Description and Definitions- Scope: This manual provides instructions for installation, operation, and maintenance of the Servomex 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers.
- Safety Information: Important safety warnings and cautions are highlighted to prevent personal injury or equipment damage.
- Description: The Multi Purpose is a lightweight gas analyser for field, laboratory, and light industrial use, capable of measuring oxygen, carbon dioxide, and carbon monoxide concentrations.
Specifications- General: Details on the general specifications of the gas analyser.
- Sample Gas: Information on the types of gases that can be measured.
- Calibration Gases: Specifications for gases used in calibration.
- Environmental Limits: Operating conditions and environmental constraints.
- Performance: Details on the performance of various sensors including standard, industrial, and high accuracy oxygen sensors, as well as infrared sensors.
Installation and Set-Up- Installation: Instructions for setting up and switching on the device.
- Battery Charging: Guidelines for charging and recharging the optional rechargeable battery.
- Set-Up: Steps for configuring security levels, setting the clock, and changing regional settings.
General Operation- Calibration: Procedures for calibrating the analyser.
- Sample Readings: Instructions for taking and correcting sample readings.
- Display Units: Options for selecting display units and configuring measurement alarms.
Routine Maintenance- Cleaning: Guidelines for cleaning the device and inspecting the inlet filter.
- Maintenance: Instructions for regenerating or replacing the drying agent and performing preventative maintenance.
Fault Finding- Fault Messages: Introduction to fault messages and general fault finding procedures.
Storage and Disposal- Storage: Recommendations for storing the device.
- Disposal: Guidelines for disposing of the device in accordance with the WEEE directive.
Appendices- Data Log Output Formats: Formats for data logging and serial outputs.
- RS232 Connection Details: Instructions for connecting the analyser to a PC.
- Optional Accessories: Information on optional flowmeters, sample conditioning panels, and gas probe accessories.
Overview: The document provides detailed specifications and operational guidelines for the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. These devices are designed for measuring gas flow rates and are equipped with various features such as rechargeable batteries, printers, milliAmp outputs, flowmeters, and sample conditioning panels.
Specifications: The analysers require a mains supply to comply with TUV/UBA standards. They have specific dimensions and weight, and operate on a power supply of 100 to 240 V a.c. or 12 to 24 V d.c. The minimum gas flow rate for the standard Multi Purpose is 700 ml/min, while the Multi Purpose HF requires 1.8 l/min.
Sample Gas and Calibration: The document warns about the toxicity of gases like carbon monoxide and outlines the pressure ranges for safe operation. Calibration gases include oxygen-free nitrogen and certified oxygen supplies, with specific flow rates and pressure ranges detailed for both standard and HF models.
Environmental Limits: The analysers operate within a temperature range of -10 to +50 °C and a humidity range of 0 to 95% RH. They are designed to function at altitudes from -500 to 5000 meters and have an ingress protection rating of IP40.
Performance: The document details the performance metrics for different sensors, including standard, industrial, and high accuracy oxygen sensors, as well as IR sensors for carbon monoxide and dioxide. Key performance indicators include response time, accuracy, and effects of environmental factors like temperature and pressure.
Optional Features: The analysers can be equipped with a rechargeable lithium-ion battery, offering 8 to 35 hours of operation per charge, and milliAmp outputs with specific load resistance and isolation voltage requirements.
Unpacking and Setup: Instructions are provided for unpacking the device, removing protective covers, and inspecting for damage. Users are advised to retain packaging for future servicing needs.
User Interface: The interface includes various keys and indicators, with an audible alarm for initial switch-on and other alerts.
Overview: This document provides detailed instructions for the operation, setup, and troubleshooting of the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. It includes sections on start-up procedures, screen navigation, alarm conditions, and installation guidelines.
Start-up and Measurement Screens: Upon powering on, the device displays a start-up screen while performing a self-test. Messages such as "System Check" and "Infrared Initialising" appear if IR sensors are configured. The measurement screen varies based on the configuration for single or dual gas measurements, displaying current measurements, status icons, and soft key functions.
Soft Key Functions: The soft keys provide quick access to various functions such as Menu, Calibrate, Alarm, and Logging. Their functions change depending on the current screen displayed. The document details how to navigate these options and the significance of each soft key legend.
Status Icon Bar: This bar appears on all screens, indicating system status such as faults, battery levels, and alarm conditions. Specific icons alert users to issues like low battery or disabled alarms.
Menu Structure and Password Protection: The menu allows access to data logs, setup configurations, calibration, and fault viewing. Some options are password-protected, requiring entry for access. Passwords remain active for 10 minutes after the last key press.
Installation and Setup: The document outlines installation steps, emphasizing safety precautions for handling toxic or asphyxiant gases. It warns against using the device in high-vibration areas and provides guidelines for connecting external devices like printers or PCs.
Warnings and Cautions: Several warnings highlight the importance of ensuring leak-free connections and proper ventilation when using sample or calibration gases. The document stresses compliance with local electrical safety standards.
