ANALOX ACG+ User manual

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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Table of Contents
1Contents checklist ........................................................... 8
1.1 Standard contents.......................................................................................8
1.2 Optional accessories....................................................................................8
2Safety information ........................................................... 9
2.1 Capabilities to test gases against the EN 12021:2014 standard ........................9
2.2 Electrochemical sensors (oxygen and carbon monoxide) ..................................9
2.3 PID lamp cleaning kit ................................................................................ 10
2.4 Inlet pressure & flow ................................................................................. 10
3Introduction .................................................................. 11
3.1 ACG+ overview ........................................................................................ 11
4Installation details......................................................... 13
4.1 Mechanical overview ................................................................................. 13
4.2 Gas sample connection (Both fixed and portable versions) ............................. 14
4.3 Installation (Portable)................................................................................ 15
4.4 Installation (Fixed).................................................................................... 17
4.5 Safety interlock relay (ACG+ Fixed) ............................................................ 20
4.6 Safety interlock override key-switch (ACG+ Fixed)........................................ 21
4.7 Switched 24V DC outputs (ACG+ Fixed) ...................................................... 22
5Operating instructions ................................................... 23
5.1 Start-up .................................................................................................. 23
5.2 Controls................................................................................................... 24
5.3 Inlet/purge valve ...................................................................................... 25
5.4 Display .................................................................................................... 26
5.5 Menu....................................................................................................... 27
5.6 Adjusting the backlight .............................................................................. 28
5.7 Power sub-menu....................................................................................... 29
5.8 System flow ............................................................................................. 29
5.9 Sensor readings........................................................................................ 30
5.10 Alarms..................................................................................................... 32
5.11 Clearing alarms and hysteresis ................................................................... 33
5.12 Calibration adjustment .............................................................................. 37
5.13 Viewing device information ........................................................................ 44
5.14 Viewing sensor information ........................................................................ 44
5.15 Data-logging ............................................................................................ 45
5.16 Sensor replacement reminder..................................................................... 48
5.17 Timed sample draw ................................................................................... 49
5.18 Setting the date and time .......................................................................... 53
6Configuration................................................................. 54
6.1 Software installation.................................................................................. 54
6.2 Making a connection.................................................................................. 57
6.3 Changing options ...................................................................................... 59
6.4 Downloading data-logs .............................................................................. 60
6.5 Setting the time........................................................................................ 61
7Networking .................................................................... 62
7.1 Overview ................................................................................................. 62
7.2 Connection............................................................................................... 62
7.3 Transmission method ................................................................................ 62
7.4 Setting the ACG Static IP Address ............................................................... 63
7.5 Retrieving Data using TCP/IP Requests ........................................................ 63
7.6 Retrieving Data using UDP ......................................................................... 64
7.7 Datagram Structure .................................................................................. 64
8Troubleshooting............................................................. 70
8.1 System faults ........................................................................................... 70
9Recommended spares and accessories .......................... 75

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9.1 Service requirements ................................................................................ 77
10 Maintenance requirements .......................................... 78
10.1 Sensor & filter replacement ........................................................................ 78
10.2 Filter replacement ..................................................................................... 91
10.3 Service requirements ................................................................................ 92
11 Specifications .............................................................. 99
11.1 Instrument specification ............................................................................ 99
11.2 Sensor specification ................................................................................ 100
12 UK Declaration of Conformity .....................................101
13 Declaration of conformity ...........................................102

