ANALOX Sub Mk III F User manual

Analox Military Systems Ltd
15 Ellerbeck Court, Stokesley Business Park,
North Yorkshire, TS9 5PT, UK
T: [phone] F: [phone]
W: www.analoxmilitarysystems.co.uk E: [e-mail]
Copyright © 2009 Analox Ltd. All Rights Reserved.
Sub MkIIIF
User Manual
Commercial in Confidence

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Copyright © 2009 Analox Ltd. All Rights Reserved.
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Table of contents
1Safety Information ...................................................................6
2Package Contents Checklist ......................................................7
3Abbreviations............................................................................8
4Quick Start Guide......................................................................9
5Introduction............................................................................11
5.1 Sensor Measurement Techniques........................................................................... 11
5.2 System Types ..................................................................................................... 11
5.3 Brief Overview .................................................................................................... 12
6Installation .............................................................................13
6.1 General System Overview .................................................................................... 13
6.2 Mechanical Installation ......................................................................................... 15
6.3 System Electrical Installation ................................................................................ 20
6.4 System Gas Handling Installation .......................................................................... 30
7Operation................................................................................33
7.1 Switching On And Off........................................................................................... 35
7.2 Main Display Screen ............................................................................................ 37
7.3 Remote Sensor Displays....................................................................................... 39
7.4 Alarm System ..................................................................................................... 42
7.5 Oxygen Injection System ..................................................................................... 47
8Function Keys .........................................................................49
8.1 Top Level Main Menu ........................................................................................... 49
8.2 Setup Menu ........................................................................................................ 50
8.3 Alarm Set-point Menu .......................................................................................... 53
8.4 Calibration Menu ................................................................................................. 54
8.5 Control Menu ...................................................................................................... 56
9Data Communications Output .................................................59
9.1 Data Interface to External Systems ....................................................................... 59
10 Calibration ............................................................................61
10.1 User Calibration .................................................................................................. 62
10.2 Background to Calibration .................................................................................... 62
10.3 Pressure Sensor Calibration .................................................................................. 63
10.4 Oxygen Sensor Calibration ................................................................................... 65
10.5 Carbon Dioxide Sensor Calibration......................................................................... 66
11 Troubleshooting ...................................................................67
12 Maintenance .........................................................................68
12.1 Replacement Parts............................................................................................... 68
12.2 Accessories......................................................................................................... 68
12.3 Fitting Replacement Oxygen Sensor to Rem1 (Or Rem3) .......................................... 69
12.4 Fitting Replacement Co2Sensor ............................................................................ 70
12.5 Fitting Replacement Rem2 Temperature/Humidity Sensor ........................................ 71
12.6 Fitting Replacement LCD Module ........................................................................... 71
12.7 Fitting Replacement Batteries ............................................................................... 71
12.8 Internal Sensor Views .......................................................................................... 72
13 Safety Warnings ...................................................................74
13.1 Oxygen Sensor –Caustic Electrolyte ...................................................................... 74
13.2 Pressurised Gas................................................................................................... 75
13.3 Oxygen Systems ................................................................................................. 75
14 Fault Reporting to Analox .....................................................76
15 Specifications .......................................................................77
16 Disposal................................................................................79

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List of figures
Figure 1 Standard system on a chamber using 1x REM1 and 1x REM2 ........................ 13
Figure 2 Typical Monitoring System in a Submarine Rescue Vehicle (2
compartments) .............................................................................................................. 14
Figure 3 REM1 Remote Sensor Dimensions ................................................................. 18
Figure 4 REM2 Remote Sensor Dimensions ................................................................. 19
Figure 5 Connection for a Chamber Monitor with a REM1 and REM2 sensor ................ 20
Figure 6 Monitoring System in Submarine Rescue Vehicle .......................................... 21
Figure 7 Injection Valve Timing .................................................................................. 32

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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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1Safety Information
Refer to the safety warning information in Section 13 and Section 8.4.

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2Package Contents Checklist
•Analox Sub Mk III F Operator Console.
•Analox Sub Mk III F Remote Sensor Units (REM) appropriate to the system (either one,
two or three sensor modules)
•Cables and connectors to connect Operator Console to REM units
•Gas sensor calibration adaptors and tubing
•User Manual
•Test Certificate

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3Abbreviations
ABBREVIATION
DESCRIPTION
CO2
Carbon Dioxide
FSUB
Analox Fixed Sub
LCD
Liquid Crystal Display
LED
Light Emitting Diode
O2
Oxygen
REM1
Analox Remote Sensor Type 1 (O2+CO2+Depth)
REM2
Analox Remote Sensor Type 2 (Temperature and Humidity)
REM3
Analox Remote Oxygen Injection Controller (O2 only)

