ENMET SPECTRUM-RAL-DC User Manual

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ENMET Corporation PO Box 979 Ann Arbor, Michigan 48106-0979

SPECTRUM-DC-RAL

Compressed Air Line

Carbon Monoxide Monitor

Instrument Manual

80002-035 08-22-97

MCN 192 04-24-98

Table of Contents

1.0 DESCRIPTION AND GENERAL INFORMATION

1.1 U

PON RECEIPT

1.1.1 Unpack

1.1.2 Turn On

1.1.3 Check

1.1.4 Expose Sensor

1.1.5 Acknowledge Alarm

1.1.6 Remove Gas

1.1.7 If Non-response

2.0 FEATURES AND OPERATION

2.1 I

NSTALLATION AND OPERATION

2.1.1 Installation

2.1.1.1 Mount Enclosure

2.1.1.2 Air Supply

2.1.1.3 Turn On / Turn Off

2.1.2 Operational Menu

2.1.3 Gas Concentration Display and Alarms

2.1.4 Alarm Acknowledge

2.1.5 Data

2.1.6 Backlight

2.1.7 Low Battery Alarm

2.2 I

NTERFERENCE GASES

3.0 MAINTENANCE

3.1 M

AINTENANCE MENU

3.1.1 Key

3.1.2 Zero

3.1.3 Calibration

3.1.4 Changing the Alarm Level

3.1.5 Setting the Battery Type

3.1.6 Setting a New Key

3.2 C

HANGING COMPONENTS

3.2.1 Sensor Removal and Replacement

3.2.2 Battery Removal and replacement

3.3 ENMET P

4.0 WARRANTY

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ART NUMBERS FOR REPLACEMENT PARTS AND ACCESSORIES

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4 4 4 4 4 4 4

5 5 6 6 6 6 6 7 7 7

9 10 10 11 11

11 12

APPENDIX A

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List of Illustrations

Figure 1 Carbon Monoxide Monitor Features

•

Figure 2 Operation Menu Diagram

•

Figure 3 Maintenance Menu Diagram

•

Figure 4 % COHb vs. Time

•

PUSHBUTTON

SWITCHES

SAMPLE INPUT

(LUER DISCONNECT)

VISUAL

ALARM

CORD TO

AUDIO ALARM

SENSOR

HOUSING

DISPLAY

POWER-----OPTION-----SELECT

BACKLIGHT

Figure 1: Carbon Monoxide Monitor Features

XX YY °C

Maintenance

Clr DATA

Reset

go Setup

Min=XXXX

Max=XXXX

See DATA

Alm=XXXX

SOO

Batt=OK*

*may also be

Operational

Display

XXXX

Acknowledge

O = Option Switch

Figure 2 Operation Menu Diagram

Alarm

Function

“low” or “LOW”

Function

Menu Key

S = Select Switch

Function

Data

Function

Key=0000

To Operational

Display

From Operational

Locks underscored digit and moves cursor

OSS

VALID

z30:0.0v

O, S, No Function

AIR SET?

O, To Exit

GAS=XXXX

O, No Function

GAS SET?

O, To Exit

XXX:Y.Yv

C-FAULT

To Operational Display

VALID

INVALID

OOS

SSO

run ZERO

O, to Exit

z30:0.0v

C-FAULT

To Operational Display

VALID

INVALID

To Operational Display

Figure 3 Maintenance Menu Diagram

O = Option Switch O

new=XXXX

KEY=0000

new=XXXX

O or S

INVALID

go SETUP

run CAL

Changes digit indicated by underscore cursor

Locks underscored digit and moves cursor

Display

Changes digit indicated by underscore cursor

AIR SET?

ALM=0000

set ALM

INVALID

Exit

set KEY

Alk/Lithset BATT

NiCad

Changes digit indicated by underscore cursor

Locks underscored digit and moves cursor

S = Select Switch

1.0 Description and General Information

The SPECTRUM-DC-RAL carbon monoxide monitor is a small battery operated instrument for the detection of carbon monoxide gas in compressed air lines. An electrochemical cell detects the gas, and the gas concentration is displayed on an LCD. Audio and visual alarms occur when the gas concentration exceeds a preset alarm point. At relatively low concentrations of CO, an alarm can be acknowledged, which results in the temporary cessation of the audio alarm. Operation and maintenance procedures are managed with two pushbutton switches.

