PureAire Monitoring Systems Air Check Advantage Acrylonitrile Monitor User manual
Air Check Advantage
Acrylonitrile Monitor
Instruction Manual
PureAire Monitoring Systems, Inc.
557 Capital Dr.
Lake Zurich, IL. 60047
Phone: 847-726-6000
Fax: 847-726-6051
Toll-Free: 888-788-8050
Web: Pureairemonitoring.com
PureAire Monitoring Systems, Inc.
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Welcome to PureAire Monitoring Systems
I’d like to thank you for investing in our continuous life safety and process control toxic gas
monitoring systems.
PureAire offers an unbeatable combination of experience and innovation in solving the safety
and environmental needs of our customers. We’re capable of providing small systems of a few
points to a total multi-point turnkey computerized package.
PureAire’s proprietary sensor cell technology and state-of-the-art electronics are designed to
interface with the latest distributive or PLC based control systems. We believe that our
experience, innovative products and commitment to service will satisfy your specific
monitoring needs now and in the future.
Our growth is a result of our total commitment to supporting our customers. We’re available
24 hours a day, 7 days a week to help you when you need us. Our 24 hour Emergency phone
number is 1-847-420-3814. We can provide field service, preventative maintenance programs
and training to your technicians in the operation of our equipment. Our goal is to provide the
best after sale service and support in the industry. That’s just one way PureAire takes that
extra step to ensure your complete satisfaction.
Thank you again for investing in PureAire Monitoring Systems for your monitoring needs and
I’m proud to welcome you to our family of valued and satisfied customers.
Sincerely,
Albert A. Carrino
President
PureAire Monitoring Systems, Inc.
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PureAire Monitoring Systems, Inc.
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Read Before Operating
This gas monitoring system has been designed to provide long-term reliable performance. We recommend the
following basic precautions while installing, operating and maintaining this device.
Read this “Guide to Operation and Installation” carefully. Installation, maintenance, calibration and testing
should be carried out by qualified personnel only.
Check if the power supply matches the specifications given in this guide and ensure that the system has been
connected properly. This monitor must be powered by a regulated 24VDC power supply.
Please insure the proper polarity. Reversing the polarity will damage the fuse on the drive PCB.
This monitor has a digitally controlled flow system and cell test function. Once per hour the internal
sample pump will power off and on in one second increments. This self-test lasts only 5 seconds without
interfering with methyl bromide readings.
After power up, please let the system equilibrate a few hours before making any adjustments.
NOTE: Please refer to the Quick Start Guide supplied with this manual.
PureAire Monitoring Systems, Inc.
557 Capital Drive
Lake Zurich, Illinois 60047
Ph: 888-788-8050
Ph: 847-726-6000
Fax: 847-726-6051
After Hours Hot Line: 847-420-3814
www.pureairemonitoring.com
This system has a built-in pyrolizer. The pyrolizer insulation temperature can reach
150 F and can cause burns if touched. Use Caution when working near the pyrolizer.
PureAire Monitoring Systems, Inc.
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Table of Contents
1: Introduction........................................................................................ 5
1.1 Component Identification……………………………………….6
2: Specifications.................................................................................... 11
2.1 Performance Specifications........................................................ 11
2.2 Gas Detection System................................................................ 11
2.3 Signal Outputs............................................................................ 12
2.4 Electrical Requirements............................................................. 12
2.5 Physical Characteristics............................................................. 12
2.6 Air Check Acrylonitrile Default Settings................................... 13
3: Installation........................................................................................ 14
3.1 Site Requirements...................................................................... 14
3.2 Mounting.................................................................................... 14
3.3 Sensor Installation...................................................................... 14
3.4 Wiring........................................................................................ 15
3.5 Initial Startup ............................................................................. 16
4: Air Check Methyl Bromide Programming.................................... 17
4.1 Control Panel Overview............................................................. 17
4.2 Joystick Operation ..................................................................... 17
4.3 Program Flow Chart................................................................... 18
4.4 Entering the Password................................................................ 22
4.5 Changing the User Password..................................................... 23
4.6 Entering the Menus.................................................................... 26
5: Maintenance & Calibration ............................................................ 37
5.1 Routine Maintenance Schedule.................................................. 37
5.2 Loss of Power Indication........................................................... 37
5.3 Sensor Cell Removal and Installation........................................ 38
5.4 Electrolyte Replacement............................................................ 39
5.5 System Calibration..................................................................... 43
6: Appendix........................................................................................... 47
Rev 3.08 3/1/12
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1: Introduction
The Air Check Acrylonitrile Monitor is a compact extractive gas sampling system designed for the
continuous detection and measurement of toxic gas leaks. It is capable of sampling over distances of
up to 100 feet (33 meters).