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List of figures
Figure 1 ACG+ Overview ................................................................................. 11
Figure 2 ACG+ Mechanical Overview ............................................................... 13
Figure 3 Typical ACG+ Portable Installation.................................................... 15
Figure 4 Typical ACG+ Fixed installation ......................................................... 17
Figure 5 Connector Locations .......................................................................... 18
Figure 6 ACG+ Power ...................................................................................... 19
Figure 7 Typical Interlock Relay Wiring........................................................... 20
Figure 8 Typical Use of Switched 24V Outputs ................................................ 22
Figure 9 Start-Up Splash Screen...................................................................... 23
Figure 10 ACG+ Front Panel........................................................................... 24
Figure 11 Main Display Overview ................................................................... 26
Figure 12 System Status Indicator................................................................. 27
Figure 13 The Main Menu ............................................................................... 27
Figure 14 The Backlight Sub-Menu................................................................. 28
Figure 15 Power Sub-Menu ........................................................................... 29
Figure 16 Example of a Sensor that is in a Warm-Up State ............................ 31
Figure 17 Sensor Bar Graph Indicator............................................................ 31
Figure 18 Degraded State Sensor Bar Graph Indicator .................................. 31
Figure 19 Out Of Display Range Bar Graph Indicators ................................... 31
Figure 20 Sensor in Fault Bar Graph Indicator ............................................... 32
Figure 21 A Low-Going Alarm That Has Been Triggered................................. 32
Figure 22 Mute Button ................................................................................... 32
Figure 23 Hysteresis Band on a High Going Oxygen Alarm ............................ 33
Figure 24 Selecting a CO2Alarm to Adjust ..................................................... 35
Figure 25 Example of Alarm Set-Point Adjustment ........................................ 36
Figure 26 Flow Regulator Fitted to Calibration Bottle .................................... 39
Figure 27 Connecting Calibration Fitting to ACG+ Calibration Port ................ 39
Figure 28 Calibration Adjustment Screen Showing High Calibration Bottle .... 40
Figure 29 Calibration Adjustment Results - CO2Sensor Failed to Adjust........ 41
Figure 30 Excluding the VOC Sensor from the Calibration Adjustment........... 42
Figure 31 Adjusting the CO2Calibration Value ............................................... 43
Figure 32 Calibration Adjustment Reminder .................................................. 43
Figure 33 Device Information Screen............................................................. 44
Figure 34 Sensor Information Screen for O2.................................................. 44
Figure 35 Data-Log Download Screen ............................................................ 46
Figure 36 Data-Log Download in Progress ..................................................... 46
Figure 37 Sensor Change Reminder ............................................................... 48
Figure 38 Sensor Replacement Reset Confirmation Screen ............................ 49
Figure 39 A Dräger Impactor Attached to the Outlet Port for Oil Mist Testing 51
Figure 40 Timed Sample Setup ...................................................................... 52
Figure 41 Timed Sample Progress.................................................................. 52
Figure 42 Date And Time Adjustment Screen ................................................. 53
Figure 43 ACG+ Software without Device Connected ..................................... 57
Figure 44 Connecting a USB Cable to an ACG+............................................... 57
Figure 45 ACG Software with Device Connected Showing General Options .... 59
Figure 46 The Data Logs Available on a Connected ACG+ .............................. 60
Figure 47 Downloading Data Logs from an ACG+........................................... 61
Figure 48 Setting the Date and Time on an ACG+ .......................................... 61
Figure 49 System Showing a Fault Condition ................................................. 70

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List of tables
Table 1 Electrochemical sensor first aid procedures ........................................ 9
Table 2 Connector J17 Pin Assignments......................................................... 18
Table 3 Connector J3 Pin Assignments........................................................... 19
Table 4 Relay and 24V Output Operation under Fault and Alarm Conditions .. 21
Table 5 Sensor Status Icons........................................................................... 30
Table 6 Scaled Hysteresis Values ................................................................... 33
Table 7 Recommended Calibration Gas Concentrations.................................. 37
Table 8 Data-Log Formatting Example ........................................................... 45
Table 9 List of System Faults and Possible Solutions ..................................... 71
Table 10 List of Sensor Faults and Possible Solutions ...................................... 72
Table 11 List of Spares..................................................................................... 75
Table 12 List of Accessories ............................................................................. 76
Table 13 6 monthly service for ACG+.............................................................. 77
Table 14 12 monthly service for ACG+............................................................ 77
Table 15 24 monthly service for ACG+............................................................ 77
Table 16 Maintenance Schedule of ACG+ Components..................................... 78
Table 17 Service Schedule of ACG+ Components ............................................. 92

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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.

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1Contents checklist
1.1 Standard contents
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
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 75.
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

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Body
Part
Effect
First Aid Procedures
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.
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

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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

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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.
•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.

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4.3 Installation (Portable)
The ACG+ Portable can be powered by either the optional rechargeable battery pack (Li-
Ion or NiMH variants) or an external PSU. Both options connect to the front panel power
connector located next to the USB port.
Gas connection should be made as per section 4.2
Figure 3 Typical ACG+ Portable Installation
ACG+ power (Portable or fixed)
Power should be applied using either the optional rechargeable battery pack or the optional
external PSU. Connection should be made through the 3 way panel mount socket on the
front panel located next to the USB connector.
Battery Connected
Battery Connection

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Charging the optional rechargeable battery pack
To charge the optional rechargeable battery pack the charger supplied with the battery
pack kit MUST be used as these are set to supply the correct power to the battery during
charge.
NOTE:
USING ANY OTHER CHARGER WILL INVALIDATE
YOUR WARRANTY.
Connect the charger connector to the battery connection lead coming from
the battery case (This will only fit one way) and secure using the bayonet
nut on the battery cable.
Plug the charger into a mains supply, the charger will do a battery check
prior to charging (The charger the LED will be yellow).
If any faults are found the charger LED will flash orange/green.
If all is okay the charger will then start to charge the battery (The charger
LED will be orange).
Once the charge is complete, the charger will go into trickle mode until
disconnected (The charger the LED will go green).
Once complete, disconnect the charger, the battery is then ready for
connection to the ACG+.
External PSU Connection
External PSU Connected

