ANALOX CO Clear User manual

Analox Ltd.
15 Ellerbeck Court, Stokesley Business Park
North Yorkshire, TS9 5PT, UK
T: [phone] F: [phone]
W: www.analox.net E: [e-mail]
CO Clear
User Manual
Commercial in Confidence

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 3 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Table of Contents
1Safety information ........................................................... 4
1.1 Electrochemical sensors (Carbon monoxide) .......................................... 4
1.2 Fuse ratings ............................................................................................ 5
1.3 Other information ................................................................................... 5
2Package contents checklist .............................................. 6
3About the product............................................................ 7
4Sensor characteristics and helium effect ......................... 8
5Installation of the product ............................................... 9
5.1 Wall mounting ........................................................................................ 9
5.2 Wiring installation .................................................................................. 9
6Option available............................................................. 10
6.1 AC supply models.................................................................................. 10
6.2 DC supply models ................................................................................. 10
6.3 Alarm repeaters .................................................................................... 10
6.4 Alarm relay output models.................................................................... 10
6.5 Relay wiring.......................................................................................... 11
6.6 4 to 20mA output models...................................................................... 12
7Operation....................................................................... 13
7.1 Normal operation .................................................................................. 13
7.2 Alarm indications .................................................................................. 13
8Compressor connection ................................................. 14
9Maintenance .................................................................. 15
9.1 Recommended calibration interval........................................................ 15
9.2 Carbon Monoxide sensor replacement .................................................. 15
10 Calibration................................................................... 17
10.1 0 to 10ppm in nitrogen range calibration gases.................................... 17
10.2 0 to 25ppm in nitrogen range calibration gases.................................... 17
10.3 Zero calibration..................................................................................... 18
10.4 Span calibration.................................................................................... 19
10.5 Alarm check .......................................................................................... 19
10.6 Adjusting alarm set points .................................................................... 20
11 Fault conditions........................................................... 21
12 Specifications .............................................................. 22
13 Disposal....................................................................... 23
14 Declaration of conformity ............................................ 24

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 4 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
1Safety information
1.1 Electrochemical sensors (Carbon monoxide)
Electrochemical sensors contain toxic compounds. Under normal conditions the sensor will
be safely sealed. To prevent leakage, the unit must not be exposed to temperatures
outside the specified range, or be exposed to organic vapours, which may cause physical
damage to the body of the sensor. The unit must not be stored in areas containing organic
solvents or in flammable liquid stores.
When the life of the sensor has expired, or it is leaking or otherwise damaged it must be
disposed of safely in accordance with local regulations.
Carbon monoxide cell contains an acidic electrolyte (sulphuric acid). In the event of an
accident, use the following first aid procedures.
Table 1 Electrochemical sensor first aid procedures
Body
Part
Effect
First Aid Procedures
Skin
Contact could result in a chemical burn.
Persons with pre-existing skin disorders
may be more susceptible to the effects
of the substance.
Immediately flush the skin thoroughly
with water for at least 15 minutes.
Remove contaminated clothing and wash
before re-use.
Obtain medical advice if continued
irritation.
Ingestion
Corrosive. May cause sore throat,
abdominal pain, nausea, and severe
burns of the mouth, throat, and
stomach, and may be fatal.
If swallowed DO NOT INDUCE VOMITING.
Wash out mouth thoroughly with water
and give plenty of water to drink.
Obtain medical advice immediately
Eye
Persons with pre-existing eye problems
may be more susceptible to the effects
of the substance.
Corrosive. May cause redness, pain,
blurred vision, and eye burns.
Contact can result in the permanent loss
of sight.
Irrigate thoroughly with water for at least
15 minutes.
Obtain medical advice immediately.
Inhalation
Persons with pre-existing impaired
respiratory function may be more
susceptible to the effects of the
substance.
Inhalation is not an expected hazard
unless heated to high temperatures.
Mist or vapour inhalation can cause
irritation to the nose, throat, and upper
respiratory tract.
Remove to fresh air.
Rest and keep warm.
Obtain medical advice if applicable.
Should leakage of any electrolyte occur as a result of misuse, incorrect operation,
manufacturing error, physical damage, etc. then wear protective gloves when cleaning any
spills. Should electrolyte contact skin then the affected area should be washed thoroughly
with copious water and medical advice sought if there has been any contact with the eyes
or mouth. If connected to any electrical equipment, the sensor should be immediately
removed.