The Air Check is a single point monitoring system built into an a Nema 4x water resistant housing
that may be wall mounted and is designed to require as little space for installation as possible.
The system has the following features:
24 VDC operation
Built-in pyrolizer
Integral digitally controlled sampling pump and flow system
Local digital display
User selectable dual level alarm and system fault relays
4-20 mA output
Renewable long life electrochemical sensor cell
Supervised electronics monitors sensor, pyrolizer and sample pump
NOTE: The Air Check Acrylonitrile enclosure is NOT rated for Class 1, Division 1
Groups B, C & D
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1.1 Component Identification
1.1.1 Overall System Composition
The Air Check Acrylonitrile Monitor may be integrated into the overall hazardous gas monitoring
system. As a result, it may be remotely located for the monitoring of process areas and other
environments where access to the instrument for maintenance or service may be restricted. It may
also be used as a stand-alone detection system.
Front Cover—This permits accessing the inside of the sample and control system.
Mounting Tabs—Adjustable feet designed to connect the methyl bromide enclosure to walls or
other solid surface. There is one on each corner of the enclosure.
Cover Fastening Screws—Captive Philips head plastic screws used to fasten the front cover to the
base of the methyl bromide monitor. There is one on each corner of the front cover.
NOTE: Please Do not over tighten the screws as the Phillips head will strip.
Cable Port —This is the opening in the transmitter housing for connecting the 4-20 mA output, 24
VDC power cable, and alarm relay wiring.
Sample Inlet —This serves as the connection for the incoming sample line.
Sample exhaust —This serves as the connection for the sample exhaust line.
Mounting Tabs
(on each corner)
Cable Port
Sample Inlet
Front Cover
Cover fastening
screws
(on each corner)
Mounting Tabs
(on each corner)
Sample Exhaust
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1.1.2 Front View Control Panel
1. Local Digital Display —During normal operation, displays the name and concentration of the
target gas. Also displays alarm messages and programming/calibration menus and information.
2. Joystick —Used for selecting and adjusting the built-in menus for alarm threshold settings,
relay state, alarm delay etc.
3. Alarm & Fault LED’s —These LED’s illuminate when a gas concentration alarm or
instrument fault is detected.
4. Flowmeter —This flow meter displays the flow rate to the sampling system in SCFH.
NOTE –The flow rate is factory set and is continuously regulated via a built-in flow sensor.
Flow rate is factory set for sampling distances up to 100 feet. Field adjustment should
not be required.
Front Cover
Cover fastening
screws
(on each corner)
Local Digital
Display
Joystick
Alarm &
Fault
(LED’s)
AL 2 , AL 1
& Fault
Flowmeter
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1.1.3 Internal View
1. Main Power Connector —Connector for 24VDC power input. See section 3: Installation for
more information.
2. Pyrolizer Assembly —Converts AN gas into HCN gas prior to presentation to the gas sensor.
CAUTION - The pyrolizer insulation temperature is above 150 F and can cause burns if touched
3. Pyro & Pump Drive PCB —Controls power to the pyrolizer filament and regulates the sample
pump flow control
4. Control Electronics and readout —Converts the signal from the sensor cell and sends
information to the local digital display and analog /relay terminal block.
5. Flow Meter —Provides positive indication of flow through the monitor.
NOTE –The flow rate is factory set and is continuously regulated via a built-in flow sensor.
6. Flow Chamber —The converted gas from the pyrolizer is introduced to the gas sensor in this
chamber. Sample flow into the chamber is continually monitored. If the sample pump fails, the
system fault relay is activated.
7. Acrylonitrile Sensor Cell —A renewable electrochemical sensor cell. Typical life is 3 to 6
years.
8. Sample Pump —This internal sample pump is used to draw the gas sample from the area into
the pyrolizer and flow chamber.