A description of the characteristics and toxic effects of carbon monoxide is given in Appendix A, and should be reviewed by the user.

1.1 Upon Receipt

1.1.1 Unpack

Unpack the instrument and examine it for shipping damage. If such damage is observed, notify both ENMET customer service personnel and the commercial carrier involved immediately; save the shipping box and the packing material.

1.1.2 Turn On

Turn the instrument ON, by pressing and releasing the left pushbutton switch and attach to your compressed air line system. In uncontaminated air, the display should read 0000 within ten seconds of turn-on.

1.1.3 Check

Check display operations by pressing the OPTION and SELECT switches as descibed in Figure 2. The SPECTRUM-DC-RAL instrument is calibrated prior to shipment. However, it is advisable to

apply a known source of carbon monoxide to the instrument to verify the sensor has not been damaged during shipment.

1.1.4 Expose Sensor

If there is access to a source of CO in compressed air, such as in a calibration kit, expose the sensor to CO, and observe that the instrument is responsive.

1.1.5 Acknowledge Alarm

If the concentration of CO is greater than 10 ppm, the instrument indicates an alarm condition. Acknowledge the alarm by pressing and releasing the right hand pushbutton, SELECT; this silences the audio alarm for four minutes unless the concentration of CO is greater than 50 PPM.

1.1.6 Remove Gas

Remove source of CO. After the display reads zero or close to it, turn the instrument off, by pressing and holding the left pushbutton switch for 3 seconds.

1.1.7 If Non-response

If the instrument does not operate as described, contact ENMET customer service personnel immediately.

2.0 Features and Operation

The features of the SPECTRUM-DC-RAL Carbon Monoxide monitor are shown in Figure 1. These are:

DISPLAY an LCD upon which either the gas concentration, or prompts for the operational

and maintenance menus, are given.

PUSHBUTTON there are three of these, as follows:

SWITCHES

POWER/ BACKLIGHT the left hand switch

OPTION the middle switch SELECT the right hand switch

These switches are used to access and utilize the operational and maintenance MENUS.

SENSOR a small cylindrical turret on the display surface; inside which the membrane of HOUSING the electrochemical sensor is exposed to the compressed air through the air

supply line.

REGULATOR a pressure regulator with a gauge, flowmeter and an adjustable valve, connected

by tubing to the sensor housing. Available on some models per order.

VISUAL ALARM a red LED which is ON whenever the CO concentration is above the alarm

point.

AUDIO ALARM a small horn which is ON whenever the gas concentration is above the alarm

point, until the alarm is acknowledged. There are two variations of audio alarm location, one with the alarm on a cable, the other with the alarm mounted on the enclosure.

COVER retained with four screws, and removed to change the sensor and battery.

2.1 Installation and Operation

2.1.1 Installation

2.1.1.1 Mount Enclosure

Mount the enclosure at an appropriate location using the four mounting holes accessible inside the enclosure. The location should be far enough upstream from the user that the sample air reaches the monitor before the air reaches the user.

2.1.1.2 Air Supply

If the model without a regulator is ordered, supply air at approximately 20 PSIG at a flow rate of approximately 1.0 SCFH. If the regulator is supplied, the male quick disconnect pneumatic connector on the regulator-flowmeter assembly is a Milton 1000 series. Plumb the associated female connector into the air line. Connect the regulator-flowmeter and set the pressure at approximately 20 PSIG, and the flow at 1.0 SCFH.

2.1.1.3 Turn On / Turn Off

To turn on, press and release the POWER/BACKLIGHT pushbutton switch. The display should read "0000" within ten seconds when the monitor is supplied with uncontaminated air. To turn off, press the POWER/BACKLIGHT bushbutton switch for three seconds.

2.1.2 Operational Menu

The operational menu diagram is shown in Figure 2. This menu is accessed with the OPTION pushbutton switch, the middle switch as viewed from the front of the instrument. Successive displays are achieved by repeatedly pushing the switch, as indicated by "O" in the menu flow diagram. The alarm acknowledgement function, and displays and functions in the "see DATA" area, are accessed with SELECT pushbutton, indicated by "S" in the menu diagram.

