFF STATE  
#
Measure > 1230mV;  
Reference > 1230mV;  
UV Lamp Off (Reference < 250 mV);  
Sensor  
O.K.  
1
YES  
YES  
Normal State  
No data from The O3 sensor  
Pressure > 14.9 psia;  
Pressure < 9 psia;  
Negative Ozone Concentration;  
Concentration Over-Range  
Invalid  
Reading  
2
Normal State  
Reference <375 mV  
3
4
Lamp Low  
YES  
YES  
Normal State  
Alarm  
Active  
Either the HI or the HI-HI O3  
concentration alarm is active  
No O3 Concentrati0on alarms are active  
Measured O3 concentration is ≥  
than the HI alarm set point  
5
6
HI Alarm  
NO  
NO  
Normal State  
Normal State  
HI-HI  
Alarm  
Measured O3 concentration ≥ the  
HI-HI alarm set point  
11.2. Troubleshooting Using Status Outputs  
11.2.1. Sensor OK  
The normal state for the Sensor OK output in ON. During the warm-up period on start-up this  
output will stay off until the UV lamp reaches a minimum intensity. If this output remains OFF  
after the 15 minute warm-up period, or goes off during normal operation the 460L is in need of  
servicing.  
If the Sensor OK output turns OFF  
One of the analog voltages output by the sensor module (reference / measure) is too high.  
This could mean that the lamp output has drifted high  
The reference voltage output by the sensor module (reference / measure) is too low. This  
could mean that the lamp intensity has drifted very low or the lamp is completely off.  
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The O3 sensor is not responding to CPU requests for data. This could represent a variety  
of electronic problems with the sensor module or internal communication between the CPU  
and the sensor module.  
11.2.2. Invalid Reading  
The normal state for the Invalid Reading output is OFF. When this output turns ON, the 460L is  
still operational, but a system fault or calibration fault exists that may make the current ozone  
reading invalid.  
The Invalid Reading output is turned ON for any of the following conditions:  
The measured pressure in the measurement cell exceeds too high indicating that the O3  
supply is under pressure.  
The measured pressure in the measurement cell exceeds too low indicating that there  
could be a blockage in the monitor’s internal pneumatic lines.  
The measured concentration has exceeded the measurement range selected for the  
monitor.  
The measured concentration is an excessively negative reading (less than -0.10 ppm or –  
10.0 ppb).  
11.2.3. Lamp Low  
The normal state for the lamp low output is OFF. This output turns on when the UV lamp intensity  
as measured by the reference detector has dropped below 375mV. This could mean that the lamp  
has drifted has started to drift low and that the lamp output should be adjusted.  
11.2.4. Status LED / Status Output Troubleshooting Summary  
Table 11-2 below is a logic truth table summarizing the recommended actions based on the states  
of the four status front panel status LED’s. A ‘1’ indicates the LED is ON, a ‘0’ indicates the LED is  
OFF, and ‘X’ indicates the LED can be in either state.  
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Table 11-2 Status LED / Output Trouble shooting Truth Table  
SENSOR INVALID  
LAMP  
LOW  
ACTIONS  
OK  
READING  
Normal operation, no action required.  
1
0
0
0
The Lamp intensity has drifted and is too high for proper operation.  
Adjust the lamp.  
0
0
The O3 sensor is not responding to request from the CPU for data.  
UV Lamp output is starting to drift low.  
1
0
X
X
1
1
Adjust the lamp output.  
The UV lamp is either completely off or its intensity has drifted so low  
that the monitor can not reliable measure O3.  
Replace the UV lamp (see Section 9.3).  
O3 reading is above the upper limit of the range selected for the  
monitor.  
Check or change the range setting (see Sections 7.3.9 to 7.3.11).  
O3 reading is too negative.  
Calibrate zero point (see Section 8.1).  
X
1
X
Possible Internal blockage.  
check or replace the filter (see Section 9.1.1).  
O3 supply under high pressure.  
Check gas lines from O3 source.  
11.3. Concentration Alarm Outputs  
Table 11-3 Alarm Output Troubleshooting  
FAULT CONDITION  
POSSIBLE CAUSES  
Alarm mode is set for Non-Latching and Concentration value is ≥  
relevant alarm set point.  