Specifications and Setup
The document provides detailed instructions for setting up and operating the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. It includes steps for connecting milliAmp outputs, fitting power supplies, and switching on the device. The importance of using correctly sized tubes for venting gases is emphasized to prevent over-pressurization.
Battery Charging and Recharging
For units with an optional rechargeable battery, an initial charge of at least 4 hours is recommended. The battery status is displayed on the icon bar, and recharging can occur with the device on or off, though it is faster when off. Users are advised to recharge when the battery is below 10% capacity.
Security and Password Management
The device offers three security levels: low, standard, and high, with varying degrees of password protection. The supervisor password can override operator-level protections. Users are encouraged to change default passwords for enhanced security.
Clock and Regional Settings
Instructions are provided for setting the date and time, which can be displayed in different formats. Regional settings allow customization of language, date format, and decimal format to suit local conventions.
Power Save and Pump Operation
For devices with a rechargeable battery, a power save mode is available to conserve energy by automatically switching off after 30 minutes of inactivity. The internal sample pump can be operated manually or on a timed basis, with durations adjustable between 1 to 999 seconds.
Calibration Procedures
Calibration involves using sample and calibration gases, which may pose toxic hazards. Users must conduct risk assessments and adhere to safety practices. Calibration gas pressures must match sample gas pressures for accurate measurements, and a purge time of 3 to 5 minutes is recommended before starting calibration.
Calibration Procedures
The document outlines the calibration procedures for the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. It emphasizes the importance of not moving the device during calibration to avoid inaccurate measurements. For standard models with a sample pump, manual pump operation is assumed, and the pump operation time must be set correctly. The Multi Purpose HF model does not require a calibration 'T' piece, and its sample pump should not be activated during calibration.
Calibration Steps
1. Connect the calibration gas supply to the sample gas inlet.
2. Allow the gas to pass through for 3 to 5 minutes.
3. Access the Calibrate screen and select the required calibration ('Lo' or 'Hi').
4. Adjust the target value if necessary and stabilize the current reading before proceeding.
5. Disconnect the calibration gas supply after calibration.
Taking Sample Readings
Ensure the device is calibrated before taking readings. Connect the sample gas supply and start the sample pump if applicable. Wait for the measurement to stabilize before recording the reading. Disconnect the sample gas supply after measurement.
Correcting Oxygen Measurement Errors
The document provides guidance on correcting oxygen measurement errors due to background gases. It lists specific errors for various gases and provides a procedure to enter a compensation for these errors.
Display Units Selection
The analyser supports various display units such as % volume, ppm, and mg/m3. Users can change the display units and conversion factors through the setup menu.
Configuring Measurement Alarms
Two measurement alarms can be configured for each sample gas. Alarms can be set to low, high, or none, and can be latching or non-latching. Hysteresis levels determine when an alarm condition is deactivated. Proper configuration of alarm levels and modes is crucial to avoid spurious alarms.
Alarm Configuration and Management- Setting Up Alarms: Access the Alarm option screen from the Measurement screen to configure alarms. Use the soft keys to select and set the desired alarm mode (none, low, or high).
- Audible Alarm: Enable or disable the audible alarm through the Alarms option screen. The alarm can be muted temporarily if triggered by a measurement condition.
- Unlatching Alarms: Use the Unlatch option to reset any latched alarms.
- Viewing Alarm Status: The Alarm status screen displays current alarm conditions, including alarm number, sample reading, mode, and level.
MilliAmp Output Configuration- Overview: The device can output milliAmp signals for gas measurements, configurable in two ranges (0-20 mA or 4-20 mA).
- Output Parameters: Set parameters such as high levels for ranges, behavior during calibration, fault conditions, and under-range settings.
- Setup Procedure: Access the mA configuration screen to set up output parameters and select the range associated with measurements.
- Calibration and Checking: Calibrate the milliAmp output using the service menu and check outputs by setting override values.
Data Logging and Serial Outputs- Options: Configure the device for data logging, serial outputs, or printed outputs. Data can be logged internally or output to a connected device.
- Serial Output Configuration: Set parameters such as period, baud rate, stop bits, data bits, and parity to match connected devices.
Data Logging and Management
The Multi Purpose memory allows for the storage of up to 200 sample measurements, organized into batches. Each measurement includes a batch number, sequence number, date and time, and indications of alarms or faults. Users must manually transfer measurements into the log, initiate new batches, and clear the log when necessary. Data can be viewed on the Multi Purpose display or output to a connected device.
Entering and Managing Data
To enter data, users press a soft key to capture the current measurement. New batches can be started by pressing the soft key again. Data logs can be outputted if the serial output parameters are correctly configured. Viewing and clearing the data log involves navigating through menu options and confirming actions.
Display Adjustments
The display settings, including backlight timer and contrast, can be adjusted to suit ambient light conditions. The backlight timer can be set between 0 and 999 seconds, and the contrast can be adjusted using soft keys.