2.1.3 Gas Concentration Display and Alarms

The LCD furnishes a numerical display of CO concentration from 0000 to 100 ppm; this is the operational display. If the CO concentration exceeds 100 ppm, the display reads "100+." When the concentration of CO exceeds the preset alarm point, the audio and visual alarms are activated. The gas concentration continues to be displayed during alarm. The alarm point is adjustable between 5 and 100 ppm CO by accessing the maintenance menu; the factory setting of the alarm point is 10 ppm CO, the value recognized by OSHA as the acceptable exposure limit for compressed air lines. A user should have a justifiable application-based reason for setting the alarm point higher than 10 ppm. When the CO concentration drops below the alarm point, the audio and visual alarms cease operation. The alarm point setting can be observed on the display by pushing the OPTION switch twice.

If an alarm concentration is encountered when the display is at a location in the operational menu other than the operational display, the audio and visual alarms are activated and the alarm cannot be acknowledged.

If the display is left idle at a location other than the operational display for 45 seconds it automatically transfers to the operational display.

2.1.4 Alarm Acknowledge

When the instrument is in alarm, and the CO concentration is below 50 ppm, the alarm can be acknowledged by pressing and releasing the SELECT pushbutton, but only when the instrument is in the operational display location of the operational menu. The acknowledgement causes the temporary cessation of the audio alarm; the red LED continues to be ON. The audio alarm is OFF for a period of four minutes, after which it is reactivated, if the gas concentration is still above the alarm point. The alarm can again be acknowledged. However, acknowledgement of the alarm at gas concentrations above 50 ppm does not result in audio alarm cessation, and if the gas concentration rises above 50 ppm during an alarm condition which has been acknowledged, the audio alarm resumes operation.

2.1.5 Data

The SPECTRUM-DC-RAL monitor retains the maximum and minimum gas concentration values encountered since turn-on, or since the data was cleared and reset. There is a one minute delay from the time the instrument is turned on until when it starts storing the information. To access this press the OPTION switch three times; "see DATA" is displayed. Press the SELECT switch; the maximum concentration since turn-on or last reset is displayed. Press the OPTION switch again; the minimum concentration since turn-on or last reset is displayed. Press the OPTION switch again; "clr DATA" is displayed. Pushing the SELECT switch clears the data and resets it to the current concentration.

Pushing the OPTION switch once more results in a display of both the countdown to the confidence beep and the internal temperature of the instrument in degrees centigrade. Push the OPTION switch three more times to return to the operational display.

2.1.6 Backlight

To backlight the display for observation in a dark area, press and quickly release the POWER / BACKLIGHT pushbutton. The LCD backlight comes ON for a period of 45 seconds and then turns OFF automatically. The backlight can be turned off sooner than 45 seconds by pressing the POWER / BACKLIGHT pushbutton a second time. Use the backlight feature sparingly; it is a relatively high energy user, and extensive use rapidly depletes the battery.

2.1.7 Low Battery Alarm

The battery status display is accessed by pressing the OPTION pushbutton once. When this display is "Batt=OK", the battery energy level is sufficient for operation of the instrument. In this condition, the confidence beep occurs every thirty seconds when the instrument is not in alarm.

When the battery energy level drops below the critically low point, the instrument automatically shuts off, and cannot be used until the battery is replaced. See paragraph 3.2.2 for batter removal and replacemamt.

2.2 Interference Gases

Some gases other than CO cause a sensor response, and thus are termed "interference gases". Known interference gases are as follows:

Gas Concentration Reading

in ppm in ppm

Hydrogen 1,000 100+ Nitric oxide 100 25

The following levels of gases are known to cause no sensor response:

Gas Concentration

Ammonia 100 ppm Carbon dioxide 5,000 ppm Chlorine 5 ppm Ethylene Gasoline vapor Hydrogen cyanide 10 ppm Hydrogen sulfide Isopropanol Methane 10,000 ppm Nitrogen dioxide Sulfur dioxide

10 ppm

2 % saturated

10 ppm 1,025 ppm

10 ppm

*For indicated gases or vapors, prolonged exposure may reduce the efficiency of the sensor filter.