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 5 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
The Analox CO Clear is designed to be compliant with the following standards: EN61010-1:
2001, IEC61010-1: 2001, CAN/CSA-C22.2 No. 61010-1 Second Edition 2004, ANSI/UL
61010-1 Second Edition 2005. It is designed to be safe at least under the following
conditions.
•Indoor use
•Altitude up to 2000m
•Temperature -5°C to +40°C
•Maximum relative humidity 80% for temperatures up to 31°C decreasing linearly
to 50% relative humidity at 40°C.
•Mains voltage supply fluctuations not to exceed 10% of the nominal voltage
•Impulse withstand (over-voltage) category II of IEC 60364-4-443
•Pollution degree 2
•Mains voltage: -
230V AC (Not Adjustable - Instrument will be factory set)
110V AC (Not Adjustable - Instrument will be factory set)
24V DC (Not Adjustable - Instrument will be factory set)
•Mains power: -
Less than 5VA –110V AC and 230V AC Versions
Less than 5W –24V DC Version.
•Mains frequency - 50/60Hz
•The Remote Alarm Repeater has ingress protection to IP43: direct sprays of water
up to 60° from the vertical in accordance with EN 60529:1991 + A1. All other
units have ingress protection to IP65: low pressure water jets from all directions
and totally protected from dust in accordance with EN 60529:1991 + A1.
•Insulation: - Reinforced insulation, class II product according to IEC536.
•Not for use in corrosive or explosive atmospheres
•Not approved for use in vehicles, ships or aircraft
1.2 Fuse ratings
Table 2 Fuse ratings
230V AC, 500mA
F rating 250V (20mm x 5mm Glass Cartridge)
110V AC, 500mA
F rating 250V (20mm x 5mm Glass Cartridge)
9-24V DC, 200mA
AS rating 250V (20mm x 5mm Glass Cartridge)
1.3 Other information
Battery Back-Up
The Battery Back-Up is non-repairable. Please return faulty units to Analox for
refurbishment or replacement.
4 to 20mA (or 0-1V) Output
Connected equipment must meet the requirements for reinforced insulation.
NOTE:
IF THE EQUIPMENT IS USED IN A MANNER NOT
SPECIFIED BY THE MANUFACTURER, THE PROTECTION
PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED.

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 6 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
2Package contents checklist
On receipt of the Analox CO Clear please check you have the following:
1) Analox CO Clear main unit and Alarm Repeater
2) User Manual
3) Test Certificate
4) Rawl Plugs and Screws for Wall Mounting
5) Drilling Template
6) Analox CO Clear Window Sticker
7) Analox CO Clear wall notice
Any optional items ordered such as:
1) Battery back-up
2) Relay junction box
3) Additional 6mm Push-fit connector
4) Additional ¼ inch Push-fit connector
5) 6mm tubing
6) ¼ inch tubing

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 7 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
3About the product
Two variants of the Analox CO Clear are available.
The Analox CO Clear is designed to detect the presence of Carbon Monoxide in air or Nitrox
gas compressors.
The Analox CO Clear He is designed to detect the presence of Carbon Monoxide in Heliox
(HeO2) gas compressors. This variant can be identified by the serial number label as
shown below.
Different versions of the instrument allow operation from:
1) 210/250V AC supply
2) 110/120V AC supply
3) 9-24V DC supply
The Analox CO Clear is intended to be used as a permanent installation. It provides a
digital readout of Carbon Monoxide and 2 audio and visual alarms to warn you of elevated
levels of Carbon Monoxide. The alarms are set with a small hysteresis (0.5ppm) which
means the CO concentration must fall below the alarm set point before the alarm cancels.
The instrument uses an Electrochemical cell together with state-of-the-art technology, built
in an IP65 splash proof housing and is designed to provide long, trouble free service, with
minimum maintenance.
Optional items fitted to or supplied with the unit may include the following:
1) One or two medium duty relays
2) Test Gas and control valve
3) Battery Back-Up
4) 4-20mA output

