ANALOX ACG+ User manual

Analox Limited
15 Ellerbeck Court, Stokesley Business Park,
North Yorkshire, TS9 5PT, UK
UK/RoW T: [phone] F: [phone]
US T: [phone]
W: www.analox.net E: [e-mail]
Copyright © 2014 Analox Ltd. All Rights Reserved.
ACG+
User Manual
Commercial in Confidence
The ACG+ must be returned to Analox in its
original storage and transit case.
Failure to do so may result in damage which
will be chargeable.

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User Manual Int. Approved
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Copyright © 2014 Analox Ltd. All Rights Reserved.
Commercial in Confidence
List of contents
1Contents checklist......................................................................................................... 3
1.1 Standard contents................................................................................................................. 3
1.2 Optional accessories.............................................................................................................. 3
2Safety information ........................................................................................................ 4
2.1 Capabilities to test gases against the EN 12021:2014 standard .................................................. 4
2.2 Electrochemical sensors (oxygen and carbon monoxide) ............................................................ 4
2.3 PID lamp cleaning kit ............................................................................................................ 5
2.4 Inlet pressure & flow ............................................................................................................. 5
3Introduction ................................................................................................................. 6
3.1 ACG+ overview .................................................................................................................... 6
4Installation details ........................................................................................................ 7
4.1 Mechanical overview ............................................................................................................. 7
4.2 Gas sample connection (Both fixed and portable versions) ......................................................... 7
4.3 Installation (Portable)............................................................................................................ 9
4.4 Installation (Fixed)...............................................................................................................11
4.5 Safety interlock relay (ACG+ Fixed) .......................................................................................13
4.6 Safety interlock override key-switch (ACG+ Fixed)...................................................................14
4.7 Switched 24V DC outputs (ACG+ Fixed) .................................................................................15
5Operating instructions ................................................................................................. 16
5.1 Start-up..............................................................................................................................16
5.2 Controls..............................................................................................................................17
5.3 Inlet/purge valve .................................................................................................................18
5.4 Display ...............................................................................................................................18
5.5 Menu..................................................................................................................................19
5.6 Adjusting the backlight .........................................................................................................20
5.7 Power sub-menu..................................................................................................................20
5.8 System flow ........................................................................................................................21
5.9 Sensor readings...................................................................................................................22
5.10 Alarms................................................................................................................................24
5.11 Calibration adjustment .........................................................................................................27
5.12 Viewing device information....................................................................................................32
5.13 Viewing sensor information ...................................................................................................32
5.14 Data-logging .......................................................................................................................33
5.15 Sensor replacement reminder................................................................................................35
5.16 Timed sample draw ..............................................................................................................37
5.17 Setting the date and time .....................................................................................................39
6Configuration ............................................................................................................. 40
6.1 Software installation.............................................................................................................40
6.2 Making a connection.............................................................................................................55
6.3 Changing options .................................................................................................................56
6.4 Downloading data-logs .........................................................................................................57
6.5 Setting the time...................................................................................................................57
7Networking ................................................................................................................ 59
7.1 Overview ............................................................................................................................59
7.2 Connection..........................................................................................................................59
7.3 Transmission method ...........................................................................................................59
7.4 Setting the ACG Static IP Address ..........................................................................................60
7.5 Retrieving Data using TCP/IP Requests ...................................................................................61
7.6 Retrieving Data using UDP ....................................................................................................61
7.7 Datagram Structure .............................................................................................................62
8Troubleshooting.......................................................................................................... 68
8.1 System faults ......................................................................................................................68
9Recommended spares and accessories .......................................................................... 72
10 Maintenance requirements ....................................................................................... 74
10.1 Sensor & filter replacement ...................................................................................................74
10.2 Filter replacement................................................................................................................82
10.3 Service requirements ...........................................................................................................83
11 Specifications ......................................................................................................... 91
11.1 Instrument specification .......................................................................................................91
11.2 Sensor specification .............................................................................................................91
12 Declaration of conformity......................................................................................... 93

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User Manual Int. Approved
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Commercial in Confidence
List of tables
Table 1 Electrochemical sensor first aid procedures........................................................................ 4
Table 2 Connector J17 pin assignments.......................................................................................12
Table 3 Connector J3 pin assignments ........................................................................................12
Table 4 Relay and 24V output operation under fault and alarm conditions ........................................14
Table 5 Sensor status icons.......................................................................................................22
Table 6 Scaled hysteresis values ................................................................................................25
Table 7 Recommended calibration gas concentrations ...................................................................27
Table 8 Data-log formatting example..........................................................................................33
Table 9 List of system faults and possible solutions.......................................................................69
Table 10 List of sensor faults and possible solutions......................................................................70
Table 11 List of spares .............................................................................................................72
Table 12 List of accessories.......................................................................................................73
Table 13 Maintenance schedule of ACG+ components ...................................................................74
Table 14 Service schedule of ACG+ components ..........................................................................83