3.0 Maintenance

3.1 Maintenance Menu

From the gas operational display, push the OPTION button four times; "go SETUP" is displayed. This is the entrance to the maintenance menu. The maintenance menu diagram is shown in Figure 3.

3.1.1 Key

Entrance to the maintenance menu is guarded with a four digit numerical key. The factory default setting of the key is 1270. When the valid numerical key is inserted, the user is allowed to enter the maintenance menu.

When in the "go SETUP" location, press the SELECT pushbutton; "Key=0000" is displayed. The underscore cursor is under the left hand digit. To insert the key, press the OPTION pushbutton to index the left hand digit, and choose the correct digit; then press the SELECT pushbutton, which locks in the chosen left hand digit and moves the underscore cursor one space to the right. Continue this process until the four digit key is complete. When the valid key is inserted in this manner, the display is transferred to the "run ZERO" portion of the maintenance menu. When an invalid key is inserted, "INVALID" is briefly displayed, and the instrument returns to the operations menu.

The process by which means a different key is set is given in paragraph 3.1.6, below.

3.1.2 Zero

A valid key entry sets the instrument at the "run ZERO" location, of the maintenance menu, which enables the setting of the zero gas concentration point. This is desirable if the zero reference of the gas sensor has drifted over a period of time, indicated by a persistent gas concentration reading in a clean environment. Note that the calibration sequence given below also includes setting the zero point. If a full calibration is required, instead of setting just the zero point, push the OPTION button once; "run CAL" is displayed. See paragraph 3.1.3, below.

To set the zero point without performing full calibration, from the "run ZERO" location press the SELECT button; "AIR SET?" is displayed. Be certain that the instrument is supplied with clean air, uncontaminated by carbon monoxide. If uncertain of the environment, use pure compressed air from a pressurized cylinder, and flow it over the sensor at a flow rate of 1 SCFH.

With the instrument in zero air, press the SELECT button again. "ZERO=30" is displayed; this is a counter that counts down in seconds from 30 to 0. The validity of the new zero setting is then examined; if it is reasonable, the display is transferred to the concentration numerical display in the operations menu.

If the new zero setting is not between reasonable parameters, "C-FAULT" is displayed. Turn the instrument OFF, the ON again. This re-boots the system with the most recent valid zero setting.

3.1.3 Calibration

NOTE: Calibration should be performed at normal room temperature (20-25°C) for optimal

performance. If the instrument is exposed to temperature extremes just prior to calibration, it should be allowed to stabilize to room temperature. The internal temperature of the instrument can be verified by cycling through the "see DATA" menu.

In order to calibrate the instrument, it is first zeroed as described above. Then the sensor is presented with a known concentration of the target gas, in air or an inert gas such as nitrogen, called the "span gas". After an appropriate interval, which is timed, the new span setting is examined for validity.

A valid key entry sets the instrument at the "run ZERO" location of the maintenance menu. Press the OPTION pushbutton once to access the "run CAL" display, then press the SELECT pushbutton; "AIR SET" is displayed. Zero the instrument as described in paragraph 3.1.2 above. When the zero timer is complete, the display indicates "SPAN=XXX", where the numbers indicate the correct span gas concentration for the instrument. The span gas value for this instrument is 20 ppm CO.

Assure that the correct span gas is available, connect the calibration adapter to the cylinder, then press the SELECT button; "GAS SET" is displayed. Unplug the regulator-flowmeter assembly from the airline, connect it to the calibration adapter and set the flow at 1.0 SCFH. Then press the SELECT button; "XXX:0.Yv" is displayed. The XXX is a counter which counts down in seconds to zero from 120 to provide the proper time interval for calibration. The 0.Yv indicates a sensor signal which is used during the sensor replacement procedure. When the timer reaches zero, the new calibration and zero gas settings are examined for validity. If the values are reasonable, the display is transferred to the gas concentration numerical display in the operations menu. Return the regulator-flowmeter assembly to the airline.