Routine Maintenance
Regular cleaning and inspection of the Multi Purpose are recommended. The inlet filter element should be inspected every 3 months or more frequently depending on usage. The drying agent in the drying tube should be regenerated or replaced based on usage and type.
Carbon Monoxide Measurements
For carbon monoxide measurements, regular leak testing of the Multi Purpose and associated equipment is essential. Leaks must be sealed, and the device should not be used if internal leaks are detected.
Preventative Maintenance
An annual preventative maintenance program is recommended to ensure proper operation and compliance with regulatory guidelines. This includes inspection and repair at a Servomex service facility.
Fault Finding
When a fault is detected, an audible alarm sounds, a fault LED lights up, and a fault icon appears on the screen. Fault messages are stored and can be viewed, with recommended actions provided for each fault type.
Fault Messages and Recommended Actions
The document provides a comprehensive list of fault messages for the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers, along with recommended actions. Key faults include calibration faults, charging timeouts, communication failures, and various sensor errors. For most faults, the primary recommendation is to recalibrate or restart the device, and if the issue persists, contact Servomex or a local agent.
Viewing and Managing Faults
Users can view current faults via the Fault status screen, which displays the date, time, and fault message. For unresolved issues, users are advised to consult the fault finding table or contact Servomex.
General Fault Finding
The document outlines common symptoms such as slow response, unexpected measurements, and calibration issues. It provides troubleshooting steps like checking gas inlets/outlets, ensuring correct calibration gases, and verifying ambient conditions.
Storage and Disposal
Instructions for storing the analyser include using original packaging and avoiding extreme conditions. Disposal must comply with local regulations, especially for units with rechargeable batteries.
Spares and Maintenance
A list of standard spare parts is provided, including inlet filter elements and power supply units. Regular maintenance of these parts is recommended to ensure optimal performance.
Data Log Output Formats
The data log format includes identifiers for serial numbers and gas types, with each log entry detailing date, time, measurement, and status indicators.
Data Log and Serial Output Formats
The document describes the data log and serial output formats for the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. Each data log entry includes the date, time, gas type, measurement, units, and alarm or fault status. Serial outputs do not include alarm or fault information.
Printer Output Formats
Printed reports include the date, time, serial number, gas measurements, and alarm status. Alarms can indicate 'Pass', 'FAIL', 'FAULT', or 'RECALIB'. Batch and product fields are available for manual completion.
RS232 Connection Details
The RS232 connection uses a 9-way 'D' type connector. Specific pins are designated for receiving and transmitting data. A compatible cable is recommended for connection to a PC, and HyperTerminal can be used for data capture.
Display Unit Conversion Factors
Conversion factors are provided for various units, such as % to ppm and ppm to mg/m3, for gases like CO, CO2, and O2. Users must ensure correct conversion factors are applied.
Optional Flowmeters
Two types of flowmeters are available: unvalved and valved. They measure and control the flow rate of sample or calibration gas. Proper installation and connection are required for accurate measurements.
Optional Sample Conditioning Panel
This panel is used for measuring oxygen content in wet gas samples. It includes a catchpot and drier, and requires regular maintenance. Proper sampling techniques are recommended for accurate results.
Specifications and Procedures:
The document provides detailed instructions for the operation and maintenance of the 5200 Multi Purpose and 5200 Multi Purpose HF Gas Analysers. It includes procedures for sampling flue gases, ensuring the sample pipe is positioned correctly to obtain representative samples. The document also describes the components of the sample conditioning panel, including the drier and catchpot, and provides instructions for draining the catchpot and replacing or regenerating the drying agent.
Maintenance and Replacement:
Maintenance procedures include draining the catchpot when liquid is visible and replacing the drying agent when it changes color. The drying agent can be regenerated by heating or replaced with new material. The document warns against allowing liquid levels in the catchpot to rise too high and provides safety instructions for handling new drying agents.
Optional Accessories:
The document describes an optional gas probe accessory, detailing its components and assembly. It provides instructions for using the probe during gas sampling and maintaining the optional filter. Additional spares for the gas probe accessory are listed, including part numbers for ordering.
Materials and Compatibility:
The document lists materials used in parts of the analyser that contact sample and calibration gases, highlighting their chemical compatibility and corrosion resistance. Materials include various metals, plastics, and glass, each chosen for specific properties.
Disposal and Compliance:
The analyser is subject to the Waste Electrical and Electronic Equipment (WEEE) Directive, requiring disposal through material recovery and recycling. Compliance with various European Community directives and standards is confirmed, including electromagnetic compatibility and electrical safety. The analyser is also validated for compliance with specific requirements of The Food and Drug Act.
Standards and Certifications:
The document confirms that the analyser complies with several European directives and standards, including the Electromagnetic Compatibility Directive and the Low Voltage Directive. It also notes that Servomex Group Ltd is certified to BS EN ISO 9001:2000 and EN ISO 14001:1996 standards.