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Honeywell ACM 150 Manual To Installation, Operation, And Maintenance

Honeywell ACM 150 Manual To Installation, Operation, And Maintenance

Air composition monitor


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ACM 150 Air Composition Monitor
Guide to Installation, Operation, and Maintenance


Table of Contents

Summary of Contents for Honeywell ACM 150

  • Page 1 ACM 150 Air Composition Monitor Guide to Installation, Operation, and Maintenance...
  • Page 3: Table Of Contents

    Warranty ........................6 Safety ..........................7 Technical description and theory of operation ............17 Air sampling system ....................34 ACM 150 operating principle ..................40 Installation environment ..................... 43 Installation drawings ....................58 Operation ........................61 Setup menus ....................... 81 Shutdown procedure ....................
  • Page 4: Introduction

    Notes: 1. “Honeywell Analytics” is abbreviated “HA” throughout this document. 2. The ACM 150 monitor gas list is updated frequently. Please contact us for the latest version. 3. The ACM 150 Air Composition Monitor is manufactured by: Life Safety Germany GmbH, Elsenheimerstr.
  • Page 5: Contacts

    Tel: +1 847 955 8200 Toll free: +1 800 538 0363 Fax: +1 847 955 8208 Asia Pacific Honeywell Analytics Asia Pacific #701, Kolon Science Valley (l) 43 Digital-Ro 34-Gil, Guro-Gu Seoul, 152-729 Korea Tel: +82 (0)2 6909 0321 Fax: +82 (0)2 2025 0388
  • Page 6: Warranty

      ACM 150 ACM 150 standard warranty The following warranty is between the Purchaser and Honeywell Analytics known hereafter as Seller. • Seller warrants that for a period of one year after on-site start-up, its products shall be free from defects in material and workmanship provided that inspection by seller indicates such defects developed under normal and proper use.
  • Page 7: Safety

    CAUTION, WARNING and DANGER notes contained in this manual. If the ACM 150 monitor is used in a manner not specified in this manual, the protection provided by the equipment may be impaired.
  • Page 8 ERM, facility and/or management level responsibility for the ACM 150 monitor are defined as Authorized Users. Such users make decisions about the ACM 150 monitor set-up and use, the location of monitoring points, the use of data produced by the ACM 150 monitor, response to warn and alarm activation levels and incidents and the response procedures.
  • Page 9 An employee of the user’s company or a third party service company who is a service technician or engineer and who has received training from Honeywell Analytics or its agent on the operation and service of the ACM 150 monitor and who is authorized by his/her company to perform this service.
  • Page 10 The majority of the time the ACM 150 monitor is operating, it is sampling ambient air without toxics. In the event of a toxic gas release at one of the sample points for the monitor, small amounts of toxic gas and/or residue may be trapped inside the sample tubing, filters and pumps inside the monitor.
  • Page 11 ACM 150 Electrical safety Tools are required to access sections of the ACM 150 monitor with electrical connections. An appropriately sized ball driver or allen wrench is required to access the interior portions of the enclosure. A Phillips screwdriver is required to access the power cords at the AC power distribution unit, located immediately behind the computer door.
  • Page 12 ACM 150 Hazardous Energy Isolation The ACM 150 monitor uses both high pressure CDA (compressed clean dry air up to 100 psig) and low pressure (5 psig) nitrogen. Both of these energies may be stored inside the monitor and must be relieved before performing any maintenance work involving the pneumatics.
  • Page 13 The backup exhaust pump is also heavy. Should the pump need replacing, care should also be exercised. Flammability The construction of the ACM 150 monitor enclosure consists of nonflammable materials. All high voltage (110/220VAC) is contained within nonflammable enclosures. Potential key failure points and trouble spots Potential key failure points and trouble spots can include, but are not limited to: •...
  • Page 14 If any label is absent or loose, please notify Honeywell Analytics. A new adhesive label will be sent. It may be applied to the ACM 150 monitor, as shown in the drawings, by the user or by one of our service engineers.
  • Page 15   ACM 150 Figure 1. ACM 150 outside labels  ...
  • Page 16   ACM 150 Figure 2. ACM 150 inside labels  ...
  • Page 17: Technical Description And Theory Of Operation