Pressing ALARM ACKNOWLEDGE button does  
not clear alarm or turn off Alarm Active LED.  
ALARM ACKNOWLEDGE button is bad.  
Using the ALMACK command over the serial  
port does not clear alarm or turn off Alarm  
Active LED.  
Alarm mode is set for Non-Latching and Concentration value is ≥  
relevant alarm set point.  
LED has Failed.  
Alarm Active LED doesn’t blink when one or  
both Alarms are active  
Display driver PCA malfunction  
Alarm does not activate at expected O3  
concentration  
Set point for alarm is set incorrectly  
Alarm Active Status Output OFF when HI alarm  
or HI-HI Alarm is active  
Electronic failure of Alarm Active status output.  
Hi alarm or HI-HI alarm status output is OFF  
when O3 concentration is ≥ related set point  
value  
Electronic failure of status output.  
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11.4. Technical Assistance  
If this addendum and its trouble-shooting / repair sections do not solve your problems, technical  
assistance may be obtained from:  
Teledyne Instruments  
Advanced Pollution Instrumentation Division  
(TAPI)  
Customer Service  
9480 Carroll Park Drive  
San Diego, California 92121-5201USA  
Toll-free Phone: 800-324-5190  
Phone: 858-657-9800  
Fax: 858-657-9816  
Email: [email protected]  
Website: http://www.Teledyne-API.com  
Before you contact Teledyne Instruments’ Customer service, fill out the problem report form in  
Appendix C, which is also available online for electronic submission at http://www.Teledyne-  
API.com/forms/p-fmapicom.asp.  
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A Primer on Electro-Static Discharge  
460L Instruction Manual  
12. A PRIMER ON ELECTRO-STATIC DISCHARGE  
Teledyne Instruments considers the prevention of damage caused by the discharge of static  
electricity to be extremely important part of making sure that your analyzer continues to provide  
reliable service for a long time. This section describes how static electricity occurs, why it is so  
dangerous to electronic components and assemblies as well as how to prevent that damage from  
occurring.  
12.1. How Static Charges are Created  
Modern electronic devices such as the types used in the various electronic assemblies of your  
analyzer, are very small, require very little power and operate very quickly. Unfortunately, the  
same characteristics that allow them to do these things also make them very susceptible to  
damage from the discharge of static electricity. Controlling electrostatic discharge begins with  
understanding how electro-static charges occur in the first place.  
Static electricity is the result of something called triboelectric charging which happens whenever  
the atoms of the surface layers of two materials rub against each other. As the atoms of the two  
surfaces move together and separate, some electrons from one surface are retained by the other.  
Materials  
Makes  
Contact  
Materials  
Separate  
+
+
+
+
PROTONS = 3  
ELECTRONS = 2  
PROTONS = 3  
ELECTRONS = 4  
PROTONS = 3  
ELECTRONS = 3  
PROTONS = 3  
ELECTRONS = 3  
NET CHARGE = -1  
NET CHARGE = +1  
NET CHARGE = 0  
NET CHARGE = 0  
Figure 12-1 Triboelectric Charging  
If one of the surfaces is a poor conductor or even a good conductor that is not grounded, the  
resulting positive or negative charge cannot bleed off and becomes trapped in place, or static.  
The most common example of triboelectric charging happens when someone wearing leather or  
rubber soled shoes walks across a nylon carpet or linoleum tiled floor. With each step, electrons  
change places and the resulting electro-static charge builds up, quickly reaching significant levels.  
Pushing an epoxy printed circuit board across a workbench, using a plastic handled screwdriver  
or even the constant jostling of StyrofoamTM pellets during shipment can also build hefty static  
charges.  
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Table 12-1 Static Generation Voltages for Typical Activities  
MEANS OF GENERATION  
65-90% RH  
1,500V  
250V  
10-25% RH  
Walking across nylon carpet  
Walking across vinyl tile  
Worker at bench  
35,000V  
12,000V  
6,000V  
100V  
Poly bag picked up from  
bench  
1,200V  
1,500V  
20,000V  
18,000V  
Moving around in a chair  
padded with urethane foam  
12.2. How Electro-Static Charges Cause Damage  
Damage to components occurs when these static charges come into contact with an electronic  
device. Current flows as the charge moves along the conductive circuitry of the device and the  
typically very high voltage levels of the charge overheat the delicate traces of the integrated  
circuits, melting them or even vaporizing parts of them. When examined by microscope the  
damage caused by electro-static discharge looks a lot like tiny bomb craters littered across the  
landscape of the component’s circuitry.  
