ANALOX ACG+ Programming manual

ACG+ Service & Troubleshooting
Manual
Service & Troubleshooting Manual
Commercial in Confidence

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 3 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Table of contents
1Safety information .................................................................................................6
1.1 Electrochemical sensors (oxygen and carbon monoxide)..................................................6
1.2 PID lamp cleaning kit ............................................................................................................7
2Introduction ............................................................................................................8
3Recommended spares and accessories ................................................................9
3.1 Service requirements...........................................................................................................11
4Maintenance..........................................................................................................12
4.1 Sensor & filter replacement ...............................................................................................12
4.1.1 Oxygen cell replacement ...............................................................................................................................13
4.1.2 Carbon monoxide cell replacement ..........................................................................................................16
4.1.3 Replacing the CO cell PCB (MEC-233B) ...................................................................................................18
4.1.4 VOC maintenance.............................................................................................................................................22
4.1.5 Water vapour sensor replacement.............................................................................................................25
4.2 Filter replacement................................................................................................................26
4.2.1 Activated charcoal filter replacement .......................................................................................................26
4.2.2 Particulate filter replacement .......................................................................................................................27
4.3 Service requirements...........................................................................................................27
4.3.1 Replacing the flow adaptor orings.............................................................................................................28
4.3.2 Replacing the PID cell .....................................................................................................................................28
4.3.3 Replacing the PID cell PCB (MEC-233C) ..................................................................................................30
5FAQ’s (most common solutions) ........................................................................35
5.1 Recommended calibration gas concentrations.................................................................35
5.2 Maintenance schedule of ACG+ components ...................................................................35
5.3 CO2sensor range fault ........................................................................................................35
5.4 VOC Sensor cannot calibrate ..............................................................................................36
5.5 COMMS.................................................................................................................................36
5.6 COSHH Regulations.............................................................................................................37
5.7 Heliox/Trimix mixes ............................................................................................................37
5.8 Nitrox gas mixes..................................................................................................................37

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 4 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
List of tables
Table 1 Electromechanical sensor first aid procedure.......................................................................................6
Table 2 List of spares...........................................................................................................................................................9
Table 3 List of accessories ..............................................................................................................................................10
Table 4 6 monthly service for ACG+.........................................................................................................................11
Table 5 12 monthly service for ACG+ ......................................................................................................................11
Table 6 24 monthly service for ACG+ ......................................................................................................................11
Table 7 Maintenance schedule of ACG+ components ....................................................................................12
Table 8 Service schedule of ACG+ components .................................................................................................27

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 5 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Warnings, Cautions and Notes
Warnings and Cautions are used in this Manual to highlight potential hazards and safety risks. Notes
are used to provide supplementary information that is not hazard-related.
WARNING:
THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT,
IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY.
CAUTION:
THIS INDICATES A POTENTIALLY HAZARDOUS SITUATION THAT,
IF NOT AVOIDED, COULD RESULT IN EQUIPMENT DAMAGE OR
LOSS OF DATA.
NOTE:
THIS INDICATES INFORMATION THAT IS CONSIDERED
IMPORTANT BUT IS NOT HAZARD RELATED.

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 6 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
1Safety information
WARNING:
READ THE SAFETY INFORMATION FULLY BEFORE USING THE
ANALOX ACG+.
1.1 Electrochemical sensors (oxygen and 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.
The carbon monoxide cell contains an acidic electrolyte (sulphuric acid) whilst the oxygen cell contains caustic
electrolyte (potassium hydroxide). In the event of an accident, use the following first aid procedures.
Table 1 Electromechanical sensor first aid procedure
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.

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 7 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
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Body
Part
Effect
First Aid Procedures
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.
1.2 PID lamp cleaning kit
The PID lamp cleaning kit (9300-1022) contains a vial of cleaning compound which contains alumina
(CAS Number 1344-28-1) as a very fine powder.
Hazard identification: May cause irritation of respiratory tract and eyes
Storage: Keep container closed to prevent water absorption and contamination
Handling:
•Do not breathe in the powder, avoid contact with skin, eyes and clothing
•Wear suitable protective clothing
•Follow industrial hygiene practices, wash face and hands thoroughly with soap and water after
use and before eating, drinking, smoking or applying cosmetics
•The powder carries a TVL (TWA) limit of 10mg/m3

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 8 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
2Introduction
This manual describes the maintenance procedures for the ACG+ and answers common
troubleshooting solutions.
Please refer to P0149-801 for the complete user manual.