9. Inlet & Exhaust —These are connections for the incoming gas sample and outgoing exhaust
sample
Main Power Connector
Pyrolizer Assembly
Control Electronics / Readout
Pyro & Pump Drive PCB
Flow Meter
Acrylonitrile sensor cell
Flow chamber
Sample Pump
Mounting Feet
Strain relief
Exhaust and Inlet
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1.2.5 Transmitter Interior
1. Power Analog Terminal Block —This terminal block is where the 24VDC power and 4-20
mA analog output connection is made.
1.2.6 Alarm Relay Board
1. Power Analog
Terminal Block
Common
mA output
+ 24VDC
Common
m
A
o
u
t
p
u
t
+
2
4
V
D
C
9
Pump Connector
Alarm 2 Relay
CONN 1
Alarm 1 Relay
CONN 2
Fault Relay
CONN 3
NO NC C NO NC C NO NC C
Alarm 2 Alarm 1 Fault Relay
Sensor cell
connector
24 VDC Power
Terminal
Block
(Terminated at
Factory)
Flow Sensor
Remote
Reset
Terminal Block
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Main power connection
(To be terminated by
customer)
Status LED’s
Green Power LED. Confirms
Power is being supplied to the monitor
Yellow Flow Status LED.
Confirms the sample pump is
operating and flow is being
maintained at the proper flow rate
Blue Fault Status LED.
Indicates various system faults.
When not in fault the Blue LED
remains illuminated continuously
Pump and Pyrolizer Drive Assembly
Pyrolizer
Filament
connector
Pyrolizer
Drive Board
Main 24VDC
Power
Connector
(Do Not
Remove
Jumper)
Sample
Pump
+ 24VDC Pin 1 Common Pin 2
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2: Specifications
NOTE: Due to our commitment to continual product improvement, all specifications are subject to
change without notice.
2.1 Performance Specifications
Models: Air Check Acrylonitrile Monitor
Sensor Type: Renewable electrochemical cell. Field rechargeable.
Response Time: Within 60 seconds to T90.
Repeatability: ±10% of full scale.
Fault Indicators: Loss of VDC power (4 mA signal drops to 0, system fault alarm relay de-energizes);
Loss of sensor signal (local visual alarms, system fault alarm de-energizes);
Loss of sample pump (4 mA signal drops to 0, system fault alarm relay de-energizes)
Loss of Pyrolizer filament (4 mA signal drops to 0, system fault alarm relay de-energizes)
Operating Temp: 14° to 86°F (0° to +30°C); consult PureAire for lower or higher operating temperatures.
Humidity: Typically 20 to 95% RH;
2.2 Gas Detection System
Type: Proprietary renewable electrochemical gas sensor.
Sensor Life: 3 to 6 years under normal conditions.
Detectable Gas: Acrylonitrile Standard Range 0-30ppm *
*Consult PureAire for other available gas ranges.
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2.3 Signal Outputs
Local Display: Digital display calibrated for Acrylonitrile. The range is stated on the serial number and can be
accessed via the joystick on the front panel.
Analog Output: DC 4-20 mA
Relay Output: Dual level user selectable alarm relays and one fault relay
Rated, 2amps @ 30VDC; 2amps @ 250VAC
2.4 Electrical Requirements
Power: 24 VDC external power. NOTE: Must be a regulated 24VDC Power Supply
Consumption: 2.0 amps.
2.5 Physical Characteristics
Dimensions: 10” W x 7.0” H x 7.0” D inches;
254 x 178 x 178 mm
Weight: 10 pounds (4.5 kg)
Enclosure Type: Polycarbonate wall mounted enclosure. Not for use in hazardous environments.
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2.6 AirCheck Acrylonitrile Default Factory Settings
The Air Check Acrylonitrile Monitor is shipped with factory defaults for the alarm relay settings. The following are
the factory defaults:
NOTE:The built in relay settings may be changed by the user in the field. Refer to Section 4.5
** NOTE: The LED indicators on the front panel are connected directly to the alarm relays.
Menu Function
Factory Default
Menu Defined
Alarm Thresholds
Alarm 1 = 1.0ppm
Alarm 2 = 5.0ppm
At what level do you want to alarm?