A quick comparison of the values in Table 12-1 with the those shown in Table 12-2, listing device  
susceptibility levels, shows why Semiconductor Reliability News estimates that approximately  
60% of device failures are the result of damage due to electro-static discharge.  
Table 12-2 Sensitivity of Electronic Devices to Damage by ESD  
DAMAGE SUSCEPTIBILITY  
VOLTAGE RANGE  
DEVICE  
DAMAGE BEGINS  
OCCURRING AT  
CATASTROPHIC  
DAMAGE AT  
MOSFET  
VMOS  
10  
100  
30  
1800  
100  
NMOS  
60  
GaAsFET  
EPROM  
60  
2000  
100  
100  
140  
150  
190  
200  
300  
300  
JFET  
7000  
500  
SAW  
Op-AMP  
CMOS  
2500  
3000  
2500  
3000  
Schottky Diodes  
Film Resistors  
This Film  
Resistors  
300  
7000  
ECL  
500  
500  
500  
500  
SCR  
1000  
2500  
Schottky TTL  
Potentially damaging electro-static discharges can occur:  
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Any time a charged surface (including the human body) discharges to a device. Even  
simple contact of a finger to the leads of a sensitive device or assembly can allow enough  
discharge to cause damage. A similar discharge can occur from a charged conductive  
object, such as a metallic tool or fixture.  
When static charges accumulated on a sensitive device discharges from the device to  
another surface such as packaging materials, work surfaces, machine surfaces or other  
device. In some cases, charged device discharges can be the most destructive.  
A typical example of this is the simple act of installing an electronic assembly into the  
connector or wiring harness of the equipment in which it is to function. If the assembly is  
carrying a static charge, as it is connected to ground a discharge will occur.  
Whenever a sensitive device is moved into the field of an existing electro-static field, a  
charge may be induced on the device in effect discharging the field onto the device. If the  
device is then momentarily grounded while within the electrostatic field or removed from  
the region of the electrostatic field and grounded somewhere else, a second discharge will  
occur as the charge is transferred from the device to ground.  
12.3. Common Myths About ESD Damage  
I didn’t feel a shock so there was no electro-static discharge: The human nervous  
system isn’t able to feel a static discharge of less than 3500 volts. Most devices are  
damaged by discharge levels much lower than that.  
I didn’t touch it so there was no electro-static discharge: Electro Static charges are  
fields whose lines of force can extend several inches or sometimes even feet away from the  
surface bearing the charge.  
It still works so there was no damage: Sometimes the damaged caused by electro-static  
discharge can completely sever a circuit trace causing the device to fail immediately. More  
likely, the trace will be only partially occluded by the damage causing degraded  
performance of the device or worse, weakening the trace. This weakened circuit may seem  
to function fine for a short time, but even the very low voltage and current levels of the  
device’s normal operating levels will eat away at the defect over time causing the device to  
fail well before its designed lifetime is reached.  
These latent failures are often the most costly since the failure of the equipment in which  
the damaged device is installed causes down time, lost data, lost productivity, as well as  
possible failure and damage to other pieces of equipment or property.  
Static Charges can’t build up on a conductive surface: There are two errors in this  
statement.  
Conductive devices can build static charges if they are not grounded. The charge will be  
equalized across the entire device, but without access to earth ground, they are still  
trapped and can still build to high enough levels to cause damage when they are  
discharged.  
A charge can be induced onto the conductive surface and/or discharge triggered in the  
presence of a charged field such as a large static charge clinging to the surface of a nylon  
jacket of someone walking up to a workbench.  
As long as my analyzer is properly installed, it is safe from damage caused by static  
discharges: It is true that when properly installed the chassis ground of your analyzer is  
tied to earth ground and its electronic components are prevented from building static  
electric charges themselves. This does not prevent discharges from static fields built up on  
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other things, like you and your clothing, from discharging through the instrument and  
damaging it.  
