AUTOZEROING MERCURY INDICATOR USER MANUAL
Contents
1. certificate of calibration and module replacement instructions New calibrated sampling module Part No 900 990 Issue 3 Part No 900 430 900 410 900 432 900 427 900 500R 900 500 Page 17 of Page 172. WARN and ALARM can be observed including associated relay operation After releasing buttons the lamps and alarm relay will auto reset Test Button Operation of the test button will show on the top line of the display three system values as shown REF 107 ACT 108 SIG 012 These values may be required in identifying certain faults Routine Maintenance The only routine maintenance required is to change the end of line dust filter and the zero filter element The frequency of change will depend on site conditions but we would recommend both are changed every month until a clear pattern of site conditions is established Changing End of Line Dust Filter The filter element is a cylindrical shape and is accessed by unscrewing the top of the filter housing Ensure that the new filter element is fitted correctly in the centre of the housing Changing the zero filter The filter element is accessed by unscrewing the top of the filter housing When fitting the new filter ensure a correct seal in the housing Safety Note As the old dust and zero filters may be contaminated by Mercury gloves should be worn whilst changing them Dispose of the filters in a safe manner DO NOT INCINERATE OLD FILTERS Part No 900 990 Issue 3 Page 13 of Page 17 Fault Identification and Rectification Pump Failure Two possible causes for this fault are 1 Blocked end of line filter 2 Pump stalled Check sample lines and end of line filters chan
3. continuously sampled via the sample inlet The bottom line of the display shows Mercury concentrations in ug M The top line of the display will be blank This operation will continue until either an alarm or a fault condition arises Alarm Operation 1 First level warn set at 10 ug M During normal operation if Mercury vapour levels exceed 10 ug M the WARN lamp will illuminate No other action will take place and this alarm is self cancelling after the concentration drops below 10 ug M 2 Second level alarm set at 25 ug M When the Mercury concentration exceeds 25 ug M the following action will take place a ALARM lamp illuminates b ALARM relay energises c AUDIBLE relay energises d DISPLAY top line shows IN ALARM The audible relay may be cancelled at any time by operating the RESET button Even when level exceeds 25 ug M Part No 900 990 Issue 3 Page 9 of Page 17 Fault Operation The AMI continuously monitors for correct operation but should problems arise then one of three fault messages will appear 1 PUMP FAILURE 2 LAMP FAILURE 3 SERVICE REQUIRED Also the fault relay and audible relay will be energised the SERVICE lamp illuminated and to confirm the fault the HEALTHY lamp will be extinguished The audible relay can be muted at any time by operation of the RESET button All other indication will remain until the fault is cleared After the fault is removed the display will clear Identificat
4. will require commissioning by qualified engineer Please contact Shawcity to arrange this commissioning visit Part No 900 990 Issue 3 Page 7 of Page 17 Internal Electrical Connections Power Supply Audible Relay Solonoid Valve 1 24 3 4 5161 74819 1101111121131141 1516 V 0V V 0V NO NC COM NO NC COM NO NC COM Signal Signal Fault Relay Alarm Relay Audible j 0 10 V 4 20mA eN b E i AC Supply Issue 3 Page 8 of Page 17 Part No 900 990 OPERATION Warm Up Sequence When power is connected the unit will take five minutes to stabilise and during this time various messages will appear on the display together with an indication of the time remaining The message sequence is shown on page 11 At the end of this time the unit commences an autozeroing sequence Auto zeroing Sequence After initial warm up and every five hours thereafter this sequence will allow the unit to sample Mercury free air via the zero gas inlet and set the instruments zero This sequence lasts approximately 36 seconds and the time remaining is shown on the lower line of the display The top line will follow the sequence shown on page 12 At the end of this time the instrument will then be in normal operational mode Normal Operation Air is
5. 0 ug M 2 over range 5 of reading or 1 digit whichever the greater 2 of reading or 1 digit whichever the 5 minutes T90 is 5 seconds Operational 0 to 35 C Storage 10 to 50 C 0 95 RM non condensing Less than 2 ug M Every 5 hours Warn 10 ug M Alarm 25 ug M Volt free changeover contacts rated at 2 Amp 240V 1 0 10V DC in 10K 2 4 20 mA into 500 Rmax current source 90 250V AC auto selection at 1 Amp 47 55 Hz 400 mm H x 200 mm D x 300 mm W 10 0 kg Issue 3 Page 4 of Page 17 200 gt 350 WwW CONNECTION DETAILS ZERO EXHAUST SAMPLE INLET INLET Q 2 Q Part No 900 990 Issue 3 Page 5 of Page 17 INSTALLATION General Qualified personnel should carry out the installation of the AMI It should be installed in areas away from direct sunlight and free from mechanical vibration A location close to the required sample point should be chosen with access for service and maintenance Mounting Standard threaded brass inserts M8 15 in the rear panel for direct wall mounting from behind the cabinet The unit is to be mounted vertically and securely and in a position which allows the door to be fully opened The clearance for door opening is 520 mm The door is hinged on the right side Also ensure access is available at the top and bottom for pipework and electrical entries If mounted outdoors locate in position sheltered from weather I