    ACM 150. This enables an automatic leak check of every sample tube once per day. The ACM 150 monitor does not monitor all locations at once. It scans one area at a time, in sequence until all active areas have been monitored. It has the capacity to scan as many as 40 sample areas.
  • Page 18   ACM 150 ACM 150 arrangement and assemblies General arrangement The ACM 150 monitor cabinet consists of these assemblies: 1. Main Power Switch 2. Sample Valve Manifolds 3. Sample Valve Control Panel 4. Touchscreen Computer Assembly 5. FTIR-Bench and Gas Cell Assembly 6.
  • Page 19 ACM 150 Main power switch This switch controls the line power. The ACM 150 monitor can not operate unless it is switched ON. Switching it OFF disconnects line power to all ACM 150 assemblies. This is also a Lockout/Tagout (LOTO) switch. It accepts an external padlock in the OFF position.
  • Page 20 LEDs light indicate the current area being sampled and analyzed. Each area number is also a momentary test switch, which may be pressed and used for test purposes when the ACM 150 monitor is in the Front Panel Mode. In other modes the switches are inactive.
  • Page 21 ACM 150 monitor. This feature may be disabled via the configuration software. Control panel status The three control panels on the ACM 150 monitor have the same Status LEDs. These LEDs provide status on the following: • Power On: Lights to confirm that power is supplied to the valves or relays associated with the Control Panel.
  • Page 22   ACM 150 Figure 9. Cycle valve assembly S1, S2, S5, S6: Solenoid Cycle Valves PI13 Pressure Indication 7. Gas Cell In 8. Gas Cell Out 9. Depending on option, either / or: To Venturi Manifold Exhaust Pump In 10. From Boost Pump 11.
  • Page 23 LEDs 1 to 6 correspond to valves S1-S6 with S7 and S8 provided for future use. When the ACM 150 monitor is in the Frontpanel Mode, press the buttons to activate the momentary test switches for test purposes. In other modes the switches are inactive.
  • Page 24 Mechanical pumps The pumps are isolated in the bottom section of the ACM 150 monitor to muffle the noise and to isolate vibration and heat. Cooling fans in the bottom section of the cabinet direct air flow across the pumps and their motors. The pumps are accessed by removing the front panel.
  • Page 25 When the air supply is restored or the problems are corrected, the user manually switches the ACM 150 monitor from the automatic mode into the manual mode and back to automatic mode, using the Diagnostic menu to use the venturi pumps again.
  • Page 26 The Optics Bench is a Perkin Elmer Model Spectrum Two FTIR (Fourier Transform InfraRed) analyzer. It is the heart of the ACM 150 monitor, providing the analytical power to identify and quantify a vast array of gases. For more information, refer to ACM 150 operating principle.
  • Page 27 Relay outputs The ACM 150 monitor Relay Output Board is shown below. It has 86 relays. Relays #1 to #80 are arranged in 4 rows of 20 relays. These are the programmable relays. By default, they are preset to activate as follows:...
  • Page 28   ACM 150 Relay #1 to #40: Assigned in sequence to Areas #1 to #40. They are activated whenever any gas monitored at the specific Area (sample point) exceeds the Alarm 1 level set point. Relay #41 to #80: Assigned in sequence to Areas #1 to #40. They are activated whenever any gas monitored at the specific Area exceeds the Alarm 2 set point.
  • Page 29   ACM 150 Figure 15. Relay output board  ...
  • Page 30   ACM 150 The output relays are provided for interface to PLCs, for direct activation or alarm devices and/or for direct initiation of automatic gas shutdown. They may also be wired to status panels. All relays are double-pole double-throw (DPDT) with dry contacts rated for maximum 30 VDC, 2 A.
  • Page 31   ACM 150 Figure 17. Typical relay layout • Relay number 1 is shown. • Typical of all 86 relays. • Figure 15 for layout and relay locations.    ...
  • Page 32 ACM 150 Relay output control panel The Relay control panel provides both status and control. When the ACM 150 monitor activates a relay, the corresponding LED lights and remains lit until the condition clears or the relay is reset. The 80 alarm relays have a momentary test switch, which is active in the Front Panel Mode.
  • Page 33 The AC line power from the main power switch wires into the power distribution panel, which is shown below. This panel provides grounded receptacles for power cords wired to the various subassemblies and mechanical pumps in the ACM 150 monitor. Each subassembly has its own DC power supply, if DC power is required.
  • Page 34: Air Sampling System