12.4. Basic Principles of Static Control  
It is impossible to stop the creation of instantaneous static electric charges. It is not, however  
difficult to prevent those charges from building to dangerous levels or prevent damage due to  
electro-static discharge from occurring.  
12.4.1. General Rules  
Only handle or work on all electronic assemblies at a properly set up ESD station. Setting up an  
ESD safe workstation need not be complicated. A protective mat properly tied to ground and a  
wrist strap are all that is needed to create a basic anti-ESD workstation.  
Protective Mat  
Ground Point  
Wrist Stra  
Figure 12-2 Basic anti-ESD Workbench  
For technicians that work in the field, special lightweight and portable anti-ESD kits are available  
from most suppliers of ESD protection gear. These include everything needed to create a  
temporary anti-ESD work area anywhere.  
Always wear an Anti-ESD wrist strap when working on the electronic assemblies of  
your analyzer. An anti-ESD wrist strap keeps the person wearing it at or near the same  
potential as other grounded objects in the work area and allows static charges to dissipate  
before they can build to dangerous levels. Anti-ESD wrist straps terminated with alligator  
clips are available for use in work areas where there is no available grounded plug.  
Also, anti-ESD wrist straps include a current limiting resistor (usually around one meg-ohm)  
that protects you should you accidentally short yourself to the instrument’s power supply.  
Simply touching a grounded piece of metal is insufficient. While this may temporarily  
bleed off static charges present at the time, once you stop touching the grounded metal  
new static charges will immediately begin to re-build. In some conditions, a charge large  
enough to damage a component can rebuild in just a few seconds.  
Always store sensitive components and assemblies in anti-ESD storage bags or bins:  
Even when you are not working on them, store all devices and assemblies in a closed anti-  
Static bag or bin. This will prevent induced charges from building up on the device or  
assembly and nearby static fields from discharging through it.  
Use metallic anti-ESD bags for storing and shipping ESD sensitive components and  
assemblies rather than pink-poly bags. The famous, pink-poly bags are made of a  
plastic that is impregnated with a liquid (similar to liquid laundry detergent) which very  
slowly sweats onto the surface of the plastic creating a slightly conductive layer over the  
surface of the bag.  
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While this layer may equalizes any charges that occur across the whole bag, it does not  
prevent the build-up of static charges. If laying on a conductive, grounded surface, these  
bags will allow charges to bleed away but the very charges that build up on the surface of  
the bag itself can be transferred through the bag by induction onto the circuits of your ESD  
sensitive device. Also, the liquid impregnating the plastic is eventually used up after which  
the bag is as useless for preventing damage from ESD as any ordinary plastic bag.  
Anti-Static bags made of plastic impregnated with metal (usually silvery in color) provide all  
of the charge equalizing abilities of the pink-poly bags but also, when properly sealed,  
create a Faraday cage that completely isolates the contents from discharges and the  
inductive transfer of static charges.  
Storage bins made of plastic impregnated with carbon (usually black in color) are also  
excellent at dissipating static charges and isolating their contents from field effects and  
discharges.  
Never use ordinary plastic adhesive tape near an ESD sensitive device or to close an  
anti-ESD bag. The act of pulling a piece of standard plastic adhesive tape, such as  
Scotch® tape, from its roll will generate a static charge of several thousand or even tens of  
thousands of volts on the tape itself and an associated field effect that can discharge  
through or be induced upon items up to a foot away.  
12.4.2. Basic anti-ESD Procedures for Analyzer Repair and  
Maintenance  
12.4.2.1. Working at the Instrument Rack  
When working on the analyzer while it is in the instrument rack and plugged into a properly  
grounded power supply  
1. Attach you anti-ESD wrist strap to ground before doing anything else.  
Use a wrist strap terminated with an alligator clip and attach it to a bare metal portion of  
the instrument chassis.  
This will safely connect you to the same ground level to which the instrument and all of its  
components are connected.  
2. Pause for a second or two to allow any static charges to bleed away.  
3. Open the casing of the analyzer and begin work. Up to this point, the closed metal casing  
of your analyzer has isolated the components and assemblies inside from any conducted  
or induced static charges.  
