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PO Box 979
Ann Arbor, MI 48106-0979
ISA-200 RAL
ISA-200 RAL O
Operation and Maintenance
Manual
80002-039
07/14/00
MCN-237, 09/20/00
MCN-274, 04/12/02
Table of Contents
1.0 I
NTRODUCTION
................................................................................................................................1
1.1 Unpack................................................................................................................................................................................ 1
1.2 Check Order....................................................................................................................................................................... 1
1.3 Serial Numbers .................................................................................................................................................................. 1
2.0 I
NSTRUMENT
F
EATURES
...................................................................................................................2
2.1 Exterior Features ............................................................................................................................................................... 2
2.2 Display Panel Features ..................................................................................................................................................... 2
2.3 Circuit Board Features ..................................................................................................................................................... 4
2.3 Power Supply ..................................................................................................................................................................... 4
3.0 I
NSTALLATION
................................................................................................................................5
3.1 Mounting of Instrument ................................................................................................................................................... 5
3.2 Sample Air Supply ............................................................................................................................................................ 6
3.3 Power Supply ..................................................................................................................................................................... 6
3.4 Outputs ................................................................................................................................................................................ 6
3.4.1 Relay Contacts .......................................................................................................................................................6
3.4.2 Optional 4-20mA Outputs ....................................................................................................................................7
3.5 Initial Calibration .............................................................................................................................................................. 7
4.0 O
PERATION
....................................................................................................................................8
4.1 Normal Operation Condition........................................................................................................................................... 8
4.2 Alarm Set Points ............................................................................................................................................................... 8
4.3 Alarm Latching.................................................................................................................................................................. 8
4.4 Audio Defeat ...................................................................................................................................................................... 9
4.5 Display ................................................................................................................................................................................ 9
4.6 Operational Menu.............................................................................................................................................................. 9
4.7 Fault Indications................................................................................................................................................................ 9
4.7.1 Low Flow Indication .............................................................................................................................................9
4.7.2 Other Fault Indications........................................................................................................................................9
5.0 M
AINTENANCE
.............................................................................................................................. 10
5.1 Maintenance Menu ......................................................................................................................................................... 10
5.1.1 Key..........................................................................................................................................................................11
5.1.2 Automatic Zeroing ...............................................................................................................................................12
5.1.3 Calibration............................................................................................................................................................13
5.1.4 Select Alarm Set Points.......................................................................................................................................14
5.1.5 Set Latches ............................................................................................................................................................15
5.1.6 Set the Key ............................................................................................................................................................15
5.1.7 Exit .........................................................................................................................................................................15
5.2 Sensor Replacement........................................................................................................................................................ 16
5.2.1 CO Sensor .............................................................................................................................................................16
5.2.2 Oxygen Sensor......................................................................................................................................................16
5.3 Humidifier Tube.............................................................................................................................................................. 16
5.4 Flow Control Orifice....................................................................................................................................................... 16
5.5 Particulate Filter Replacement...................................................................................................................................... 16
6.0 R
EPLACEMENT
P
ART
N
UMBERS
...................................................................................................... 18
7.0 WARRANTY............................................................................................................................... 19
A
PPENDIX
A....................................................................................................................................... 20
List of Illustrations
F
IGURE
1: F
EATURES OF
ISA-200 RAL(O) E
XTERNAL
..........................................................................................3
F
IGURE
1A: R
EGULATOR
...................................................................................................................................3
F
IGURE
2: ISA-200 RAL(O) I
NTERIOR
F
EATURES
.................................................................................................4
F
IGURE
3: ISA-200 RAL(O) M
OUNTING
D
IMENSIONS
............................................................................................5
T
ABLE
1: R
ELAY
C
ONTACTS
..............................................................................................................................6
T
ABLE
2: F
AULT
R
ELAY
C
ONTACTS
....................................................................................................................7
T
ABLE
3: O
UTPUTS FOR
4-20
M
A ........................................................................................................................7
F
IGURE
4: ISA-200 RAL(O) O
PERATIONAL
D
ISPLAY
............................................................................................8
T
ABLE
4: F
ACTORY
A
LARM
S
ET
P
OINTS
..............................................................................................................8
F
IGURE
5: ISA-200 RAL(O) O
PERATION
M
ENU
F
LOW
C
HART
................................................................................9
F
IGURE
6: ISA-200 RAL(O) M
AINTENANCE
M
ENU
F
LOW
C
HART
. ......................................................................... 10
F
IGURE
7: C
ONNECTION OF
C
ALIBRATION
G
AS
C
YLINDER
.................................................................................... 12
T
ABLE
5: F
AULT
A
LARM
.................................................................................................................................. 14
F
IGURE
8: R
EMOVE
S
HORTING
C
LIP
.................................................................................................................. 17
F
IGURE
9: M
ANIFOLD
...................................................................................................................................... 17
F
IGURE
10: L
OCATION OF
P
ARTS FOR
R
EPLACEMENT
.......................................................................................... 17
F
IGURE
11: C
ARBON
M
ONOXIDE
C
ONCENTRATION
.............................................................................................. 20
N
OTE
: [important information about use of instrument]
C
AUTION
: [affects equipment – if not followed may cause damage to instrument, sensor etc…]
W
ARNING
:
[affects personnel safety – if not followed may cause bodily injury or death.]