6. AMI AUTOZEROING MERCURY INDICATOR USER MANUAL POWER HEALTHY SERVICE WARN ALARM Pioneer Road Faringdon Oxfordshire SN7 7BU Tel 01367 241675 Fax 01367 242491 www shawcity co uk service shawcity co uk Part No 900 990 Issue 3 Page 1 of Page 17 INDEX Page Introduction Brief description and specification Installation Mounting and connection information Operation Description of normal operation with 2 alarms and faults described Testing and Maintenance Routine testing and maintenance 13 procedures Fault identification and rectification Calibration Procedure for changing sample la module Spare Parts List a List of user changeable spares and consumables Part No 900 990 Issue 3 Page 2 of Page 17 INTRODUCTION AMI is a single point sampling analyser for Mercury vapour built into a fibreglass reinforced polyester housing The instrument is microprocessor controlled with a large two line information display A sample of air is pumped continuously into the sample unit where it is analysed by a dual beam spectro photometer using the 254 uM U V wavelength for detection Two preset alarm limits are provided at 10 ug M and 25 ug M Occupation Exposure Limit Indication is provided on the front panel of all conditions Three relays for remote alarm signalling are provided for alarm service required fault and audible signal Very high stability of performance is provided by the control system which incorporates
7. D connector from the rear of the module g The module is now ready to remove Slip up and out the two pins in the hinges and lift out the old module Installing New Calibrated module h Place new module so that hinge pins can be reinserted Check that module moves easily on hinges i Reconnect the D connector into the socket on the rear of the module j Identify the inlet tube and push onto inlet connector k Identify the outlet tube and push onto outlet connection Swing back the sample module making sure not to trap tubing Close front panel door and restore power The unit will go through the warm up procedure 5 minutes and then should auto zero If a Pump Failure message appears at any time check the internal tubing as it may be trapped by the sample module Part No 900 990 Issue 3 Page 15 of Page 17 View with door lt REMOVABLE HINGE PINS Optics Unit lt Rear view of Optics Unit Outlet connection Inlet connection Signal connector a i Part No 900 990 Issue 3 Page 16 of Page 17 SPARE PARTS LIST Description Dust filter recommended to be replaced monthly Dust filter pack of ten Charcoal filter recommended to be replaced annually Empty filter housing for charcoal or dust filter Exchange calibrated sampling module supplied with new pump new lamp new charcoal filter complete new dust filter complete a
8. an automatic zeroing feature Approximately every five hours the system initiates a short period of testing which includes verifying and adjusting if required the zero of the instrument This will ensure that long term drift of the instrument is eliminated Description of Controls and Indicators FRONT PANEL Lamp Indicates POWER AC power on HEALTHY System correct no faults SERVICE Fault type indicated on display panel WARN Levels exceed 10 ug M ALARM Levels exceed 25 ug M BUTTON RESET Clears messages from display and mutes a audible alarm relay TEST Shows test data on display ZERO Manually starts a zeroing cycle DISPLAY Two line backlit display Top line gives status information Bottom line shows current Mercury concentration See Operation section of manual for more details on other displayed messages Part No 900 990 Issue 3 Page 3 of Page 17 OTHER OUTPUTS Analogue 1 Analogue 2 Alarm Relay Fault Relay Audible Relay Auto Resetting Specification Range Linearity Accuracy Repeatability greater Warm up Time Response Time No Sample Line Fitted Temperature Range Humidity Zero Drift Auto zero Cycle Alarm Set Points Relays 3 AC Outputs Power Requirements Frequency Cabinet Size Cabinet Weight Part No 900 990 0 10V DC 0 200 ug M 4 20 mA 0 200 ug M Level exceeds 25 ug M Energised when fault exists Any alarm or fault energises relay 2 20