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 9 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
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3Recommended spares and accessories
Table 2 List of spares
Item
Description
Part no.
1
VOC in-line filter (6mm inlet/outlet)
6000-0096
2
Internal particulate filter
2533-1008
3
MEC O2 full sensor module
MECO2ABAP
4
MEC O2cell (electrochemical)
9100-9212-9HM
5
MEC CO full sensor module
MECCOEBAP
6
MEC CO sensor PCB
MEC-233B
7
MEC CO cell (electrochemical)
9100-2030S
8
MEC VOC full sensor module
MECVOCBAP
9
MEC VOC cell (PID)
9100-2060S
10
MEC VOC sensor PCB
MEC-233C
11
Water vapour sensor
6000-0094
Replacement VOC sensor parts
12
Disposable electrode stack
9100-2060/ES
13
10.6 eV replacement lamp
9100-2060/LP
14
Replacement spring
9100-2060/SP
Service parts
15
5S3 CO2full sensor module (0-1000ppm
range)
A5S3ASN8A (See note below)
16
5S3 CO2full sensor module (0-10000ppm
range)
A5S3ALN8A (See note below)
17
ACG+ Display Module –Configured for
CO2, O2, CO, VOC and water vapour
ACGSDA/1 (See note below)
18
ACG+ Display Module –Configured for
CO2, O2, CO and VOC
ACGSDA/2 (See note below)
19
ACG+ Display Module –Configured for
CO2, O2, CO and water vapour
ACGSDA/3 (See note below)
20
ACG+ Display Module –Configured for
CO2, O2, CO
ACGSDA/4 (See note below)
21
Replacement oring for sensor flow
adaptor
2323-0017X
NOTE:
ACG+ TO BE RETURNED TO ANALOX FOR REPLACEMENT OR
SERVICE

ACG+
Service & Troubleshooting Manual Int. Approved
Document ref: P0149-825-00 October 2022 Page 10 of 37
Copyright © 2022 Analox Ltd. All Rights Reserved.
Commercial in Confidence
Table 3 List of accessories
Item
Description
Part no.
1
External PSU, 24VDC, 1.5A, 36W for connection to
front panel via panel mount connector (For use
with Portable & Fixed variants)
ACGPEXTPSU
2
External PSU, 24VDC, 2.7A, 65W for connection
through gland direct onto interface PCB (For use
with fixed variants)
ACGEXTPSU
3
Li-Ion rechargeable battery pack kit, universal
(Includes charger and battery casing –for portable
variants)
P0149-605LU
4
Spare Li-Ion rechargeable battery pack (Includes
battery casing lid –for portable variants)
P0149-605LS
5
NiMH rechargeable battery pack kit, universal
(Includes charger and battery casing –for portable
variants)
P0149-605NU
6
Spare NiMH rechargeable battery pack (Includes
battery casing lid –for portable variants)
P0149-605NS
7
Inlet/Calibration adaptor
6000-0201
8
0.5LPM 110L bottle regulator
Contact Analox or
source locally
9
Zero calibration gas (not including CO Sensor) –8%
oxygen, balance nitrogen
Contact Analox or
source locally
10
Zero calibration gas (For CO Sensor only) –20.9%
oxygen balance nitrogen.
Oxygen only span calibration gas (For part number
ACGPABXXXXX)
Contact Analox or
source locally
11
Nitrogen background span calibration gas, (18ppm
carbon monoxide, 18ppm isobutylene, 20.9%
oxygen, 900ppm carbon dioxide, balance nitrogen)
Contact Analox or
source locally
12
Carbon dioxide only span calibration gas (For part
number ACGPABXXXXX) –9000ppm carbon
dioxide, balance nitrogen
Contact Analox or
source locally
13
Pressure regulator, compact piston sensed, 300bar
max inlet, 0 to 7bar adjustable outlet (Suitable 1/8“
NPT fittings required for inlet and outlet), complete
with pressure relief valve set at 7.5bar
6000-0164
14
Combined beacon/sounder, 24V DC, IP65 (For fixed
variant)
2562-0008
15
30mm open ended spanner
9300-1020
16
Gastec Airtec Tube (Oil Mist) 109A, Pk10
9100-3500
17
Rubber Tube Holder for colorimetric tubes
GAS357
18
8mm to 4mm Push fit reducer (Required for item
17)
6000-0165
19
Drager Oil Impactor, Pk10
9100-3501
20
Override Keyswitch & Gland Kit
P0149-610
21
Humidifier Kit
P0149-660
22
External flow meter sample support kit
P0149-611
23
VOC electrode stack removal tool
9300-1021
24
VOC lamp cleaning kit
9300-1022
25
ACG+ Fixing Kit
P0075-615