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4.4 Installation (Fixed)
Mounting details (ACG+ Fixed)
The ACG+ can be mounted as a fixed unit onto a wall or vertical flat surface using the
enclosure mounting holes. The minimum area required and the mounting centres for
installing the ACG+ are shown in Figure 2.
Gas connection should be made as per section 4.2
Below shows a diagram of a typical fixed system setup.
Figure 4 Typical ACG+ Fixed installation
An optional mounting kit to install on either a solid wall or instrument panel can be
purchased.
ACG+ mounting kit contents:
•4 x Socket head cap screw, M6x60mm.
•4 x M6 full nut, A4 SS.
•4 x M6 washer, A4 SS.
•4 x Multi wall fixing, M5 x 50mm (rubber insert and M5x50mm slotted screw).
Solid wall mounting (ACG+ Fixed)
Mark on the wall the mounting hole drill positions and drill 10mm holes.
Remove the M5x50mm screw from the rubber insert and fit the rubber
inserts into the drilled holes.
Open the ACG+ lid and offer up the unit to the mounting surface.
Place an M5x50mm slotted screw in each of the 4 enclosure mounting
positions and screw in to the previously fitted rubber inserts.
Panel mounting (ACG+ Fixed)
Mark on the panel the mounting hole drill positions and drill 6.5mm holes.
Open the ACG+ lid and offer up the unit to the mounting surface.
Place a socket head cap screw in each of the 4 enclosure mounting
positions and through the drilled holes in the mounting panel.
Fit an M6 washer over each of the screw thread at the back of the
mounting panel.

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Fit an M6 full nut to the screw thread at the back of the mounting panel
and fully tighten (alternatively, the screws could be fitted into M6 tapped
holes with the M6 nuts not required).
Electrical connection
The user terminals are located at J3 and J17 on the chassis PCB of the ACG+ as shown in
Figure 5.
Figure 5 Connector Locations
Table 2 Connector J17 Pin Assignments
Connector J17 pin assignments
Terminal
No.
Function
Details
1
ACG+ power (+ve)
9 to 36V DC, 24W max
2
ACG+ power (-ve)
3
Interlock relay contacts –
normally-open (1)
Volt-free relay contacts. 8A @ 24V
max. Relay contacts are normally open
in power off conditions. This pair of
contacts will be closed circuit under
nominal conditions and open circuit in
fault or alarm conditions (see section
4.5).
4
Interlock relay contacts –
normally-open (2)
5
Interlock relay contacts –
normally-closed (1)
Volt-free relay contacts. 8A @ 24V
max. Relay contacts are normally
closed in power off conditions. This
pair of contacts will be open circuit
under nominal conditions and closed
circuit in fault or alarm conditions (see
section 4.5).
6
Interlock relay contacts –
normally-closed (2)

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Table 3 Connector J3 Pin Assignments
Connector J3 pin assignments
Terminal
No.
Function
Details
1
Solenoid drive (+ve)
Not for user connection
2
Solenoid drive (-ve)
3
Reserved
Not for user connection
4
Reserved
5
+24Vdc
Max total load of 500mA is available
between the 3 switched outputs
6
Output 1 –switched to 0V
7
Output 2 –switched to 0V
8
Output 3 –switched to 0V
NOTE:
MAX CROSS-SECTIONAL AREA FOR THE TERMINALS
IS 1.5MM2
ACG+ power (Fixed)
The ACG+ requires a power supply of 15 to 36V DC and will consume 20 Watts maximum.
It is recommended that power should be supplied using a screened, twisted pair cable,
with the cable screen clamped by the EMC cable gland, this should then be terminated to
J17 pins 1 & 2 as shown.
Figure 6 ACG+ Power

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4.5 Safety interlock relay (ACG+ Fixed)
The ACG+ has a double pole change-over relay that can be used to control external
equipment in the event of an alarm or fault condition.
Two sets of volt-free relay contacts are provided; a normally-open pair which are held
closed under ideal conditions, failing safe to their open state when a non-ideal state is
identified and a normally-closed pair which are held open under ideal conditions. Figure 6
shows the operational state of the relay under various system conditions.
A typical use of the interlock relay might be to use the normally-open pair to cut power to
a compressor or to close a filling valve on an alarm, fault condition, or in the case of power
loss. Alternatively, the normally-closed pair can be used to activate external, self-powered
alarm equipment such as a beacon.
Figure 7 shows a typical example of the relay used in a system
Figure 7 Typical Interlock Relay Wiring