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 8 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
4Sensor characteristics and helium effect
The carbon monoxide cell is a capillary type sensor. These types of sensors are affected by
the presence of Helium (He), and in such cases give higher than anticipated outputs. For
this reason, the Analox CO Clear He has been developed for use in Heliox gas applications
(e.g. Saturation diving).
For a detailed explanation of what the helium effect is and how it affects the
measurements of carbon monoxide please refer to document ACO-MISC01-00 Helium
sensitivity effect available from Analox.
The basic effect of He in the sample gas is to increase the carbon monoxide sensitivity.
This means that as the amount of He increases the sensitivity of the CO cell increases by
what we call the ‘compensation factor’ (see Table 1).
For example, if a CO Clear He measured 3ppm CO in a tank containing 99% He, the actual
CO content would be 2.1ppm (3 x 0.7 = 2.1ppm).
The look-up table below Table 3 shows a simplified representation of the helium effect to
quickly identify the compensation factor to be applied to your gas measurement.
NOTE:
THE COMPENSATION FACTORS IN TABLE 1 ARE BASED
ON A CO CLEAR HE CALIBRATED WITH A MIX
CONTAINING 79% HE BALANCE AS PROVIDE IN THE
CO CLEAR HE CALIBRATION KIT (SEE CALIBRATION
SECTION FOR DETAILS).
Table 3 Helium effect compensation factors
% Helium
in mix
Compensation
factor
79 to 83
1.0
83 to 89
0.9
89 to 94
0.8
94 to 99
0.7
The helium effect increases as the He content in the sample gas increases, so it is
important that the correct calibration gases are used. For this reason, the instrument
MUST be calibrated using 21% O2 in He balance calibration gas (see Calibration section
for details). This ensures that any measurement errors due to the helium effect are fail-
safe.

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 9 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
5Installation of the product
5.1 Wall mounting
The Analox CO Clear should be mounted onto a wall or vertical flat surface using the
mounting lugs; a paper drilling template is supplied in the packaging. Use the paper
template to drill the 4 required holes in the wall and use the Rawl plugs and screws
provided to mount the unit. It is not necessary to dismantle the Analox CO Clear main unit
in any way prior to installation. You need to ensure the mains plug, fused at 3 amps is in
easy reach of a power socket.
The Alarm Repeater housing also has wall mounting lugs.
5.2 Wiring installation
It is necessary to identify the model of Analox CO Clear prior to installation. The
Calibration Certificate accompanying each instrument will clearly identify the information
required.
WARNING:
ENSURE THAT THE ELECTRICAL SUPPLY TO THE
INSTRUMENT IS SWITCHED OFF PRIOR TO
INSTALLING ANY WIRING.

CO Clear
User Manual Int. Approved
Document ref: ACO-810-28 October 2018 Page 10 of 24
Copyright © 2006 Analox Ltd. All Rights Reserved.
Commercial in Confidence
6Option available
6.1 AC supply models
A mains powered Analox CO Clear is pre-wired with a mains cable, fitted with a plug suited
to the destination country. Where internal plug fuses are fitted, these are 3 Amp. Ensure
that the unit is connected to the correct supply voltage (i.e. 110 or 230V AC). Where no
fuse is fitted in the plug, the instrument should be powered from a 3 Amp fused outlet.
The Analox CO Clear is fitted with an internal fuse, which is rated at 500mA.
6.2 DC supply models
A DC powered Analox CO Clear require a DC supply in the range 9-24V DC. A 2m cable is
factory fitted to the instrument. The DC supply should be connected to this cable as
follows:
1. Blue wire negative (0Volts)
2. Red wire positive (+9-24Volts)
6.3 Alarm repeaters
The Alarm Repeater has four status indicators and a Mode button, which mimic the button
and indicators on the main Analox CO Clear enclosure.
An 8 metre, 8 core cable is pre-wired to the Analox CO Clear on units to be fitted with an
alarm repeater. This ensures that for a basic installation, there is no need to dismantle the
Analox CO Clear main unit. A maximum of three repeaters may be fitted in a daisy chain
configuration.
To connect and disconnect a “Quick Connect” Repeater:
Disconnect the power supply from the Analox CO Clear.
Insert the connector on the end of the cable into the socket on the base of
the Alarm Repeater.
Restore power to the Analox CO Clear. Press the mode button on the
repeater once and ensure that the four indicators flash. Note that in the
presence of a genuine alarm, the test feature is disabled.
6.4 Alarm relay output models
You may have ordered your Analox CO Clear with a relay. The relay contacts are ‘Volt-
Free’ single pole Changeover, rated 250vAC/30vDC 2 Amps. The relay is non-latching. This
means the relay will only initiate when gas is present. As standard the relays are setup in
a Fail-Safe configuration. This means that the relay is energised during normal operation.
Please note that on power up the relay is only energised after the 40 second warm-up
period. See Figure 1 for details of how the relay should be connected.