9. er housing All connections are 6 mm O D This pipework must be either stainless steel or PTFE to ensure non absorption of Mercury vapour Any pipework installed must be protected from damage and MUST be terminated at the sample point with the supplied end of line filter The AMI and the end of line filter are provided with 6 mm O D stainless steel compression fitting For best stability and performance the AMI and the sample point should be at similar temperature and humidity Contact Shawcity if sampling is required from areas with high humidity Maximum sample line length is 15 metres 50 ft Sample Exhaust Pipework The exhaust should not be allowed to discharge into clean Mercury free areas Up to 6 metres 20 ft of 6 mm tube can be used on the exhaust to pipe to a suitable well ventilated location Zero Gas Inlet An activated charcoal filter fitted inside the zero filter housing protects the zero gas inlet The zero filter housing MUST be connected at all times to the zero gas inlet This housing is normally connected directly on the zero gas inlet If the AMI is installed in an atmosphere where the Mercury concentration is continuously higher than 25 ug M the replaceable zero filter element will require frequent replacement weekly Up to 6 metres 20 ft of tubing can be added to enable air to be taken from a clean area This tubing must be stainless steel or PTFE Commissioning After installation or re location the AMI
10. f mounted indoors do not locate close to heating system or pipework Electrical Supply The AMI requires an AC supply between 90 and 250V AC This supply should be from a switched and fused supply 2 Amp The AMI has auto supply voltage selection so provided supply is within stated range the instrument unit will operate correctly The base of the cabinet has 2 pre drilled holes size M20 for cable gland entry Inside the cabinet there are DIN rail mounted field terminals for cable connection The AC line supply terminal is fitted with 20 mm fuse and isolator Fuse rated at 1 Amp The cabinet MUST be earthed via the AC supply earth conductor The electrical installation should be carried out by a qualified electrician and comply with local electrical safety codes and laws DO NOT POWER THE EQUIPMENT UNTIL COMMISSIONED BY A QUALIFIED PERSON Shawcity will normally provide the services of a commissioning engineer The guarantee may be invalidated if not commissioned by Shawcity Limited Part No 900 990 Issue 3 Page 6 of Page 17 Output Connections Two linear DC analogue outputs are available 1 0 10 V DC into a minimum of 10K 2 4 20 mA current loop in a maximum resistance of 500R These outputs will track the AMI displayed Mercury concentrations Sample Pipework 1 Sample inlet to connect to sample pipework to required sample location 2 Exhaust to carry sample to safe location 3 Zero gas inlet to connect zero filt
11. ge if necessary to ensure free flow If sample line and filter are correct then pump is stalled or stopped This will require the changing of the sample module Please refer to the next section of this manual for more details Lamp Failure This unlikely failure can only be rectified by changing the sample module Please refer to the next section of this manual for more details Service Required The system has detected signals being outside the normal range of operation This may only require resetting of some internal adjustments but as these adjustments may alter the calibration it is not normally disclosed to unauthorised personnel If this message occurs operate the TEST button and note down the four values on the display Call the Shawcity service department on 01367 241675 for advice and guidance Part No 900 990 Issue 3 Page 14 of Page 17 CALIBRATION See diagram on page 16 As the AMI is designed as a fixed instrument Shawcity have a service exchange programme to meet this requirement Downtime is minimised to a few minutes whenever calibration is required Procedure a Check the exchange samples module has a valid calibration date b Switch AMI off c Open front cabinet door and identify the existing Sample module d Swing the sample module out It is hinged on the left side e Identify the two sample tubes and connector on the rear of the sample module f With care remove the tubing and remote the
12. ion and repair of faults is in the Testing Maintenance section of the manual Part No 900 990 Issue 3 Page 10 of Page 17 Warm Up Sequence This sequence repeats via the loop until the time remaining 0 00 at which point autozeroing starts Part No 900 990 Autozeroing Mercury Indicator Vv Warm Up Delay Time Remaining MM SS v AMI Time Remaining MM SS v Issue No xx Time Remaining MM SS v Tel 01367 241675 Time Remaining MM SS v Alarm Level 25 uG Time Remaining MM SS Issue 3 Page 11 of Page 17 Auto zeroing Sequence v Zeroing Time Remaining MM SS Vv AMI Time Remaining MM SS Vv Issue No xx Time Remaining MM SS Tel 01367 241675 Time Remaining MM SS Vv Alarm Level 25 uG Time Remaining MM SS v Revert to normal display Part No 900 990 Issue 3 Page 12 of Page 17 TESTING AND MAINTENANCE Routine Testing This should be carried out regularly typically once per month to test correct operation Press and hold the RESET button then press and hold the TEST button Continue to hold both buttons This will start the test routine The measured value displayed on the second line will slowly increase in value and will continue to rise whilst both buttons are held down The correct operation of both
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