Set Alarm Threshold
Polarity
Alarm 1 = Normal
Alarm 2 = Normal
Do you want to alarm at a level
higher, (normal) or lower, (inverted)
than the alarm threshold?
Alarm Delay
Alarm = 5 seconds
How long do you want to wait until
the alarms activate?
Zero Suppression
0.3ppm
At what level do you want to see the
initial gas concentration reading?
Set Alarm Hysterisis
Alarm 1 = 0.0 ppm
Alarm 2 = 0.0 ppm
For use when using the monitor for
control. It is recommended to set both
alarm hysterisis at 0.0%
Relay Latching
Alarm 1 = Non-latching
Alarm 2 = Non-latching
Do you want the alarm to
automatically reset? (non-latching) or
do you want to manually reset the
alarm? (latching)
Format Relay - LED
State **
Alarm 1 = Normal
Alarm 2 = Normal
Fault = Normal
Do you want the relays to energize,
(normal) or de-energize, (fail safe)
when the alarm activates?
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3: Installation
3.1 Site Requirements
The Air Check Acrylonitrile monitoring system should be mounted in an area free of vibration and
electrical noise or interference. If possible, avoid areas with continuous high temperatures or relative
humidity.
The unit should be installed in a location where gas leaks are likely to occur or where released gases
may accumulate. Airflow within the monitored area, the characteristics of the target gas (lighter or
heavier than air), and the position of workstations and personnel should all be considered in
determining the most suitable installation location.
Allow sufficient space around the instrument to permit access for maintenance and calibration.
NOTE: The Air Check Acrylonitrile Monitor is NOT designed for installation in hazardous areas.
3.2 Mounting
The Air Check is designed primarily for wall mounting and should be installed no closer than 36
inches (915 mm) above floor level. If mounted outdoors, keep direct sunlight off of the enclosure.
3.3 Sensor Installation
IMPORTANT: Be careful not to turn the sensor or touch the membrane on the bottom of the sensor
during installation.
CAUTION: The target gas is factory programmed and cannot be adjusted in the field. Failure to
install the correct sensor in the instrument will adversely affect detection reliability and/or
measurement accuracy.
1. Remove the front cover by turning the cover counter clockwise.
2. Remove the sensor shorting plug or battery if supplied.
3. Plug the Methyl Bromide sensor into the flow chamber inside the instrument housing.
NOTE: Do not twist the gas sensor inside the flow chamber. This may loosen the sensor cell box
nut on H type renewable sensor cells.
IMPORTANT: Remove the shorting plug from the sensor cell connector before connecting the
sensor cell to the transmitter.
Insert the sensor cell
into the flow
chamber by pushing
the sensor cell down
until it seats inside
the O-ring.
Never twist the
sensor cell inside
the flow chamber.
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3.4 Wiring
3.4.1 24 VDC Power
Connect the 24 VDC power cable to the terminal block located on the inside of the instrument. The
terminal connections are as follows: (Pin 6) +24V, (Pin 5) Common, and (Pin 5) shield. A three-
wire shielded cable (3-conductor, 18 AWG stranded shielded) General Cable #E2203S.30.86 or
equivalent should be used for the connection. The total length of the cable between the gas detector
and controller must not exceed 0.62 miles (1 km).
CAUTION: The Air Check Acrylonitrile Monitor must only be powered using a regulated
24VDC Power Supply. Failure to use a regulated 24VDC power supply will void the warranty.
The 24 VDC power in connections are made on the 6 pin terminal connection located on the Power
Supply PCB. These connections are made as follows:
Pin #
Connection
6
DC + 24V
5
Common
4
Shield
Pyrolizer & Pump Drive Board
Flow and Pyro Factory Set
Potentiometers Do Not adjust
Status LED’s
Power Connector
Pin 6 +24 VDC
Pin 5 Common
Pin 4 Shield
Fault Relay Connector
Not Used on Acrylonitrile
Joystick style monitor
Fuses
Plug In type F3 F1 F2
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3.4.2 Alarm Relays
The Air Check monitor incorporates two, gas concentration alarm and one system fault relay. These
relays may be wired for normally open (N.O.) or normally closed (N.C.) operation and are rated as
follows:
Rated, 2amps @ 30VDC; 2amps @ 250VAC
3.5 Initial Startup
Once installation of the gas detector has been completed, it is ready for startup. The following
procedures should be performed before putting the instrument into operation:
1. Check the integrity of all wiring. Confirm the power polarity.
2. Apply 24 VDC power to the Power Supply PCB board. The sample pump and pyrolizer heater
will operate.