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4Quick Start Guide
This section is intended to aid the reader find the appropriate part of the manual, depending upon
their needs at the time. Glance through the typical queries in the table below, and see if you can
find appropriate guidance. If you can’t find what you want, please contact Analox for further
assistance. We are here to help !
ID
Query
Guidance
1
I’m new to these
systems –what do they
do?
Please read through the introduction in Section 5 to get an
overview, then perhaps come back to this table for further
guidance.
2
I’ve been given the job
of installing this system
–what do I have to do?
There are generally 3 phases to installation. You’ll have to
mechanically install the system (Section 6.2) make all of
the necessary electrical connections (Section 6.3), and then
make the necessary gas connections where appropriate
(Section 6.4). When you are ready to switch on and test,
come back to this table for further guidance.
3
I’m ready to switch on
for the 1st time. Where
should I start?
First question would be whether all of the wiring is correct
or not. If you haven’t checked your wiring, it is worth
checking first that everything appears to be OK. The
system is fairly robust in the event of something being
wrong, but it’s always best to be sure !
When you are ready to switch on, read through Section 7 .
If you have problems, refer to the suggestions in Section
11. If you are still puzzled, contact Analox to help you
through your problem.
4
Everything switches on
OK - what about
checking/calibration?
You’ll need access to some calibration gas which has a
known content of oxygen, carbon dioxide etc.
When any of the sensors are exposed to a known level of
gas etc, you just need to check that the measured reading
is within the tolerance (refer Section 15) allowed by the
system. If its not, then you’ll need to calibrate the system
(see the item below)
5
How do I calibrate the
system?
Calibration is detailed for each of the sensor types in
Section 8.4. Please don’t attempt calibration unless you
have suitable calibration equipment –cal gas, flow adaptors
etc. You’ll need to understand the calibration menus
(Section 8.4 ) to perform calibration. If you are at all unsure
about what to do, please contact Analox for advice
6
The system’s up and
running –how do I
change alarm settings?
The alarm functions are described in Section 7.4, and the
menu system for the alarms is described in Section 8.3.
Don’t interfere with the alarm settings unless you have a
good appreciation of the significance of the settings. If for
instance you set the low oxygen alarm at a level well below
normal life-support use, then you will effectively have
disabled the low oxygen alarm. Be warned –take care and
set up sensible alarm limits. The alarm settings are
generally shown on the main display to help you avoid
making mistakes.

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ID
Query
Guidance
7
Can I get any data out of
the system?
Yes. The system has specifically been configured for data
output which is particularly helpful when analysing the
overall system performance. . Refer to Section 9. Data
gathered from the port is easily imported into a spreadsheet
to allow graphical representation of readings taken over
variable periods of time.
8
I have spares I need to
fit. What do I do?
First read Section 12, or any specific instructions supplied
with the spares. If you’re in any doubt about what to do
after that, please contact Analox for advice.
9
It’s all gone horribly
wrong –I’ve tried
recalibrating and can’t.
Where do I go next?
Sorry, but you’ve reached a point beyond the scope of this
manual. Please contact Analox and we’ll do our best to
resolve the problem.

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5Introduction
5.1 Sensor Measurement Techniques
The Analox Sub Mk III F is an atmosphere monitoring system capable of measuring oxygen (O2),
carbon dioxide (CO2) and pressure (depth). Temperature and humidity sensors may optionally be
added. An optional controller module may also be added to provide oxygen injection to maintain
oxygen levels at pre-set levels.
Parameter
Sensing technology
Sensor Location
Oxygen
Electrochemical cell
REM1 / REM3
Carbon Dioxide
Infra-red absorption
REM1
Pressure
Strain gauge
REM1 / REM3
Temperature
Platinum Resistor
REM2
Humidity
Capacitive
REM2
5.2 System Types
The system is preconfigured by the manufacturer to provide a number of different functionalities.
Various configurations include the following:
System
No
Variant
Identity
Brief Details
1
-
Basic
Analox Sub
Operator Console connected to a single REM1 typically providing
O2, CO2 and depth monitoring in a hyperbaric (or hypobaric)
chamber
2
-
Standard
Analox Sub
with T/H
An Enhancement of System 1 , with an Operator Console
connected to one REM1 and one REM2, providing temperature
and humidity measurement over and above the basic features
3
-
Multi-
Channel
Monitor
Operator Console connected to either one, two or three REM1’s
measuring oxygen, optionally carbon dioxide and depth/pressure.
Essentially matches System 4, offering backup monitoring to
support the control function of System 4.
4
-
Multi-
Channel
Oxygen
Controller
Operator Console connected to either one, two or three REM3’s
measuring oxygen and depth/pressure and providing an oxygen
control function in conjunction with a connected injection
solenoid valve. (Note that for safety requirements, it will usually
be necessary to have an independent means of monitoring the
oxygen levels. (see System 3)
5
Customer
Specific
Discuss
with Analox
Variants of system by utilising various configurations of remote
sensor units.