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User Manual Int. Approved
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1Contents checklist
1.1 Standard contents
1.1.1 Below is a list of standard contents which will be supplied to the customer
a) ACG+ unit (Including transport case)
b) USB lead
c) 0.1l/m restrictor kit (For sampling using Oil mist colorimetric tubes)
d) A printed copy of the user manual (A4 booklet)
e) Software CD
f) Test certificate
1.2 Optional accessories
1.2.1 Below is a partial list of optional accessories which could be supplied to the customer
depending on the order. The full spares & accessories list can be found on page 72.
a) Li-Ion rechargeable battery pack kit (Includes battery mounting case & charger)
b) NiMH rechargeable battery pack kit (Includes battery mounting case & charger)
c) External PSU (If not using rechargeable battery pack option, connection via front panel)
d) External PSU (For fixed installation using cable gland direct to interface PCB)
e) External beacon (For fixed units only)
f) Pressure regulator (2 stage)
g) Humidifier (For when the ACG+ is in constant use)
h) Mounting kit to install on either a solid wall or instrument panel (For fixed units only)
i) Gland and Override Keyswitch kit (For fixed units only)
The humidifier (g) should be installed if the ACG+ is going to be continuously connected for over 12 hours
to the compressed gas source with no exposure to ambient air. The humidifier is required to pull moisture
from the ambient air to re-hydrate the electrochemical cells within the ACG+. If dry gas is constantly
being passed over the sensors they will dry out and stop performing correctly.

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2Safety information
WARNING: Read the safety information fully before using the Analox ACG+.
2.1 Capabilities to test gases against the EN 12021:2014 standard
The ACG+ is partially capable to test gases against EN 12021:2014.
The ACG+ can test the following gas types from the standard:
•Breathing air
•Oxygen compatible air
•Nitrogen depleted air
2.2 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 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.

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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.
2.3 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
2.4 Inlet pressure & flow
The system maximum inlet pressure is 10 bar gauge (145 psig). Ensure that appropriate pressure
reduction measures have been taken when connecting the sample inlet. Pressure relief is fitted to the unit
such that damage from over pressurisation is minimised but units may still be damaged.

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3Introduction
The ACG+ is a multi sensor gas analyser, specifically designed for the analysis of contaminants in
compressed breathing air. The ACG+ can be used as a portable instrument for use between compressors
on site or can be permanently connected to a compressor outlet, enabling you to continually verify the
quality of your breathing air. This delivers a much greater degree of system safety than a 3 or 6 month
spot check. The unit will provide continuous ‘on line’ monitoring of O2, CO2, CO, volatile organic compounds
(VOC) and water vapour in compressed breathing air lines.
3.1 ACG+ overview
Figure 1 - ACG+ overview
1) Display
2) USB port for data-download, with waterproof cap
3) Power connection (Via either optional rechargeable battery pack or external mains adaptor)
4) Gas inlet/purge valve
5) Gas inlet/calibration port
6) Sample support port
7) Exhaust
8) Exhaust
9) Breather
10) Humidifier (Optional)
11) M16 cable gland (Optional)
12) Override keyswitch (Optional)
13) Exhaust
14) Blow out blanking plug

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4Installation details
4.1 Mechanical overview
Figure 2 - ACG+ mechanical overview
4.2 Gas sample connection (Both fixed and portable versions)
•The sample gas inlet to the ACG+ must be at a regulated pressure in the range of 5 to 10 bar
gauge (72.5 to 145psig), taken directly from a sample line from a compressor, after all filtering
and regulation, which is supplying the bottles, air banks or breathing masks.
•The ACG+ is supplied with a 2m length of 6mmOD x 3mmID PTFE tubing which the
inlet/calibration adaptor should be connected to. Longer pipes can be used but purge times and
response times will be longer.
•It is recommended that a 2-stage regulator is used to maintain the sample gas inlet pressure
within operating limits.
•The ACG+ provides a Linktech panel mount coupling for the connection of the sample gas line or
calibration gas and also a Linktech inline socket (Which accepts up to ¼” OD tubing) for connection
to the ACG+ panel mount coupling.
•Before fitting the pipe-work the PTFE tubing should be fitted to the rear of the supplied Linktech
inline socket.
•The ID at one end of the PTFE tubing will require stretching slightly to fit over the rear of the
Linktech inline socket.

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User Manual Int. Approved
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Commercial in Confidence
•Remove the nut from the rear of the Linktech inline socket and place over the supplied length of
PTFE tubing.
•Fit the 6mmOD x 3mmID tubing over the end of the Linktech inline socket by slightly stretching
the inner of the tube so that it fits over the rear of the adaptor and secure in place with the nut.
•At the free end of the PTFE tubing, a compression nut should be fitted to connect to the regulated
pressure source.