NOTE: The Air Check requires a regulated 24VDC power supply
CAUTION - The pyrolizer insulation temperature is above 150 F and can cause burns if
touched.
3. On power up, the monitor will immediately start a 4-minute countdown. It will then display a
Flow Fault Out of Range (F34) then Pyrolizer Heater Fault (F02). In approximately 40
seconds the Yellow Fault LED will clear and a ppm gas concentration will display on the second
line of the digital display. The last remaining Fault , Pyrolizer Heater Fault will display on
the first line. To clear this fault from the display, push the joystick down.
NOTE: After power up, please let the system equilibrate a few hours before making any
zero and span adjustments. The Acrylonitrile sensor may read a high ppm gas concentration
on startup. The sensor’s zero will stabilize during this warm period.
3.5.1 Pump Adjustment
The Air Check Acrylonitrile Monitor has a built in digitally controlled flow controlled sample pump.
The pump flow is set at the factory and should not require adjustment. It has a range to accommodate
tubing lengths of 3 feet to over 100 feet. Flow rate is between 0.5 and 0.9 SCFH. If flow
adjustment is necessary, please contact PureAire.
NOTE: Once per hour the internal sample pump will power off and on in one second
increments to verify system integrity. This self-test lasts only 5 seconds and will not interfere
with methyl bromide gas concentration readings.
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4: Air Check Monitor Programming
The Air Check Acrylonitrile Monitor is supplied with user selectable settings to adjust the alarm settings, 4 and 20mA
output and minor sensor adjustments. The settings are arranged in menus that are accessed by moving the joystick.
To access the menus a factory set password is used.
NOTE: The Air Check Acrylonitrile Monitor will continuously monitor Acrylonitrile while accessing the menus.
The alarm, fault relays and mA output are all active and on line while making any changes to the menus.
4.1 Control Panel Overview
All instrument configuration and operational programming is performed from the front panel of the
Air Check Monitor using the joystick.
4.2 Joystick Operation
The Air Check Acrylonitrile monitor uses an 8-position joystick with a center pushbutton for selecting menus and
changing values. The joystick is programmed to standard protocol as follows:
NOTE: The joystick has a built-in delay to prevent accidental tampering of the menus. Deliberate entries
are required.
P
r
e
v
i
o
u
s
s
Plus –Pushing the joystick in this direction increases the value
Minus –Pushing the joystick in this direction decreases the value
Next –Pushing the joystick in this direction moves you to the next level of the menu hierarchy.
Previous –Pushing the joystick in this direction takes you out to the last level of menu hierarchy.
Enter –Pushing the joystick directly in the center enters the information into the microprocessor
NOTE: The joystick has four other positions that are only used to only access factory menus. A separate
factory password is required obtain entry.
Plus
Minus
Previous
Next
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4.3 Program Flowchart
PassCode OK
PassCode OK
Set 4-20mA
l
o
o
p
Set 4mA
Z
e
r
o
128
Set 20mA
S
p
a
n
098
CH3Br
2
0
.
9
%
Enter
P
a
s
s
w
o
r
d
A
Force loop
Not Available
Set Formats
Format
Relay 2
R
e
l
a
y
2
Format
Relay 1
Normal
Invert
Normal
Invert
Format Fault
Relay
F
a
u
l
t
R
e
l
a
y
Normal
Invert
NOTE: All
numerical values
shown are only
examples and are
not Factory
Defaults
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Set Alarm
Threshold
Polarity
Set Alarm 1
P
o
l
a
r
i
t
y
Normal
Invert
Set Alarm 2
P
o
l
a
r
i
t
y
Normal
Set Audio
Alarm
Not available
PassCode OK
Not Available
Set Latching
Relay 2
Set Latching
Set Latching
R
e
l
a
y
1
Nonlatch
Latching
Nonlatch
Latching
Set Latching
Audio
NOTE: All
numerical
values
shown are
only
examples
and are not
Factory
Defaults
N
O
T
E
:
Z
e
r
o
s
u
p
p
r
Invert
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