4. If you must remove a component from the instrument, do not lay it down on a non-ESD  
preventative surface where static charges may lie in wait.  
5. Only disconnect your wrist strap after you have finished work and closed the case of the  
analyzer.  
12.4.2.2. Working at an Anti-ESD Work Bench.  
When working on an instrument of an electronic assembly while it is resting on a anti-ESD  
workbench  
1. Plug your anti-ESD wrist strap into the grounded receptacle of the work station before  
touching any items on the work station and while standing at least a foot or so away.  
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TELEDYNE INSTRUMENTS  
A Primer on Electro-Static Discharge  
460L Instruction Manual  
This will allow any charges you are carrying to bleed away through the ground connection  
of the workstation and prevent discharges due to field effects and induction from  
occurring.  
2. Pause for a second or two to allow any static charges to bleed away.  
3. Only open any anti-ESD storage bins or bags containing sensitive devices or assemblies  
after you have plugged your wrist strap into the workstation.  
Lay the bag or bin on the workbench surface.  
Before opening the container, wait several seconds for any static charges on the  
outside surface of the container to be bled away by the workstation’s grounded  
protective mat.  
4. Do not pick up tools that may be carrying static charges while also touching or holding an  
ESD sensitive Device.  
5. Only lay tools or ESD-sensitive devices and assemblies on the conductive surface of your  
workstation. Never lay them down on any non-ESD preventative surface.  
6. Place any static sensitive devices or assemblies in anti-static storage bags or bins and  
close the bag or bin before unplugging your wrist strap.  
7. Disconnecting your wrist strap is always the last action taken before leaving the  
workbench.  
12.4.2.3. Transferring Components from Rack to Bench and Back  
When transferring a sensitive device from an installed Teledyne Instruments analyzer to an Anti-  
ESD workbench or back:  
1. Follow the instructions listed above for working at the instrument rack and workstation.  
2. Never carry the component or assembly without placing it in an anti-ESD bag or bin.  
3. Before using the bag or container allow any surface charges on it to dissipate:  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is  
connected to a ground point.  
If you are at an anti-ESD workbench, lay the container down on the conductive work  
surface.  
In either case wait several seconds.  
4. Place the item in the container.  
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5. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape.  
Folding the open end over isolates the component(s) inside from the effects of static  
fields.  
Leaving the bag open or simply stapling it shut without folding it closed prevents the  
bag from forming a complete protective envelope around the device.  
6. Once you have arrived at your destination, allow any surface charges that may have built  
up on the bag or bin during travel to dissipate:  
7. Connect your wrist strap to ground.  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is  
connected to a ground point.  
If you are at a anti-ESD workbench, lay the container down on the conductive work  
surface.  
In either case wait several seconds.  
8. Open the container.  
12.4.2.4. Opening Shipments from Teledyne Instruments’ Customer  
Service.  
Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of  
static electric charges. To prevent damage from ESD, Teledyne Instruments ships all electronic  
components and assemblies in properly sealed ant-ESD containers.  
Static charges will build up on the outer surface of the anti-ESD container during shipping as the  
packing materials vibrate and rub against each other. To prevent these static charges from  
damaging the components or assemblies being shipped make sure that you:  
1. Always unpack shipments from Teledyne Instruments Customer Service by.  
2. Open the outer shipping box away from the anti-ESD work area.  
3. Carry the still sealed ant-ESD bag, tube or bin to the anti-ESD work area.  
4. Follow steps 6 and 7 of Section 12.4.2.3 above when opening the anti-ESD container at the  
work station.  
5. Reserve the anti-ESD container or bag to use when packing electronic components or  
assemblies to be returned to Teledyne Instruments.  
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A Primer on Electro-Static Discharge  
460L Instruction Manual  
12.4.2.5. Packing Components for Return to Teledyne Instruments  
Customer Service  
Always pack electronic components and assemblies to be sent to Teledyne Instruments Customer  
Service in anti-ESD bins, tubes or bags.  
CAUTION  
ESD Hazard  
DO NOT use pink-poly bags.  