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A complete system therefore consists of:
An Operator Console intended for installation in control rooms. (It is assumed the control room is
at normal atmospheric pressure. Special versions are available if it is required to mount in the
hyperbaric environment).
One or more sensor units of types REM1, REM2 and/or REM3 intended for installation in hyperbaric
(or hypobaric) environments. Note special versions of REM1 and REM3 may be configured to be
mounted externally, and take sample flow from a hyperbaric chamber.
Systems will normally be purchased to operate over a defined range of pressures. For instance a
hyperbaric saturation diving system may be rated between 0.8 and 35 bar absolute (other variants
also available); a hyperbaric air diving system may be rated between 0.8 and 10 bar absolute;
whilst a hypobaric flight simulator chamber may use a system rated between 0.1 and 2 bar
absolute.
5.3 Brief Overview
A large graphic display on the Operator Console shows the value of each measured parameter.
The remote units provide local displays of the monitored parameters (although note that some
special versions of remote sensor are not fitted with displays).
The Operator Console provides audio and visual alarms for the measured gas parameters. The
alarm set-points may be easily adjusted using the pushbuttons on the Operator Console. The
Remote sensor can also provide audio and visual alarm indication.
The overall system can be powered by a single supply connected to the rear of the Operator
Console. The remote unit may be connected to the Operator Console, from which it can obtain its
power, or it can be separately powered.
The sensors are housed in splash proof enclosures that are vented to prevent implosion/explosion
in hyperbaric/hypobaric environments. Gas levels are monitored by sensors built into the REM1
(and REM3 when fitted) unit. Gas enters the sensors through waterproof membranes.
The user should ensure that the gas inlet ports remain as clean as possible to prevent the
waterproof membranes becoming blocked. The sensor enclosure vent must also be kept clean.

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6Installation
6.1 General System Overview
The drawings below shows various configurations of common installations.
Figure 1 shows the Operator Console mounted externally to a chamber, with both a REM1 and a
REM2 sensor mounted internally. The system wiring has to pass through penetrators.
Figure 1 Standard system on a chamber using 1x REM1 and 1x REM2

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Figure 2 shows a typical monitoring system installed inside a submarine rescue type vehicle with
two compartments. The Operator Console is mounted inside the Pilot Compartment, together with
a REM1 sensor unit monitoring that compartment. A second REM1 is mounted in the Rescue
Compartment and connects via penetrators to the operator console.
Figure 2 Typical Monitoring System in a Submarine Rescue Vehicle (2
compartments)

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6.2 Mechanical Installation
6.2.1 Operator Console Mechanical Installation
The standard Operator Console is designed to be panel mounted as shown below. The shaded
area represents the aperture into which the Operator Console will fit. 10mm diameter mounting
holes will accept the M5 fixings supplied with the system.
240
225
207
OUTLINE OF FRONT PANEL
SHADED AREA REPRESENTS
APERTURE INTO WHICH
INSTRUMENT WILL FIT
Ø10.00
117
129
133
PANEL MOUNTING DETAIL
NOTE:
ADDITIONAL SPACE WILL BE REQUIRED BEHIND THE UNIT
FOR THE MATING CONNECTORS.
NOTE:
THE CONSOLE IS USUALLY SUPPLIED WITH A PROTECTIVE
FILM OVER THE FRONT PANEL LABEL AND DISPLAY VIEWING
WINDOW. THIS PROTECTIVE FILM IS INTENDED TO BE
REMOVED TO PROVIDE BETTER VISIBILITY OF THE DISPLAY.
NOTE:
A NON-STANDARD OPERATOR CONSOLE IS ALSO AVAILABLE
WHICH IS BUILT INTO A DIECAST ALUMINIUM IP65 RATED
ENCLOSURE. MOUNTING DETAILS ARE AS SHOWN USING M6
SCREWS.

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Operator Console Dimensions
239
133 117
225
FRONT PANEL VIEW
SUB Mk III F
FAULT F2F1 F3 F4 F5 ALARM
POWER
F1
ACK
F4
F3
F2

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89
2SIDE VIEW
127
104

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6.2.2 Remote Sensor Mechanical Installation
The various sensor modules are built into different enclosures to suit particular system versions.
The diagrams below show the standard enclosures which are mounted using M8 fixing bolts.
Figure 3 REM1 Remote Sensor Dimensions

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Figure 4 REM2 Remote Sensor Dimensions
The REM3 shares the basic dimensions of the REM1, although in standard form it does not have a
CO2 sensor fitted.
All enclosures intended for hyperbaric/hypobaric conditions are fitted with a vent to prevent
implosion/explosion. Ensure that the vent is not obstructed.
Ensure that the remote sensor units are positioned sensibly with regard to the gases being
monitored, and the protection to personnel that the sensors are to provide. Gas sensors should
not be mounted in locations where air circulation is likely to be restricted. Access for calibration
must also be provided.
REM3’s being used as part of oxygen injection systems should not be positioned too closely to the
injection point(s) in the chamber.
Note also that sensor modules with displays are usually supplied with a protective film over the
front panel label and display viewing window. This protective film is intended to be removed to
provide better visibility of the displays.

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6.3 System Electrical Installation
Connections for typical systems are shown below.
Figure 5 shows a chamber monitoring system comprising an Operator Console mounted externally
to the chamber, with both a REM1 and a REM2 sensor mounted internally.
TO J11 - 24V TO J6 - REM A
OPERATOR CONSOLE
CUSTOMER
PENETRATOR
CUSTOMER
JUNCTION BOX CUSTOMER
JUNCTION BOX
REM 2 REM 1
CHAMBER
Figure 5 Connection for a Chamber Monitor with a REM1 and REM2 sensor