ISA 200 RAL (O) ENMET Corporation
The ISA-200 RAL(O) is an instrument that monitors compressed air supply systems for certain hazards to the user.
The instrument is available with sensors that monitor air for carbon monoxide (CO), for variations in the oxygen (O
2
) content. The sensors can be used alone or both used together. In the instrument, a sample of the compressed air is passed over electrochemical CO and O
2
sensors , the resultant electrical outputs are used to evaluate the air for the target gases. Some features of the instruments are as follows:
§ continuous monitoring of the sample air
§ continuous LCD display of gas and vapor concentrations
§ menu driven operational and maintenance controls
§ menu driven calibration procedure
§ audio and visual alarms indicate unsafe conditions
§ alarm relay contacts available on terminals
§ a fault relay and visual fault alarm
§ flowmeter plus low flow fault indication and display
§ alarm acknowledgement capability including audio defeat
§ mA outputs for each target gas
§ NEMA-12 packaging
N
OTE
: All specifications stated in this manual may change without notice.
1.1 Unpack
Unpack the ISA-200 RAL(O) and examine it for shipping damage. If such damage is observed, notify both ENMET customer service personnel and the commercial carrier involved immediately.
Regarding Damaged Shipments
N
OTE
: It is your responsibility to follow these instructions. If they are not followed, the carrier will not honor any claims for damage.
q
This shipment was carefully inspected, verified and properly packaged at our company and delivered to the carrier in good condition.
q q
When it was picked up by the carrier at ENMET, it legally became your company’s property.
If your shipment arrives damaged:
•
Keep the items, packing material, and carton “As Is.” Within 5 days of receipt, notify the carrier’s local office and request q immediate inspection of the carton and the contents.
•
After the inspection and after you have received written acknowledgment of the damage from the carrier, contact ENMET
Customer Service for return authorization and further instructions. Have your Purchase Order and Sales Order numbers available.
ENMET either repairs or replaces damaged equipment and invoices the carrier to the extent of the liability coverage, usually
$100.00. Repair or replacement charges above that value are your company’s responsibility.
q
The shipping company may offer optional insurance coverage. ENMET only insures shipments with the shipping company when asked to do so in writing by our customer. If you need your shipments insured, please
forward a written request to
ENMET Customer Service.
Regarding Shortages
If there are any shortages or questions regarding this shipment, please notify ENMET Customer Service within 5 days of receipt at the following address:
ENMET Corporation
680 Fairfield Court
Ann Arbor, MI 48108
734-761-1270 734-761-3220 Fax
1.2 Check Order
Check, the contents of the shipment against the purchase order. Verify that the ISA-200 RAL(O) is received as ordered. If there are accessories on the order, ascertain that they are present. Check the contents of calibration kits. Notify ENMET customer service personnel of any discrepancy immediately.
1.3 Serial Numbers
Each ISA-200 RAL(O) is serialized. These numbers are on tags on the equipment and are on record in an ENMET database.
1
ENMET Corporation ISA 200 RAL (O)
2.1 Exterior Features
The exterior of the instrument is shown in Figure 1. The exterior features are as follows:
Feature
Enclosure
Sample Air Hose
Sample Port
Sample/Calibration
Valve
Calibration Port
Front Cover Latch
Humidifier Tube
Line Cord
Audio Alarm
Mounting Flanges
Regulator
Description
A NEMA-12 plastic box, approximately 10x8x6, with a clear hinged front cover.
A six foot long hose to conduct a sample of the air from the source to the instrument.
See Figure 1A.
The fitting for the sample air hose.
A red handled ball valve which directs the air from either the sample or the calibrate port.
The handle points at the port, sample or calibrate, which is providing the air to the instrument
The entrance for the calibration gas. The quick release fitting mates with one on the calibration adapter.
A quick-release latch that holds the clear front cover in place, and is capable of being padlocked if desired.
Located under a black sheet metal cover. Is a tube that extracts moisture from the atmosphere and adds it to dry sample air, before it is presented to the carbon monoxide and oxygen sensors .
A cord to supply 110 V
AC
to the equipment. Not illustrated.
A loud horn activated by certain alarm conditions.
Flanges with holes for mounting the enclosure to a vertical surface.
To connect to the compressed air line. Regulator output to the ISA-200 RAL(O) should be set to 55 PSI. See Figure 1A.