    Air sampling system ACM 150 flow cycles The ACM 150 monitor is designed to move air samples from one area to the next as quickly and efficiently as possible, while assuring that each sample is fresh and representative of the air at the sampled area when it is analyzed. The Cycle Valves...
  • Page 35 As the ACM 150 monitor samples and analyzes areas, another bypass flow continues for all areas not currently sampled. This flow is drawn through the Sample Valves by the Bypass Venturi Pump.
  • Page 36 You can also observe this on the local or remote computer screen by selecting View Cycle Valves. The timing is set by the Honeywell Analytics service engineer in the configuration software. These times may be increased or decreased to get good sampling and analysis results in the minimum amount of time.
  • Page 37   ACM 150 Figure 20. CDA panel 1. Line Leak to Sample Rail 2. Line Leak Gauge 3. Line Leak Needle Valve 4. CDA In 5. To Venturi Pumps 6. Line Leak and Venturi Regulators/Gauges 7. Isolation Valve S9 / Solenoid Valve S10 / Solenoid Valve Figure 21.
  • Page 38 An inline filter must be installed on every uncapped sample port to protect it, even if the filter is locally mounted at the inlet tie point on top of the ACM 150 monitor. Checking and replacing filters is required during periodic service.
  • Page 39 If the tube holds pressure, it passes the test. If a tube fails to hold pressure, it fails the test and the ACM 150 monitor displays a malfunction message on the touchscreen.
  • Page 40: Acm 150 Operating Principle

    The air sample spectra collected by the ACM 150 monitor contains all of the identifying absorption peaks of the gases that make up that air sample. However, the ACM 150 monitor will only report the gases that are set up as active for that sample area.
  • Page 41 Use of the background spectrum It is critical that calibrations taken on one ACM 150 are valid for computing accurate concentrations on any other ACM 150. In that way, calibration spectra are valid for all ACM 150s and older models as well. This is accomplished by using a reference(or background) spectrum to which each analysis spectrum is ratioed.
  • Page 42 IR radiation. Or, if the ACM 150 monitor has a 10 cm cell for % LEL/LFL ranges, the relation may be expressed as milliabsorbance units per % concentration.
  • Page 43: Installation Environment

    Installation environment Space requirement No access is required from the rear or from either side. The ACM 150 monitor may be against a wall or set back-to-back with another monitor. Allow a space of 3 inches (8 cm) behind the rear for air circulation. Front access is required. Leave a clear space of 36 inches (91 cm) in front of the cabinet door.
  • Page 44 60 to 85 °F (15 to 30 °C). The standard cabinet is designed to meet an IP 20 rating. Electrical area The ACM 150 monitor is designed to be located in a non-hazardous or general purpose electrical area. Refer to Technical Specifications on page 97. Utility requirements The ACM 150 monitor requires the following utilities: •...
  • Page 45   ACM 150 Vacuum sampling system The ACM 150 monitor samples up to 40 areas, which are scanned and analyzed in sequence, as described in Air sampling system. The main assemblies are: Bypass Venturi Pump Draws flow through sample tubes and bypasses the...
  • Page 46 ACM 150 Receipt and unpacking ACM 150 systems and parts may be shipped in one or more containers. Each packing slip indicates the number of crates. Report any signs of rough handling or damage during shipment to the transportation carrier. Inspect all equipment and/or parts after removal from shipping containers.
  • Page 47   ACM 150 Figure 23. Ergonomics Figure 24. Main power switch and supply connections NOTE For safe operation, Ground must be connected to an equipment grounding conductor or Protective Earth. DANGER! Electrocution danger. Before removing the Main Power Switch cover or connecting line power, verify that the external AC supply power is disconnected at the source in accordance with your company’s Lockout/Tagout procedures.
  • Page 48 International line power The ACM 150 monitor will operate at either 50 Hz or 60 Hz, single phase power. If your line power is not within the range of 110-115 VAC, advise Honeywell Analytics prior to placing an order. The ACM 150 monitor can be set up at the factory to operate on AC power in the range of 200-230 volts AC.
  • Page 49 Utility gases and exhaust piping Nitrogen supply The ACM 150 monitor requires a constant supply of nitrogen, which is used as a dry purge gas for the optics bench and as a zero gas for the Background cycle. The requirements are:...
  • Page 50 ACM 150 Exhaust The ACM 150 monitor exhausts the air it samples through an exhaust pipe located on the top. Connect this to an exhaust duct with no flow restriction that is compatible with the types of gases monitored by the ACM 150 monitor. The requirements are:...
  • Page 51 Discard short lengths that are left over instead of joining them to make longer runs. ACM 150 tube connection points Each sample tube is connected to an inlet on top of the ACM 150 monitor using 3/8 inch Swagelok tube fittings. The inlet fittings are numbered from 1 to 40, as shown in Figure  ...
  • Page 52 High PPM level leaks that saturate the ACM 150 monitor with oxidizing or corrosive vapors. • Liquids (water, solvents or oil) present in the sampled air that enter the ACM 150 monitor via the sample tubing. • Flammable gases above explosive levels that might increase the risk of fire inside the ACM 150 monitor.
  • Page 53 Filters, check valves and probes In-line filters The ACM 150 monitor requires a filter at the inlet of each sample line to protect the tubing and internal sampling system from an accumulation of particulates. Honeywell Analytics supplies one filter for each sample port. Install the filters at the sample pick-up point when the tubing is run to each port.
  • Page 54 Six status relays are on the Relay Output Board. They activate when service request or malfunction incidents are detected by the ACM 150 monitor or when power is lost. It is highly recommended that these relays be connected to a continuously monitored alarm system.
  • Page 55 Honeywell Analytics. NOTE If you use the fail-safe configuration, all of the ACM 150 monitor output relays will activate on loss of power, which is likely to cause wide-spread alarms and gas shut-downs. Even a reboot of the computer will cause this to occur. It is...
  • Page 56 , un relais de verrouillage doit être utilisé dans la boucle de commande . Si non, l' ACM 150 moniteur relais arrêt de la source et de gaz arrêter la fuite que a été détecté par le moniteur ACM 150 . L'alarme sera bientôt claire et réinitialiser le relais , le redémarrage de l'écoulement du gaz , et la fuite sera à...
  • Page 57 Interface You can connect a remote computer to the ACM 150 monitor via the internet or local network. Authorized employees can then access the ACM 150 monitor from remote locations. If a local network is used, you may connect as many remote computers as you need to one or more ACM 150 monitors.
  • Page 58: Installation Drawings

