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

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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.
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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
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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.

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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

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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.

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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

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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

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3.1 Service requirements
The following tables specify the description of the service parts and their associated part numbers for
the 6 monthly, 12 monthly and 24 monthly service requirements.
NOTE:
THE SPARES SHELF LIFE IS 3 MONTHS FROM THE DATE
OF DESPATCH FROM ANALOX.
Table 4 6 monthly service for ACG+
Item
Description
Part no.
1
10.6 eV replacement lamp
9100-2060/LP
2
Internal particulate filter
2533-1008
3
VOC electrode stack removal tool
9300-1021
Table 5 12 monthly service for ACG+
Item
Description
Part no.
1
10.6 eV replacement lamp
9100-2060/LP
2
Internal particulate filter
2533-1008
3
VOC in-line filter (6mm inlet/ outlet)
6000-0096
4
VOC electrode stack removal tool
9300-1021
Table 6 24 monthly service for ACG+
Item
Description
Part no.
1
10.6 eV replacement lamp
9100-2060/LP
2
Internal particulate filter
2533-1008
3
VOC in-line filter (6mm inlet/ outlet)
6000-0096
4
MEC O2cell (electrochemical)
9100-9212-9HM
5
MEC CO cell (electrochemical)
9100-2030S
6
Water vapour sensor (Capacitive)
6000-0094
7
Replacement o'ring for sensor flow
adaptors (5 off)
2323-0017X
8
VOC electrode stack removal tool
9300-1021

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4Maintenance
Certain elements of the ACG+ system require regular, preventative maintenance to ensure optimum
operation. Section 3.1 shows the maintenance that is required and the scheduled interval for
performing the maintenance.
Table 7 Maintenance schedule of ACG+ components
System component
Maintenance required
Maintenance interval
Oxygen sensor
Replace electrochemical cell
Approx. 2 years or as required.
Carbon monoxide sensor
Replace electrochemical cell
Approx. 2 years or as required.
VOC sensor
Clean PID lamp and
electrode stack
As required, recommended every 3
months.
Replace PID lamp or whole
PID cell
Lamp - 5,000 hours (~6 months) Cell –
5 years or as required.
Carbon dioxide sensor
Replace sensor
6 years
Water vapour sensor
Replace water vapour sensor
2 years
Activated charcoal filter
Replace filter
1 year
PID particulate filter
Replace filter
6 months or as required (Depending on
how dirty sample is)
Sensor flow adaptor orings
Replace oring
Check yearly and replace if required
NOTE:
A ‘RECOMMENDED SPARES AND MAINTENANCE
INTERVALS’ (P0149-955) GUIDE WILL BE PROVIDED WITH
THE ACG+, THIS INCLUDES RECOMMENDED
MAINTENANCE INTERVALS AND REPLACEMENT PART
NUMBERS. WE RECOMMEND THIS DOCUMENT IS USED TO
TRACK ANY MAINTENANCE CARRIED OUT ON THE ACG+.
4.1 Sensor & filter replacement
Before attempting to replace any filters or sensors ensure that the ACG+ is switched off and the gas supply has
been isolated and disconnected. Using a Pozi-drive screwdriver loosen the 4 enclosure lid screws and open the
lid.

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4.1.1 Oxygen cell replacement
The part number for your sensor’s replacement cell is: 9100-9212-9HM
When a replacement cell is received check that the cell has not leaked. The cells are themselves sealed
and do not under normal circumstances present a health hazard however if leakage of the electrolyte
has occurred use rubber gloves and wear chemical splash goggles to handle and clean up. Rinse
contaminated surfaces with water. If contact is made with the electrolyte, refer to section 1 Safety
Information.
1] Remove the flow adaptor from the sensor inlet.
2] Loosen the corner screws of the enclosure and remove the lid.

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3] Using a terminal screwdriver push down the clamp release button to release the clamp
and gently pull the cell wire from the clamp. Repeat this for both the red and black
wires.
4] Unscrew the green locking ring from the chimney of the cell housing and remove from
the enclosure lid.
5] Fit the new cell in to the enclosure lid and secure in place using the locking ring.

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6] Using a terminal screwdriver, push down the clamp release button to release the clamp.
Push the ferrule of the cell wire in to the clamp and remove the screwdriver from the
clamp release button. Gently pull on the wire to ensure that the wire is held by the
clamp. Repeat this for both the red and black wires, taking note of the correct polarity
as shown below.
7] Refit the enclosure lid in place and secure in place using the corner screws.
8] Refit the flow adaptor into the sensor inlet
NOTE:
FOLLOWING AN OXYGEN CELL REPLACEMENT A FULL
CALIBRATION MUST BE PERFORMED. SEE P0149-801 ACG+
USER MANUAL FOR DETAILS. ALSO, A REPLACEMENT
NOTIFICATION RESET SHOULD BE PERFORMED. SEE
P0149-801 ACG+ USER MANUAL FOR DETAILS.
Black
Red

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4.1.2 Carbon monoxide cell replacement
The part number for your sensor’s replacement cell is: 9100-2030S
When a replacement cell is received check that the cell has not leaked. The cells are themselves sealed
and do not under normal circumstances present a health hazard however if leakage of the electrolyte
has occurred use rubber gloves and wear chemical splash goggles to handle and clean up. Rinse
contaminated surfaces with water. If contact is made with the electrolyte, please refer to Section
Error! Reference source not found.
1] Remove the flow adaptor from the sensor inlet.
2] Use a flat blade screwdriver to pop out the cell holder from the sensor bulkhead fitting.

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3] Rotate the cell PCB connector clockwise to release from the cell holder.
4] Disconnect the cell from the PCB connector.
5] Connect the new cell to the PCB connector (Note that it will only connect in one
orientation).
6] Fit the cell in to the housing and rotate anti-clockwise to lock in place.
7] Refit the cell holder into the sensor bulkhead.
8] Refit the flow adaptor into the sensor inlet.

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NOTE:
FOLLOWING A CARBON MONOXIDE CELL REPLACEMENT
A FULL CALIBRATION MUST BE PERFORMED. SEE P0149-
801 FOR DETAILS. ALSO, A REPLACEMENT NOTIFICATION
RESET SHOULD BE PERFORMED. SEE P0149-801 ACG+
USER MANUAL FOR DETAILS.
4.1.3 Replacing the CO cell PCB (MEC-233B)
1] Remove the flow adaptor from the sensor inlet.
2] Use a terminal screwdriver to pop out the sensor holder from the sensor bulkhead
fitting.

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3] Rotate the CO PCB connector clockwise to release from the CO holder.
4] Disconnect the CO cell from the PCB connector.
5] Remove the lid from the CO sensor housing and feed the cell PCB through the bulkhead.

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6] Disconnect the damaged cell PCB wiring loom from the MEC PCB connector.
7] Connect the sensor wires of the new cell PCB to the corresponding ‘Red’, ‘Black’ and
yellow terminals of connector J3.
Release the terminal clamp button. The
clamp should now have a firm grip on
the wire. Gently pull on the wire to
confirm that the wire is firmly held. If not
repeat the steps shown until the wire is
held firmly.
Repeat this for the other wires.
Using a terminal screwdriver press firmly
down on the terminal clamp button to
open the clamp.
While still pressing down on the terminal
clamp button insert the bootlaced wire into
the terminal clamp as shown.