2.2 Display Panel Features
The display panel, shown in Figure 1, is viewed through the clear front cover of the enclosure, and is accessed by opening the cover. Features are as follows:
Feature
Display
Flowmeter
Visual Alarms
Pushbutton Switches
Option Switch
Select Switch
Alarm Acknowledge/
Audio Defeat
Switch
Description
A 2 line, 16 character per line, LCD with backlight. The numerical values of gas concentrations, and other information are displayed.
A flow indicator located at the output of the sample flow stream, which indicates quantitatively the flow of sample air or calibration gas through the instrument.
On both sides of the display, a red LED for each sensor on the instrument.
Near the center of the panel,. a green power LED and a red fault LED,
There are three of these, located near the center of the panel; they are yellow rectangular membrane switches. They are:
The top left switch.
Directly to the right of the option switch.
Directly under the option switch.
2
ISA 200 RAL (O)
Visual Alarm
CO
Audio Alarm
OPTION
Switch
A
LARM
A
CKNOWLEDGE
A
LARM
D
EFEAT
Switch
Flow Meter
Strain Relief for Line Cord
CO ppm
OPTION
AUDIO
DEFEAT
ALARM
ACKNOWLEDGE
SELECT
POWER
FAULT
O
2
%
ENMET Corporation
Cover, Humidifier Tube
Display
Visual Alarm O2
If Oxygen option is installed
Calibration
Port
SELECT
Switch
Power LED
Front Cover
Latch
Fault LED
Sample/Calibration
Valve
Sample
Port
Mounting Flanges
2 places
Figure 1: Features of ISA-200 RAL(O) External
Sample Air Hose to Sample Port
Figure 1A: Regulator
3
ENMET Corporation ISA 200 RAL (O)
2.3 Circuit Board Features
The Display Panel is hinged on the right and is released by unscrewing the 2 thumb screws located in the left corners.
After releasing the panel, it is swung to the right, exposing the interior of the enclosure. The Circuit Board is mounted on a plate at the back surface of the enclosure interior. Features are shown in Figure 2.
Feature
Terminal Strip
Manifold Housing
Description
This twenty-three position terminal is located at the bottom of the Circuit Board. On it are twelve positions for three contacts for each of four alarm relays, and three positions for the contacts of a fault relay.
There are also two positions for each of the 4-20 mA outputs. (optional)
The sample manifold, the carbon monoxide and oxygen sensors are located under this small aluminum housing. Not illustrated in figure 2, see Figure 8.
2.3 Power Supply
The power supply circuit is located on the bottom surface of the inside of the enclosure. The circuit is protected by two 1.0 Amp fuses mounted in fuse holders on the power supply board.
Cover, Humidifier Tube
Humidifier
Tube
Audio Alarm
Particulate
Filter
Sensor O2
If Oxygen option is installed
Sensor CO
Fuse Holder
Power Supply
PCB
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3
1
N C C N O N C C N O N C C N O N C C N O N C C N O C O - C O + D P - D P + O 2 - O 2 +
05217-001 Ass'y Rev
Terminal
Strip
Power Supply
PCB
Figure 2: ISA-200 RAL(O) Interior Features
4
ISA 200 RAL (O) ENMET Corporation
3.1 Mounting of Instrument
The ISA-200 RAL(O) should be located near the pipe or tank containing the air to be monitored, and upstream from where the air is being used. So that, the air sample enters the instrument before it reaches the users.
Upright (plumb and level) vertical orientation of the instrument is necessary for proper operation. Mount the instrument on an appropriate vertical surface using the mounting flanges provided. The holes in the flanges are 0.31
inch in diameter and form a 6 x 10.75 inch rectangle. See Figure 3.
OPTION
AUDIO
DEFEAT
ALARM
ACKNOWLEDGE
SELECT
POWER
FAULT
Mounting Holes
0.31” dia. 4 places
Figure 3: ISA-200 RAL(O) Mounting Dimensions
5
ENMET Corporation ISA 200 RAL (O)
3.2 Sample Air Supply
Tap the pipe or tank containing the breathing air and use appropriate fittings to connect the sample input hose. The instrument is designed to operate from an air supply pressure of 50-55 psig; adjust the regulator and set the pressure at
55 psig. The flowmeter on the display panel indicates approximately 2 SCFH when the input pressure is 55 psig.
The sample air exits the instrument from two separated ports on the back surface of the enclosure. Take care not to obstruct these exit ports. After mounting the enclosure, they are not accessible.
Be sure that the red sample-calibrate valve handle on the right side of the enclosure is pointed down toward the sample input port.
3.3 Power Supply
Plug the line cord in a source of 110V
AC
power. The input power can vary from 100 to 240V
AC
, 50/60 Hz; if other than 110 V
AC
power is desired, the plug on the line cord must be changed.
Upon supplying air and power to the instrument:
§ The green power on LED is lit.
§ The display backlight is lit, and numbers are given on the display.