If the new zero and calibration settings are not reasonable, "C-FAULT" is displayed. Turn the instrument OFF, then ON again. This re-boots the system with the most recent valid zero and calibration settings.

3.1.4 Changing the Alarm Level

A valid key entry sets the instrument at the "run ZERO" location of the maintenance menu. Press the OPTION push button twice to access the "set ALM" display, then press the SELECT button; ALM=0000" is displayed. This is called the alarm update window, and the value displayed is the present alarm setpoint. The underscore cursor is under the far left digit. Press the OPTION button to index the underscored digit; press the SELECT button to index the underscore cursor one position to the right. When the desired new alarm point is set, press either the OPTION or SELECT button to return to the alarm update window. If the new alarm setting is valid, "set ALM" is again displayed. Press the OPTION button four times to return to the operations menu.

For the safety of the user, there is an upper limit past which the alarm setting is invalid, and the instrument does not accept it. If an invalid alarm setting is attempted, after the numerical value is inserted in the "ALM=0000" window, pressing the OPTION or SELECT button results in a momentary display of "INVALID" after which the display returns to the alarm update window. Exiting the alarm update window at this point results in an alarm point setting unchanged from the value present when the procedure was begun.

For the SPECTRUM-DC-RAL, the factory default alarm setpoint is 10 ppm, and the upper alarm limit is 50 ppm.

3.1.5 Setting the Battery Type

A valid key entry sets the instrument at the "run ZERO" location of the maintenance menu. Press the OPTION pushbutton three times to access the "set BATT" display, then press the SELECT pushbutton; "Alk/Lith" is displayed. Press the OPTION pushbutton to cycle the display among the two types of batteries which are valid, "Alk/Lith" and "NiCad". Choose the battery type that is being used to power the instrument by pressing the SELECT pushbutton; doing so returns the display to "set BATT" location. Push the OPTION pushbutton three times to return to the maintenance menu. The NiCad display is equal to the Ni/MH battery.

If the "set batt" selection is not identical with the battery being used, incorrect low battery indications are furnished.

3.1.6 Setting a New Key

A valid key entry sets the instrument at the "run ZERO" location of the maintenance menu. Press the OPTION button four times to access the "set KEY" display. Press the SELECT pushbutton once; "KEY=0000 is displayed. A new key can be set by indexing the underscored number with the OPTION button and indexing the underscore cursor with the SELECT button. Four digit key numbers should be selected carefully and recorded. Without the correct key, the maintenance menu cannot be accessed. If a four digit key number is lost, call ENMET customer service personnel.

3.2 Changing Components

Changing the sensor requires that the front of the instrument be removed; remove the four phillips head cover retaining screws, and then the cover.

3.2.1 Sensor Removal and Replacement

A sensor must be replaced when it no longer responds adequately to the target gas. This is indicated by a low gas concentration reading when exposed to a known concentration of the target gas, and the inability to calibrate the instrument, with a "C-FAULT" display after calibration. The expected sensor lifetime in normal environments is one to two years.

Remove the front cover of the instrument enclosure. Unplug the sensor from the circuit board, and plug in the new sensor in its place. Allow the sensor to stabilize in the instrument with the power on for one hour before recalibrating.

The initial calibration of a new sensor must be performed with the front cover of the enclosure removed. A calibration cup is provided with the calibration kit. Follow the procedure for calibrating the instrument as outlined in Section 3.1.3 of this manual with the following modification.

During the application of the span gas, the counter counts down from 120. When the counter gets down to 30, adjust the potentiometer next to the display module on the instrument PC board, so that the display to the right of the counter reads 0.65v. This is a one-time adjustment to align the sensor output with the instrument electronics. It should only be performed upon sensor replacement. All future calibrations should follow the procedure in Section 3.1.3.

Replace the front cover on the instrument enclosure. Calibrate the instrument according to the procedure in paragraph 3.1.3.

3.2.2 Battery Removal and replacement

Remove the front of the instrument. The battery is in a clip in the lower right of the enclosure. Remove it, unclip the battery connector, replace with a 9 volt alkaline battery. Push the new battery into the clip and replace the cover.