NEVER allow any standard plastic packaging materials to touch the  
electronic component/assembly directly  
This includes, but is not limited to, plastic bubble-pack, Styrofoam  
peanuts, open cell foam, closed cell foam, and adhesive tape  
DO NOT use standard adhesive tape as a sealer. Use ONLY anti-ESD  
tape  
1. Never carry the component or assembly without placing it in an anti-ESD bag or bin.  
2. Before using the bag or container allow any surface charges on it to dissipate:  
If you are at the instrument rack, hold the bag in one hand while your wrist strap is  
connected to a ground point.  
If you are at an anti-ESD workbench, lay the container down on the conductive work  
surface.  
In either case wait several seconds.  
3. Place the item in the container.  
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460L Instruction Manual  
4. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape.  
Folding the open end over isolates the component(s) inside from the effects of static  
fields.  
Leaving the bag open or simply stapling it shut without folding it closed prevents the  
bag from forming a complete protective envelope around the device.  
NOTE  
If you do not already have an adequate supply of anti-ESD gags or containers available,  
Teledyne Instruments’ Customer Service department will supply them  
(see Section 11.4 for contact information).  
Follow the instructions listed above for working at the instrument rack and workstation.  
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460L Instruction Manual  
Spare Parts List  
USER NOTES:  
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M460L Instruction Manual  
Appendix A - Spare Parts list  
Appendix A - Spare Parts list  
•
05128 – Spare Parts List M460L  
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Appendix A - Spare Parts list  
M460L Instruction Manual  
A-2  
05229 Rev B  
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M460L Spare Parts List  
Part Number  
025710100  
Description  
PCA, UV DETECTOR PREAMP, M454/M460  
OVERLAY, FRONT PANEL, O3 SENSOR, M460L  
PCA, FRONT PANEL, M454 PRODUCTS  
PCA, EXPANSION BD, M554/M460X/03/CAL  
ASSY, WATER DROP OUT FILTER, PFA, M450  
AKIT, ELEMENTS, 47MM, 30 MICRON (10 PCS)  
ASSY, UV LAMP (BIR) M452/454/460X/465L *  
ASSY, FLOWMETER, 0-2.5L, M460M/L  
CBL, PS AC IN, M454 NEMA  
030500400  
031680100  
034920000  
036280000  
036750000  
037420000  
037490100  
040530000  
040540100  
041980000  
046170000  
046740000  
047110000  
048490100  
049680000  
049910100  
050120000  
050170000  
050300000  
053010000  
CN0000350  
DR0000006  
HW0000120  
OP0000031  
OR0000039  
OR0000050  
OR0000098  
OR0000099  
PS0000035  
CBL, DC POWER, M460L NEMA  
CBL ASSY, GROUND STRAP, 4.5"  
ABSORPTION TUBE, M460L  
ASSY, PUMP, 12VDC, M460M/M700E  
ASSY, VALVE, M460L  
PCA, O3 BENCH, M460L/M465L  
ASSY, SENSOR, HI-CONC, M460L/M465L  
PCA, MAINBOARD, M460L  
MANUAL, OPERATORS, M460L  
ASSY, DFU SAMPLE FILTER  
ASSY, REF SCRUBBER, HI-CONC, M460L/M465L  
AKIT, EXP KIT, CARULITE 200  
CONNECTOR, 16 PIN, W/SCREW FLANGE  
DRYER, 24", 1/4" SS FITTINGS  
SHOCKMOUNT, GROMMET ISOLATOR  
WINDOW, QUARTZ, 1/2"DIA, .063" THICK (KB  
ORING, BENCH  
ORING, BENCH  
ORING, BENCH  
ORING, WATER DROP OUT FILTER  
EOS SWITCHING PS, 15V, 40W  
05128C M460L- SPL.xls DCN5164  
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460L Instruction Manual  
Appendix B – Electronic Schematics  
Appendix B – Electronic Schematics  
Table B-1  
M460L List of Electronic Schematics  
DOCUMENT #  
03169  
DESCRIPTION  
PCA, FRONT PANEL DISPLAY  
PCA, MAINBOARD  
PCA, CPU  
04992  
03493  
05230 Rev A  
B-1  
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Appendix B – Electronic Schematics  
460L Instruction Manual  
B-2  
05230 Rev A  
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