The instrument may go into alarm briefly, but the sensors stabilize quickly. If the instrument persists in alarm, acknowledge the alarm by pressing the ALARM ACKN/AUDIO DEFEAT switch. If alarm persists longer than 30 minutes, call ENMET customer service personnel.
3.4 Outputs
Two types of alarm outputs are available, relay contacts and optional 4-20mA outputs.
3.4.1 Relay Contacts
Relay contacts are available for each alarm; these are SPDT, rated at 2.0Amp at 110V
AC
, and may be latching or nonlatching as required by the application. They are accessed on the terminal strip at the bottom of the circuit board see
Figure 2. The positions given in Table 1:
Table 1: Relay Contacts
Position Function Contact
9
10
11
6
7
8
3
4
5
1
2
CO Alarm
CO Alarm
CO Alarm
O
2
Alarm*
O
2
Alarm*
O
2
Alarm*
Not Used
Not Used
Not Used
Not Used
Not Used
NC
C
NO
NC
C
NO
12 Not Used
* This relay is activated by both the deficiency and abundance alarms.
These relay coils are energized when they are in the non-alarm state; the contact conditions given above are for the non-energized state, which is identical to the alarm state.
6
ISA 200 RAL (O) ENMET Corporation
In addition, there is a fault relay, which changes state whenever the instrument is in a fault condition.
The contact positions are given in Table 2:
Table 2: Fault Relay Contacts
Position
13
14
15
Function
Fault
Fault
Fault
Contact
NC
C
NO
The coil of this relay is energized when the instrument is in the non-fault state; the contact conditions given above are for the non-energized state, which is identical to the fault state.
These relay contacts can be used to operate auxiliary alarms or other functions. Punch a hole at the bottom of the left side of the enclosure for a wire exit, and use appropriate cable and fittings to preserve the NEMA-12 rating of the enclosure.
3.4.2 Optional 4-20mA Outputs
Isolated 4-20 mA outputs are available for data logging or other purposes. An output is supplied for each sensor supplied in a particular instrument, and can be added when a sensor is added in the field. When all three sensors are supplied, these outputs are available on the terminal strip in the positions given in Table 3:
Position
19
20
21
16
17
18
Table 3: Outputs for 4-20mA
Channel
CO
CO
Not Used
Not Used
O2
O2
Function
Ground
+ 4 to 20 mA
Ground
+ 4 to 20 mA
Range
4 mA = 0 ppm
20 mA = 100 ppm
4 mA = 0%
20 mA = 25.5%
When both sensors are supplied, the sensor for CO output is on positions 16 and 17. The Oxygen output is on positions 20 and 21. Positions 18 & 19 are not used.
Wiring requirements are the same as for the relays.
3.5 Initial Calibration
If a calibration kit is available, calibrate the CO and O
2
channels of the instrument 24 hours after installation. See
Section 5.0, Maintenance, for calibration instructions. After calibration, be sure to return the red sample-calibrate valve handle to the down position, pointing toward the sample input port.
7
ENMET Corporation ISA 200 RAL (O)
4.1 Normal Operation Condition
With the ISA-200 RAL(O) installed as described in section 3, and in clean air, the POWER green LED is on, the display is lit, the flowmeter reads approximately 2 SCFH, and the information on the display is as shown in Figure 4
Display, for the sensor(s) installed in the ISA-200 RAL(O). The red alarm and fault LEDs are not lit.
CO
PPM
000
PPM
20.9%
FLOW:y
O
2
%
Example of display with O (Oxygen) option installed
Figure 4: ISA-200 RAL(O) Operational Display
4.2 Alarm Set Points
There is one alarm set point for CO, and two for oxygen. The factory settings of these alarm set points are as follows:
Table 4: Factory Alarm Set Points
Gas
Carbon Monoxide
Oxygen Deficiency
Oxygen Abundance
Set Point
10 ppm
19.5 % by volume
23.5 % by volume
These alarm set points can be changed within limits; see the maintenance portion of this manual for the procedure.
If the CO concentration increases above that of the alarm set point, the associated red LED is lit, the associated relay changes state, and the audio alarm is activated.
If the oxygen content of the sample air decreases below the deficiency alarm set point, the associated red LED is lit, the associated relay chances state, and the audio alarm is activated.
If the oxygen content of the sample air exceeds that of the abundance alarm set point, the associated red LED is lit, the audio alarm is activated, and both the oxygen alarm relay and the oxygen high alarm relay change state. There is one alarm LED for both the deficiency and abundance alarms.
4.3 Alarm Latching
An instrument is shipped with the alarms in the non-latching mode. The alarms may be independently configured in the non-latching mode by use of the maintenance menu.
§ I
N THE LATCHING MODE
: at the cessation of the condition which causes an alarm, the alarm indications do not cease, and the alarm relay contacts do not revert to the non-alarm state, until the ALARM ACKN/AUDIO
DEFEAT switch is pressed. An alarm can also be acknowledged by pressing the switch during the alarm condition; then at the cessation of the alarm condition, alarm indications cease and alarm relays revert to the nonalarm state. After an alarm is acknowledged, alarms in the latching configuration are re-armed to latch at the next alarm condition.
§ I
N THE NON
-
LATCHING MODE
: at the cessation of the condition which causes an alarm, the alarm indications automatically cease, and the alarm relay contacts revert to the non-alarm state.
8
ISA 200 RAL (O) ENMET Corporation
4.4 Audio Defeat
With the alarms in the non-latching configuration, pressing the ALARM ACKN/AUDIO DEFEAT switch during an alarm silences the audio alarm.
With an alarm in the latching configuration, pressing the ALARM ACKN/AUDIO DEFEAT switch during an alarm silences the audio alarm and unlatches the associated relay(s).
4.5 Display
In clean air, the display is as shown in Figure 4, for the sensor(s) installed in the ISA-200 RAL(O). This position of the display is termed the "operational display". As explained below, the display can be changed to furnish other information by using the OPTION and SELECT switches.
Concentrations of CO are given in PPM (parts per million parts of air). Oxygen concentration is given in per cent by volume. When sample flow is reduced below a limit, the display switches from "Flow: yes" to" Flow: no", or from
"Flow: y" to "Flow: n".
4.6 Operational Menu
The operational menu allows the user to:
§ View alarm set point concentration values
§ View alarm latching configurations
§ Enter the maintenance menu with the proper key.
The operational menu is accessed with the OPTION and SELECT switches. The operational menu flow chart is shown in Figure 5,
§ The OPTION switch is indicated with a "O"
§ The select switch is indicated with a "S".
If the instrument is left at any location in the operational or maintenance menus, other than the operational display, with no action taken for a period of 45 seconds, it returns to the operational display.
Operational
Display
000 PPM 20.9%
FLOW :y
O
S
No Function view ALARMS
& LATCHES
O
S
PPM
CO:
LATCH:
O
%O2: 19.5
LATCH: no
10 no
23.5
no
O
S
S
No Function
No Function
O
run Maintenance
Menu
S
To Key
O = Option Switch
S = Select Switch
Figure 5: ISA-200 RAL(O) Operation Menu Flow Chart
4.7 Fault Indications
4.7.1 Low Flow Indication
A sensitive pressure switch is used to furnish a low flow indication. When the sample air pressure drops below approximately 30 psig, the fault light and audio alarm are activated, and the display reads either "Flow: no" or "Flow: n", depending upon the number of sensors installed in the instrument.
4.7.2 Other Fault Indications
Other fault indications are associated with sensor zero and calibration activities, and are described in the maintenance section 5.0 of this manual.
9
ENMET Corporation ISA 200 RAL (O)
5.1 Maintenance Menu
The ISA-200 RAL(O) maintenance menu is accessed with the OPTION and SELECT switches. The maintenance menu diagram is shown in Figure 6 Maintenance Menu Flow Chart. From the operational display, press the
OPTION switch twice; " run MAINTENANCE MODE" is displayed.
Figure 6: ISA-200 RAL(O) Maintenance Menu Flow Chart.
O = Option Switch
S = Select Switch
10
ISA 200 RAL (O) ENMET Corporation
5.1.1 Key
Entrance to the maintenance menu is guarded with a four-digit key. The factory default setting of the key is 1270.
When a valid numerical key is inserted, the user is allowed to enter the maintenance menu.
In the "run MAINTENANCE MODE" position
§ Press the SELECT switch; "KEY = 0000" is displayed.
§ In the "KEY = 0000" position, the underline cursor is under the left digit.
§ Press the OPTION switch to change the left digit; select the correct digit.
§ Press the SELECT switch, which locks the correct digit in place and moves the cursor one digit to the right.
Continue this process until the four-digit key is complete. When a valid key is inserted in this manner, the display is transferred to the " run AUTOMATIC ZEROING" portion of the menu. If an invalid key is inserted, "INVALID" is displayed briefly; then the ISA-200 RAL(O) returns to the operational display.
CO
PPM
KEY = 1270
O
2
%
To Operational
Display
O
From Operational Menu run MAINTENANCE
MODE
S
KEY=0000
Invalid
O
Changes digit indicated by underscore cursor
S
Locks underscore digit and moves cursor to next digit
Valid entry
To Automatic Zeroing
O = Option Switch
S = Select Switch
Example: Key Display and Flow Chart
11
ENMET Corporation ISA 200 RAL (O)
5.1.2 Automatic Zeroing
A valid key entry sets the instrument in the " run AUTOMATIC ZEROING" position, which enables the setting of the zero gas concentration point. This is desirable if the zero reference of one of the sensors has drifted over time. For
CO, the zero reference point is 0000 ppm CO; the zero reference point for oxygen is 20.9% oxygen by volume. Note that the calibration procedure described in section 5.1.3 also includes setting the zero point. If a full calibration is required, instead of setting just the zero point, press the OPTION switch once; " run FULL CALIBRATION" is displayed. See section 5.1.3.
T
O SET THE ZERO POINT WITHOUT PERFORMING FULL CALIBRATION
:
§ From the "run AUTOMATIC ZEROING" position, see flow chart.
§ Press the SELECT button; "ATTACH ZERO GAS" is displayed.
N
OTE
: While it is possible to zero the sensor(s) using a sample from a "clean" air line, this entails using the sample as a standard, and is best avoided. The best zero gas is a cylinder of 20.9% oxygen in nitrogen with no CO present. This is available in the calibration kit listed in section 6.0
Pressing the OPTION switch at this point aborts the procedure and transfers the display to the " exit MAINTENANCE
MODE" position.
From Valid Key Entry run AUTOMATIC
ZEROING
S
ATTACH
ZERO GAS
O
Exit Maintenance Mode
O = Option Switch
S = Select Switch
O
To Full Calibration
S
ZERO=30 .00V
20.9 130 00.0
Valid
Return to Operational Display
Invalid
Return to Operational Display with
“Fault 01” in place of the PPM reading
Example: Automatic Zeroing Flow Chart
T
O CONTINUE THE PROCEDURE
: attach a cylinder of zero gas to the Calibration Port using the calibration adapter, as shown in Figure 7. Open the cylinder valve, set the regulator at 55 psig, and turn the red handle of the samplecalibrate valve up toward the calibration port. Let the gas flow for about a minute
Calibration Port
Cylinder Valve and Regulator
OPTION
AUDIO
DEFEAT
SELECT
POWER
FAULT
ALARM
ACKNOWLEDGE
Cylinder of Gas
Sample/Calibration
Valve – Up to Calibrate
Figure 7: Connection of Calibration Gas Cylinder
12
ISA 200 RAL (O) ENMET Corporation
§ press the SELECT switch.
§ "ZERO = 30 .00V" is displayed. This is a timer that counts down from 30 seconds, at the end of that time the procedure is finished. The instrument sets the clean air voltage point for the CO sensor and the 20.9% O
2
point for the oxygen sensor if it is present. It then examines the validity of these values; if they are valid, it goes back to the operational display. If a failure occurs, "Fault-01" is displayed in place of PPM reading in the operational display.
FAULT 01 indicates a clean air fault. Verify the proper zero gas is attached to the calibration Port and the samplecalibrate valve is up toward the calibration port. Repeat automatic zeroing procedure. If fault 01 still occurs, replace sensor in accordance with section 5.2.
After this procedure is complete, be sure to return the red handle of the Sample-Calibrate valve to the down position, pointing toward the Sample Port. If the Sample-Calibrate valve is not switched back to the sample port, the low flow fault indication is activated when the zero gas is removed.
5.1.3 Calibration
Insertion of a valid key results in the display: "run AUTOMATIC ZEROING". Press the OPTION switch once; " run
FULL CALIBRATION" is displayed. Press the SELECT switch; "ATTACH ZERO GAS" is displayed; this is the start of the automatic zeroing procedure as described in paragraph 5.1.2, above. When this procedure is complete,
"ATTACH SPAN GAS - SPAN = 20" is displayed to indicate that the correct span gas for this procedure is 20 ppm
CO in a mixture of 20.9% oxygen in nitrogen. Do Not Use Any Other Than The Correct Span Gas For This
Procedure.
Pressing the OPTION switch at this point aborts the procedure and sets the display at the " exit MAINTENANCE
MODE" position.
From Automatic Zeroing run FULL
CALIBRATION
S
O
To Selectable Alarms
ATTACH
ZERO GAS
S
ZERO=30 .00V
20.9 130 00.0
S
ATTACH SPAN
GAS PPM CO
S
SPAN=120 .65V
20.9 130 00.0
O
Exit Maintenance Mode
O
Exit Maintenance Mode
Valid
Return to Operational Display
Invalid
Return to Operational Display with
“Fault 01, Fault 02 or Fault 03”
O = Option Switch
S = Select Switch
Example: Full Calibration Flow Chart
T
O CONTINUE THE PROCEDURE
:
§ Attach the correct span gas to the Calibration Port with the calibration adapter turn the red handle of the Sample-
Calibrate valve up toward the Calibration Port. See Figure 7.
§ Open the cylinder valve, set the regulator at 55 psig.
§ Allow the calibration gas to flow for
at least one minute
, then press the SELECT switch.
C
AUTION
: Pressure fluctuations may lead to aberrant oxygen readings if the SELECT switch is activated in less than one minute.
§ "SPAN = 120 .00V" is displayed. This is a timer that counts down 120 seconds, at that point the procedure is complete. The “.00V”portion of the display reflects the sensor signal, as it responds to the CO gas. This value should increase.
After a valid zero and calibration, the instrument reverts to the operational display.
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ENMET Corporation ISA 200 RAL (O)
After an invalid zero or calibration one of the following will be displayed in place of the PPM reading in the operational display:
Table 5: Fault Alarm
Displayed Cause Possible remedy
•
•
•
Fault 01
Fault 02
Fault 03
An invalid zero
An invalid calibration
An invalid zero and calibration
·verify proper zero gas is attached to calibration port and sample-calibration valve handle is up
·perform automatic zero
·change sensor in accordance with section 5.2
·verify proper calibration gas is attached to calibration port and sample-calibration valve handle is up
·perform calibration
·change sensor in accordance with section 5.2
·verify proper calibration gas is attached to calibration port and sample-calibration valve handle is up
·perform calibration
·change sensor in accordance with section 5.2
After this procedure is complete, return the red handle of the Sample-Calibrate valve to the down position, pointing toward the Sample Port. If the Sample-Calibrate valve is not returned to the sample port, the low flow alarm is activated when the calibration gas is removed.
N
OTE
: During the zero and span process, the sensor singles must fall within a preset limit. If they do not, the fault codes above are generated. If a fault code 2 is generated with calibrating the CO sensor, and the span voltage is close to, but not greater then 0.38V, an adjustment may be capable of being made, to extend the life of the sensor. Follow the procedure foe calibrating a sensor as outlined in section 5.2.
5.1.4 Select Alarm Set Points
§ Factory alarm set points are discussed in paragraph 4.2. To change the alarm set points, after inserting a valid key,
§ Press the OPTION switch twice; "set SELECTABLE ALARMS" is displayed.
§ Press the SELECT switch; "ALARM = 0000" is displayed, with the underscore cursor under the left digit.
§ Press the OPTION switch to change the left digit; select the correct digit.
§ Press the SELECT switch to lock in the correct digit and move the cursor one digit to the right. When a valid new alarm is selected, the "NEW = XXXX" is displayed.
§ Press the OPTION or the SELECT switch, and the display changes to the next sensor. After all sensors have been displayed, the display returns to the " set SELECTABLE ALARMS" position.
Valid alarm ranges are as follows:
•
CO: 5 to 99 ppm
•
The oxygen alarm set points are 19.5% for deficiency and 23.5% for abundance, and are not adjustable.
From Full Calibration set SELECTABLE
ALARMS
O
S
To Set Latches set CO Alarm
Invalid entry
S
ALARM=0000
O
NEW=0000
Example: Selectable Alarms Flow Chart
O
S
Changes digit indicated by underscore cursor
Locks underscore digit and moves cursor to next digit
S or O
Exit Maintenance Mode
O = Option Switch
S = Select Switch
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ISA 200 RAL (O) ENMET Corporation
5.1.5 Set Latches
To latch and unlatch the alarm relays, after inserting a valid key, press the OPTION switch three times; "set
LATCHES" is displayed.
§ Press the Select switch; the particular alarm relay and its latch mode is displayed, for example, "RELAY: 10ppm
CO, LATCH: no".
§ Use the OPTION switch to toggle the latch mode between "yes" and "no". Select the desired mode. See section 4.3.
§ Press the SELECT switch to step to the next relay. The procedure steps sequentially to all alarm relays in this manner; when complete, it returns to the "set LATCHES" position.
From Selectable Alarms set LATCHES
S
O
To Set Key
Example: Set Latches Flow Chart
RELAY 10
PPM
CO
LATCH: no
S
S
RELAY O2
LATCH: no
S
RELAY
FAULT
LATCH: no
O
O
O
Toggles “Yes” and “No”
O = Option Switch
S = Select Switch
Toggles “Yes” and “No”
Toggles “Yes” and “No”
5.1.6 Set the Key
To set a new key, after inserting a valid key, press the OPTION switch four times; " set KEY” is displayed. Press the
SELECT switch; " KEY = 0000" is displayed, with the underscore cursor under the left digit. Use the OPTION switch to change the left digit, select the desired digit, and use the SELECT switch to lock the digit in place and move the cursor one digit to the right. When all four digits of the new key have been selected, " NEW = XXXX" is displayed.
Record the new key; without it, the maintenance menu cannot be reentered once it is left. If the key is lost, call
ENMET customer service personnel.
From the "NEW = XXXX" position, press either the OPTION or the SELECT switch; "exit MAINTENANCE
MODE" is displayed.
From Set Latches set KEY
O
S
KEY=0000
O
S
Changes digit indicated by underscore cursor
Locks underscore digit and moves cursor to next digit
NEW = XXXX
To exit Maintenance Mode
Example: Set Key Flow Chart
S or O
O = Option Switch
S = Select Switch
5.1.7 Exit
From the "exit MAINTENANCE MODE" position
Press the SELECT switch to resume the operational display.
Press the OPTION switch to reenter the maintenance menu at the " run AUTOMATIC ZEROING" position.
Return to Run Automatic Zeroing
O
exit MAINTENANCE
MODE
S
Return to Operational Display
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ENMET Corporation ISA 200 RAL (O)
5.2 Sensor Replacement
5.2.1 CO Sensor
A CO sensor must be replaced when it can no longer be calibrated. To replace a sensor, perform the following steps.
§ Turn off the electrical power. The sample air can continue to flow.
§ Open the display panel and remove the two manifold retention screws and remove the manifold. See Figure 9.
§ Remove the old CO sensor, which is the bottom most sensor, and replace it with a new sensor.
C
AUTION
: New sensors come with a shorting clip that must be removed for proper operation. See Figure 8.
§ Replace the manifold. Observe that the flowmeter reading is correct.
§ Turn on the electrical power.
§ Wait 30 minutes, then recalibrate the sensor per the instructions in Section 5.1.3. As the timer is counting down during calibration, a voltage is displayed on the screen beside the timing count. This voltage must be between:
.38V – .68V
§ Adjust to: .65V if it is not between .38 – .68V. Adjust this voltage during the last 30 seconds of the calibration interval, using the bottom most potentiometer on the sensor circuit board. See Figure 10.
§ Replace the manifold housing, and secure the display panel. An instrument without the manifold housing in place is susceptible to RFI.
5.2.2 Oxygen Sensor
An oxygen sensor must be replaced when it can no longer be calibrated in clean air. To replace the sensor, follow the general steps given for the replacement of the CO sensor, but effect a replacement of the oxygen sensor, which is the large sensor in the center position of the manifold. After sensor installation, wait four hours before recalibrating.
When recalibrating, it is not necessary to make a voltage adjustment.
5.3 Humidifier Tube
The humidifier tube is used to assure that the CO and oxygen sensors are not subjected to extremely dry air for a long period of time, which would decrease their useful life. Change the humidifier tube when changing a CO sensor at the completion of its useful life.
To change the humidifier tube:
§ Remove the sheet metal cover from the top of the enclosure, exposing the humidifier tube. See Figure 10.
§ Note the coiled arrangement of the tube. Remove the old tube and replace it with the new one.
§ Replace the sheet metal cover.
5.4 Flow Control Orifice
A 0.006-inch diameter orifice is used to set the flow rate and to drop the air pressure. It is located where the air enters the humidifier tube, see Figure 10. In well-maintained medical air systems, this orifice should not clog. However, if difficulty is experienced in maintaining flow rate with assured inlet pressure, remove air pressure from the equipment and examine this orifice; replace it if necessary.
5.5 Particulate Filter Replacement
A filter is installed inside the enclosure, as shown in Figure 10.
To replace this filter:
§ Obtain a new filter
§ Note the correct direction of flow, as denoted by the arrow on the filter body
§ Remove the old filter
§ Replace with the new filter
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ISA 200 RAL (O) ENMET Corporation
Manifold
Sensor
Bottom View
Figure 8: Remove Shorting Clip
Particulate Filter
Figure 9: Manifold
Cover, Humidifier Tube
Humidifier Tube
Flow Control Orifice
Oxygen Sensor
CO Voltage adjustment
Potentiometer
CO Sensor
Figure 10: Location of Parts for Replacement
17
ENMET Corporation
ENMET part numbers for replacement parts:
Part number Description
05221-001
64002-1000
67016-1106
67016-1204
73070-009
73108-002
03401-000
03219-020
03296-209
03700-022
73089-002
05219-001
05217-001
05320-001
Power Supply Circuit
Fuse, 1.0 Amp 5x20mm
Sensor, Oxygen
Sensor, CO
Orifice
Humidifier Tube
Calibration Kit
Gas Cylinder, 20 ppm CO in air
Gas Cylinder, 20.9% oxygen in nitrogen
Calibration Adapter
Filter, particulate
Sensor Board, for units s/n 599 and below
Control Board, for units s/n 599 and below
Control/Sensor Board, for units s/n 600 and above
ISA 200 RAL (O)
18
ISA 200 RAL (O) ENMET Corporation
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 contact ENMET Corporation.
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ENMET Corporation ISA 200 RAL (O)
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 8. The ISA-200 RAL(O) instrument 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. 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, OSHA requires Grade
D breathing air supplied, using a Compressed Gas Association (CGA) definition (G-7.1). Depending on interpretation of the OSHA respiratory standard, 10 ppm and 20 ppm CO have been used as maximum limits and standard instrument alarm points.
The ISA-200 RAL(O) has two preset alarm set points, at 10 ppm and 20 ppm CO, which are adjustable, but cannot be set below 5 ppm or above 100 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 ore pronounced.
Figure 11: Carbon Monoxide Concentration
20
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