Two types of batteries are available for use with the SPECTRUM-DC-RAL: alkaline and rechargeable Ni/MH. They have different end-of-life discharge characteristics. Either replace a battery with the same type, or go to the "set BATT" portion of the maintenance menu, and select the new type being used. See paragraph 3.1.5 to set battery type.

If the "set batt" selection is not identical with the battery being used, incorrect low battery indications are furnished.

The rechargeable Ni/MH battery is of a common type which can be charged by a charger available at any electronic store.

3.3 ENMET Part Numbers for Replacement Parts and Accessories

Description Part Number

Calibration Kit 03412-001 Calibration Gas, 20 ppm CO 03219-020 Zero Gas, 20.9 % Oxygen 03296-209 Replacement CO Sensor, for S/N 41-2106 and below 67020-1200 Replacement CO Sensor, for S/N 41-2150 and above 67016-1204 Display Assembly 62022-007 PC Board Assembly 05215-002 Battery, alkaline 67012-001 Battery, Ni/MH 67011-003

4.0 Warranty

ENMET warrants new instruments to be free from defects in workmanship and material under normal use for a period of one year from date of shipment from ENMET. The warranty covers both parts and labor excluding instrument calibration and expendable parts such as calibration gas, filters, batteries, etc. Equipment believed to be defective should be returned to ENMET within the warranty period (transportation prepaid) for inspection. If the evaluation by ENMET confirms that the product is defective, it will be repaired or replaced at no charge, within the stated limitations, and returned prepaid to any location in the United States by the most economical means, e.g. Surface UPS/RPS. If an expedient means of transportation is requested during the warranty period, the customer is responsible for the difference between the most economical means and the expedient mode. ENMET shall not be liable for any loss or damage caused by the improper use of the product. The purchaser indemnifies and saves harmless the company with respect to any loss or damages that may arise through the use by the purchaser or others of this equipment.

This warranty is expressly given in lieu of all other warranties, either expressed or implied, including that of merchantability, and all other obligations or liabilities of ENMET which may arise in connection with this equipment. ENMET neither assumes nor authorizes any representative or other person to assume for it any obligation or liability other than that which is set forth herein.

NOTE: When returning an instrument to the factory for service:

-- Be sure to include paperwork.

-- A purchase order, return address and telephone number will assist in the expedient repair and return of your unit.

-- Include any specific instructions.

-- For warranty service, include date of purchase

-- If you require an estimate, please notify ENMET.

Appendix A

Figure 4 % COHb vs Time

The Characteristics and Effects of Carbon Monoxide

Carbon monoxide is a colorless odorless toxic gas generated by incomplete combustion of a hydrocarbon fuel in air. It may be present where internal combustion engines, furnaces, boilers, and other combustion devices are present. It is toxic when inhaled because of its great affinity to hemoglobin, the oxygen carriers in the red cells of the blood. CO replaces the oxygen normally carried by the hemoglobin, and thus inhibits the delivery of oxygen throughout the body; the victim suffers from oxygen deficiency, and may die from asphyxiation. The symptoms and degree of danger resulting from exposure to CO depend upon the concentration of the gas and the length of exposure; this is shown in Figure 4. The ENMET SPECTRUM-DC-RAL carbon monoxide monitor is employed to warn the user of the presence of CO, and to facilitate the assessment of the degree of danger that he or she is exposed to.

Based upon knowledge of the effects of CO, the Occupational Safety and Health Authority (OSHA) has set limits on exposure to CO in the workplace. For ambient air conditions, these are 35 ppm (parts CO per million parts air) as an time weighted average for an eight hour day, and a maximum exposure of 200 ppm. For compressed air line applications, 10 ppm is the maximum acceptable limit. The SPECTRUM-DC-RAL monitor is shipped with the adjustable alarm set at 10 ppm; this alarm cannot be adjusted above 50 ppm.

The curves below are for percent carboxalhemoglobin with 50% being the top curve, 5% the bottom. %COHb is a measure of the amount of hemoglobin occupied by CO rather than oxygen. CO effects upon children, adults engaging in physical activity, and smokers, are more pronounced.

ENMET SPECTRUM-RAL-DC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual