Quincy Compressor CO MONITOR Instruction manual

Quincy
Carbon Monoxide
Monitor
Instruction Manual
This manual contains important safety information and should be
made available to all personnel who operate and/or maintain this
product. Carefully read this manual before attempting to operate or
perform maintenance on this product.
Quincy
Compressor
Tr u e B l u e R e l i a b i l i t y
65049-CM1
®
SM
April 2001 Edition
Table of Contents
Section I - General
Standard Warranty ...................................................................................................................................................... 1
Introduction - CO Monitor for Breathing Air Systems .............................................................................................. 2
Overview .................................................................................................................................................................... 2
Description ................................................................................................................................................................. 2
Principles of Operation............................................................................................................................................... 3
Switches ..................................................................................................................................................................... 3
Indicators .................................................................................................................................................................... 4
Controls ...................................................................................................................................................................... 4
Technical Data ............................................................................................................................................................ 5
Section II - Installation
Mounting .................................................................................................................................................................... 6
Connecting to the Air Line ......................................................................................................................................... 6
Connecting to Power .................................................................................................................................................. 6
Connecting to Alarm Terminal Board ........................................................................................................................ 6
Figure 1 - Power Connection ..................................................................................................................................... 7
Figure 2 - External Alarm Connections ..................................................................................................................... 7
Section III - Operation
Calibration .................................................................................................................................................................. 8
Sensor Replacement ................................................................................................................................................... 8
Figure 3 - Calibration ................................................................................................................................................. 9
Section IV - Maintenance
Maintenance ............................................................................................................................................................. 10
Section V - Troubleshooting
Troubleshooting Guide ....................................................................................................................................... 12-13
Quincy Compressor®-Carbon Monoxide Monitor
Section I - General
Standard Warranty
Quincy Compressor Division
Carbon Monoxide Monitor
Quincy Compressor warrants each new electrical product
manufactured by it to be free from defective material and
workmanship. All such product is warranted as to its
merchantability and fitness for the purpose intended, for
a period of one (1) year from the date of sale to the
original purchaser. Quincy Compressor agrees to remedy
any such defect or to furnish a new part (at the
Company’s option) in exchange for any part of any
product of its manufacture which, under normal use and
service, discloses such defect. The product must be
delivered intact by the purchaser, with all transportation
prepaid, to Quincy Compressor’s factory for examination
which must disclose, in our judgment, that the product is
defective.
This Warranty does not extend to any products which
have been subjected to misuse, neglect, accident,
unauthorized modifications or to use in violation of
instructions furnished by us, nor does it extend to
products which have been repaired or altered outside of
our factory.
THIS WARRANTY IS IN LIEU OF ALL
WARRANTIES, EXPRESS OR IMPLIED, AND NO
REPRESENTATIVE OR PERSON IS AUTHORIZED
TO ASSUME FOR QUINCY COMPRESSOR ANY
OTHER LIABILITY IN CONNECTION WITH THE
SALE OF OUR PRODUCTS.
IN NO EVENT IS QUINCY COMPRESSOR LIABLE
FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES ARISING FROM ANY BREACH OF
WARRANTY OF PRODUCT.
NOTICE!
This warranty is the sole warranty of
seller. Any other warranties, expressed
or implied, including any warranties of
merchantability or fitness for a particular
use are hereby excluded.
Quincy Compressor®-Carbon Monoxide Monitor
1
Section I - General
Introduction CO Monitor for Breathing Air Systems
Compressors can introduce harmful toxic substances into
the compressed air from atmospheric conditions. When
using compressed air for breathing air operations carbon
monoxide can be present.
OSHA has set specific requirements on respiratory air to
meet minimum standards referred to as Grade “D” air.
OSHA regulation 1910.134 reads as follows: “if an oil
lubricated compressor is used it shall have a high
temperature or carbon monoxide alarm or both. If only
high temperature alarm is used, the air from the
compressor shall be frequently tested for carbon
monoxide to insure it meets the specifications for grade
“D” breathing air.”
The Quincy Carbon Monoxide Monitor is designed to
monitor the level of carbon monoxide, hydrocarbons, and
other oxidizable toxic gases in a respiratory air system
and activate an alarm when the concentration of these
gases exceed the unit’s preset alarm threshold. The unit
has remote alarm capability so a visual or audio alarm
can be added to the circuit.
The Quincy Carbon Monoxide Monitor, operated as
described in this manual, should give years of troublefree operation.
2
Overview
From the respiratory air line, the air to be monitored
enters the Quincy Carbon Monoxide Monitor’s
coalescing filter where 99.99% of all compressor fluid
and dirt are removed. Fluid vapors and other liquids drop
to the bottom of the bowl and are automatically drained.
The air pressure is then reduced to 10 psi at the pressure
regulator. After the gas passes through the check valve
and the 1/16” i.d. tubing, its flow rate is set at 0.5 SCFH
by the flow meter. The air then proceeds to the condulet
where the sensor monitors the air before it exits to the
atmosphere.
Description
The Quincy Carbon Monoxide Monitor is housed in a
polyester fiberglass NEMA 4 case. All of the electronic
controls and indicators are mounted behind a window in
the hinged door to provide protection for the circuitry. A
cover latch permits quick access to the interior for
calibration or adjustment, and may be secured with a
small padlock.
A particulate filter is provided to protect the sensor and to
prolong its life. An illuminated fault test checks for
sensor failure and continuity in the electronic circuits and
alarms. The sensor is provided with a flow meter which
allows visual inspection for air flowing over the sensor.
Upon start-up, the monitor goes through a 10 minute
testing procedure to purge the sensing head and clear any
debris from it.
Quincy Compressor®-Carbon Monoxide Monitor
Section I - General
Principles of Operation
Switches
The basic sensor used in the Quincy Carbon Monoxide
Monitor is a semiconductor catalytic sensor. The sensor
has a five year service life under normal operation and is
calibrated to 10 ppm for carbon monoxide and other
hazardous gases. When a catalytic oxidation occurs at
the surface of the sensor, the electron concentration in the
catalytic material increases, decreasing the resistance of
the sensor. The resistance change is measured by the
monitor’s integrated circuitry, converted to an equivalent
gas concentration, and then displayed on a meter.
Although the sensor response is optimized for Carbon
Monoxide (CO) detection, it will respond to other
oxidizable gases. It also shows a slight response to water
vapor, therefore, if used to monitor air lines where the air
has been dried (less than 50% relative humidity), a
humidifying system should be used to supply water vapor
to the air reaching the sensor.
There are three switches to allow operator control of
monitor functions.
Alarm On Switch (white)
The ALARM ON switch, when depressed, permits the
alarm relay to be energized. The red jewel light on the
cover operates whether the Alarm On switch is activated
or not.
Purge Switch (yellow)
The momentary PURGE switch initiates the purge cycle
when depressed. During the purge cycle, the sensor
temperature is elevated above normal operating
temperature to clean and condition the catalytic surface
of the sensor to ready it for normal operation. The unit
automatically goes into a purge cycle when power is
applied to the unit, or when power is restored after an
interruption of more than two minutes.
Test Switch (blue)
The momentary TEST switch connects a parallel
resistance across the sensor to simulate a gas load. It is
used to check circuit and alarm function, and for a rough
calibration check.
Quincy Compressor®-Carbon Monoxide Monitor
3
Section I - General
Indicators
Controls
There are four indicators that display the status of the
Quincy Carbon Monoxide Monitor.
Three controls regulate the Quincy Carbon Monoxide
Monitor’s operational accuracy.
Alarm Indicator (red)
Calibration Control
The red jewel alarm indicator on the cover is activated
when the instrument reading exceeds the alarm threshold.
It operates whether the ‘alarm on’ switch is in or out.
The bulb may be replaced from the front of the case by
unscrewing the red jewel.
The calibration control is used to set the unit’s CO
readout relative to a calibration gas. Under normal
conditions, the calibration control should be the only
control adjusted during calibration.
Alarm Set
Alarm On Indicator (white)
The alarm on indicator shows that the ‘alarm on’ switch
is in and serves as a pilot light to indicate that the unit is
fully operational. The switch is in the depressed position
during normal operation.
Purge Indicator (yellow)
The purge indicator shows that the unit is going through
the purge cycle. None of the alarms are operative during
the purge cycle.
Fault Indicator (blue)
The upper trim point is used to set the alarm threshold.
The alarm point may be set at any point on the meter
scale.
Zero Control
The lower trim point is used to set the circuit zero point.
Normally, it should be adjusted only in clean air, and
only if a large adjustment has been made in the
calibration control. The zero control is electronically
independent of the gain control, but a large adjustment of
gain may change the clean air voltage output enough to
require resetting of the zero control.
The fault indicator is tripped when the basic sensor
readout circuit is out of normal operating range. This
condition can be caused by an open sensor circuit, heater
failure, or amplifier failure. The indicator function and
the switch function are not related.
4
Quincy Compressor®-Carbon Monoxide Monitor
Section I - General
Technical Data
Gases Detected
CO, Oxidation Toxics
Sensor
Solid State, Catalytic Semiconductor
Meter Scale
2-50 ppm (CO)
Response
90% maximum in 30 seconds
Accuracy
+/-10%
Operating Temperature
0°F to 120°F (customer adjustable)
Factory Set Alarm
10 ppm (CO)
Standard Inlet Pressure
70 to 150 psig
Power Source
110 VAC, 1 amp or 12 VDC
Expected Sensor Life
3 to 5 years
Sensor Life Warranty
1 year
Quincy Compressor®-Carbon Monoxide Monitor
5
Section II - Installation
Mounting
The Quincy Carbon Monoxide Monitor should be
mounted in a vertical position for the flow meter to
indicate the correct reading. The NEMA 4 case provides
four holes for mounting.
CAUTION!
Reversal of the polarity will permanently damage
the unit.
Connecting to the Air Line
Install a pipe fitting into the air line (such as a pipe tee) to
supply a small flow of air through the unit. Connect the
air flow line to the monitor’s regulator using a male 1/8"
NPT fitting.
Connecting to Power
Connect 110 VAC, single-phase power to the terminals
on the upper terminal board (Figure 1). Strip the ends of
the wire to 1/4" exposed conductor, slip the bare wire
under the crimp plates on the terminals and securely
tighten the screws. To convert to 12 VDC operation,
connect the 12 VDC supply to the DC IN terminals
(Figure 1).
6
Alarm Connection to Terminal Board
A conduit hole is provided in the bottom of the case for
external alarm wiring. Remove the hole plug by
unscrewing the wing nut and insert an appropriate
conduit fitting. Relay outputs for connecting the external
alarm are on the lower terminal board (Figure 2). These
relays are rated at 2 amperes. If more current is required
to operate alarm or ventilating equipment, these may be
used as pilot relays to activate higher current relays to
control those devices.
Quincy Compressor®-Carbon Monoxide Monitor
Section II - Installation
1
2
3
4
5
6
7
8
TB1
SAFETY GROUND IN
110 VAC LOW IN
110 VAC HIGH IN
110 VAC HIGH FUSE OUT
14 VDC GROUND OUT
14 VDC GROUND IN
14 VDC POSITIVE OUT
14 VDC POSITIVE IN
1
2
3
4
5
6
7
8
TB2
ALARM NC
ALARM NO
ALARM COMMON
+ RECORDER OUT, 0-1 mA
- RECORDER OUT, 0-1 mA
FAULT COMMON
FAULT NO
FAULT NC
Figure 1. Power Connection
1
2
3
4
5
6
7
8
TB1
SAFETY GROUND IN
110 VAC LOW IN
110 VAC HIGH IN
110 VAC HIGH FUSE OUT
14 VDC GROUND OUT
14 VDC GROUND IN
14 VDC POSITIVE OUT
14 VDC POSITIVE IN
1
2
3
4
5
6
7
8
TB2
ALARM NC
ALARM NO
ALARM COMMON
+ RECORDER OUT, 0-1 mA
- RECORDER OUT, 0-1 mA
FAULT COMMON
FAULT NO
FAULT NC
Figure 2. External Alarm Connections
Quincy Compressor®-Carbon Monoxide Monitor
7
Section III - Operation
Apply power to the unit (either 110 VAC or 12 VDC).
The purge light should activate and remain on for about
five minutes. Press and hold the TEST switch; the meter
should go upscale and the alarm light should come on.
Release the TEST switch and press the ALARM ON switch;
the pilot light (white) should come on. Press the TEST
switch again. The alarm relay should engage (this will be
indicated by a click) and the external alarm should be
activated (if applicable).
The item numbers in the following calibration steps refer
to Figure 3 on page 9:
1. Attach the calibration connector to the tank of test
gas.
2. Open the flow meter valve (item 7) to its maximum
reading so that the pressure from the calibration gas
tank will not build up in the flow meter and tube
lines (a tank of calibration has a normal filled
pressure of 240 psi).
Calibration
The following procedure requires the use of a calibration
connector, and test gas to provide a known concentration
of carbon monoxide in the air.
Connector Preparation
Unlike ambient air, standard calibration gas mixtures are
bone-dry. Attempting to calibrate the Quincy Carbon
Monoxide Monitor without humidifying these mixtures
will cause a significant error to be introduced into
readings of compressor air with a normal level of
humidity.
The calibration connector should contain a moisturizing
section to humidify calibration gases. This section should
be dampened slightly with water. Distilled water is
recommended to avoid introducing any potential
contaminants into the calibration gas. Shake out any
excess water before using the connector.
4. Attach the quick disconnect end of the calibration
connector/gas to the quick disconnect (item 10) on
the monitor. Open the connector valve gently until
the flow rate is approximately 0.5 SCFH.
5. Turn the calibration control (item 15) full
counterclockwise, then turn the zero set adjustment
(item 16) full clockwise.
6. After 1.5 - 2 minutes, turn the calibration control
(item 15) until the CO level meter (item 17) reads
40. Turn the zero set adjustment (item 16) back
until the CO level meter (item 17) reads 20.
7. Turn test gas off and remove from quick disconnect.
Turn the regulator valve (item 3) on until the flow
meter (item 7) reads between 0.5 and 0.8.
8. Recheck after 30 minutes and adjust the calibration
control (item 15) as needed.
NOTICE!
At least 50 % relative humidity must be provided
to standard gases to avoid introducing error into
Quincy Carbon Monoxide Monitor calibrations.
NOTICE!
Do NOT purge the monitor when calibrating the
unit. If the unit has just been purged, wait at
least two hours for the sensor temperature to
stabilize before attempting to calibrate it.
8
3. Close the regulator valve (item 3) to shut off the air
flow from the respirator line to the monitor.
Sensor Replacement
Open the cover of the sensor condulet by removing its
two retaining screws. Remove the sensor by grasping the
sides and gently pulling it out of the socket on the
condulet cover. Plug a new sensor into the socket,
taking care not to press on the screen.
Replace the cover and put the monitor through several
successive purge cycles. Allow the unit to stabilize for
approximately 24 hours, under power, before calibration.
Calibrate the unit as described above.
Quincy Compressor®-Carbon Monoxide Monitor
Section III - Operation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
AIR INLET (1/8” FEMALE NPT)
COALESCING FILTER
REGULATOR
REGULATOR GAUGE
CHECK VALVE
AIR FUSE
FLOW METER
SENSOR CONDULET
AIR OUTLET TO ATMOSPHERE
QUICK DISCONNECT TEST GAS FITTING
ALARM SET ADJUSTMENT
ILLUMINATED ALARM CIRCUIT SWITCH
ILLUMINATED ALARM PURGE SWITCH
ILLUMINATED FAULT LIGHT & TEST SWITCH
CALIBRATION CONTROL
ZERO SET ADJUSTMENT
CO LEVEL METER
Figure 3. Calibration
Quincy Compressor®-Carbon Monoxide Monitor
9
Section IV - Maintenance
The Quincy Carbon Monoxide Monitor’s calibration
should be checked monthly to insure proper operation.
When checking calibration, the regulator filter should be
inspected and cleaned or replaced as necessary.
If an optional humidifier is used, maintain the water
supply as required.
To replace the alarm light, unscrew the red jewel from
the front of the case and insert a new bulb into the socket.
10
To replace the indicator light bulbs, pull up the colored
covers on the illuminated switches with the fingers or a
thin bladed screwdriver. Be careful not to lose the white
plastic light diffusers or film legends. Push a short length
of 1/4" diameter vinyl tubing over the end of the wedge
base bulb and pull the bulb out. Insert new bulbs using
the same piece of tubing as a tool.
Performing these minimal maintenance requirements
should provide for several years of trouble-free service
from the Quincy Carbon Monoxide Monitor.
Quincy Compressor®-Carbon Monoxide Monitor
Section IV - Maintenance
This page intentionally left blank.
Quincy Compressor®-Carbon Monoxide Monitor
11
Section V - Troubleshooting
The following is a list of the most common problems and
solutions encountered with new Quincy Carbon
Monoxide Monitor installations.
1. Reading is Too High - Unit alarms during OFF
shifts or when breathing air is not in use.
The Quincy Carbon Monoxide Monitor is
designed for continuous use. When not in use, it
should be shut down both electrically and
pneumatically. It is particularly important that
air flow not be stopped if unit is still energized.
Stopping the air flow will not harm the unit, but
the heat from the sensing element will not be
carried away and the increasing residual
temperature in the instrument will result in an
elevation of the readings. This process may take
many hours, but eventually the unit will alarm.
Properly utilized, the monitor should be kept
operational 24 hours a day with the air sample
being continuous. If interrupted operations (1
shift) are required, shut the unit off electrically
until needed again. If the unit is turned off
frequently, allow for a 15-20 minute start-up
time (purge cycle).
12
2. Reading is Too High - Constantly or cyclic in
nature.
Most often, a properly installed Quincy Carbon
Monoxide Monitor which reads too high is
“reading” air contamination from carbon
monoxide or hydrocarbon oils. In most cases,
the compressor is functioning property, but the
intake air to the compressor is contaminated.
The most common sources of contamination are:
A. Compressor intake inside a building where fuelburning trucks and Hi-Lo’s are in use.
B. Process and maintenance materials stored in the
proximity of an internal compressor intake.
C. Compressor intake outside but downwind or in
close proximity to contaminated vents.
NOTICE!
Cyclic high readings are commonly caused by this
problem. Don’t overlook your neighbor who may
be venting paint fumes, heat treat fumes, engine
exhausts, furnaces, etc.
D. Liquid pipe sealant on plumbing has not cured.
(Teflon tape pipe seal is the preferred thread
seal to avoid air contamination.)
E. Oil has accumulated in the air lines and is
releasing hydrocarbon fumes.
Quincy Compressor®-Carbon Monoxide Monitor
Section V - Troubleshooting
3. Reading High or Low - Instrument not responding.
6. Instruments Remote Apparatus Not Functioning
Although not the most common problem, it is
not unusual for a new instrument to be the victim
of human curiosity. The factory calibrated unit
may have been “readjusted” sometime during
unpacking or installation. Re-calibrate the
monitor as outlined in Section III of this manual.
Hookups to remote alarms or readouts are
common. Incorrect hookup can result in a
variety of problems which can damage the
monitor. If the unit has external devices, it is
imperative that installation be reviewed to
determine if it is, or was temporarily, defective.
Fuses and diodes protect the basic circuits but in
some cases, the units are damaged and require
electronic repair.
4. Instrument Not Responding
Humidity and humidification result in two
potential problems. If your air is extremely dry
(chemical desiccants or thermal “chillers” are
used), it is possible that the air is too dry (30%
humidity by volume is recommended).
Humidity should be introduced for proper
instrument accuracy.
NOTICE!
Air this dry is not suitable for your breathing
apparatus.
A humidifier will correct this problem for the
instrument UNLESS it is installed backwards.
Installing the unit backwards will cause it to fill
with water and damage the sensor.
5. Humidified System Reads Too High
Well water and city water can both contain low
levels of measurable contaminants. Use distilled
or deionized water in humidifiers if your local
water is producing a “reading”.
7. Instrument Not Functioning
The instrument could be damaged or defective.
New installation failures can result from
shipping damage or “infant failure” of solid state
devices.
The Quincy Carbon Monoxide Monitor is a very
durable instrument and will seldom be damaged
except by clearly negligent handling. Look for
physical damage to the case. In the case of solid
state “infant failure”, Quincy will observe
established procedures of run-in and seasoning.
Incidence of “infant failure” is very low.
Over 90% of all problems can be corrected by thorough
evaluation and correction of the first three items on this
list. If not, contact your distributor or Quincy
Compressor for assistance.
Quincy Compressor®-Carbon Monoxide Monitor
13
Notes
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Quincy Compressor®-Carbon Monoxide Monitor
Quincy Service is always near.
There are authorized Quincy
Distributors located throughout
the United States & Canada that
stock genuine Quincy parts &
accessories for a wide range of
Quincy products.
Quincy Service specialists are
factory trained and will help keep
you in business. Call for
Authorized Quincy Service.
Quincy
Compressor
Tr u e B l u e R e l i a b i l i t y
®
SM
Reciprocating / Systems:
217.222.7700
Rotary / Vacuum / Systems:
334.937.5900
Nearest Distributor:
888.424.7729
E-mail:
Discover:
[email protected]
www.quincycompressor.com
© 2000 Quincy Compressor a BFGoodrich Company Business
All Rights Reserved. Litho in U.S.A.