      ACM 150 Installation drawings In addition to the drawings in this section, drawings may be separately provided to clarify the installation of special or modified assemblies. Figure 29. Installation diagram  ...
  • Page 59   ACM 150 Figure 30. Installation diagram  ...
  • Page 60   ACM 150 Form 1: Sample point matrix Sample Point ACM 150 Port# Gases Monitored Installation Notes Name or Equipment ID #                                    ...
  • Page 61: Operation

    There is no danger to the operator when opening any of the doors or the outside panels on the ACM 150 monitor for inspection purposes. No internal plates, shields or components should be touched, tested, removed or serviced except by a Trained Technician.
  • Page 62 été appliquées à le banc optique FTIR par le fabricant. Lire et se conformer à ces étiquettes . Seul le personnel qualifié , y compris des ingénieurs de services Honeywell Analytics , êtes- qualifié pour ouvrir l'optique FTIR banc et entretenir les composants à...
  • Page 63   Status bar At the top of the ACM 150 monitor display is a status bar. It displays the current status, and it alerts the operator to any conditions requiring attention. Figure 31. Status bar...
  • Page 64 It upda ates as each h area scan comp pleted, abou ut every 15 seconds on n a standard d ACM 150 m monitor. The e display show ws variables that are de etermined by y the Setup program. T...
  • Page 65 Area Number, Port Number and area number is unlikely to have any Point Number all correspond to the meaning to the operator, the ACM 150 inlet port number, 1 - 40, on top of monitor software allows you to enter the ACM 150 monitor.
  • Page 66   ACM 150 Alarm 1 Alarm 1 level set point for this active gas. Alarm 2 Alarm 2 level set point for this active Status Status for each active gas on the dis- play • OK: Indicates the gas concentration is lower than the warn level set point.
  • Page 67 AL1 or AL2 (Warn or Alarm), the current status is left as AL1 or AL2 as before. So if EnablePreWarn is set to Yes, the ACM 150 alarm system will be returned to “alarm status = normal” if and only if the gas reading is absolutely = 0.000.
  • Page 68   ACM 150 Figure 34. Current alarms Press “Show Alarm History” to display the last 500 Alarm 1 or the last 500 Alarm 2 events of the past. Figure 35. Alarm history. When the alarm history is displayed, press “Backup this list…” to generate the “al_back.csv”...
  • Page 69 With the gas supply cut off, the leak should dissipate. However, if the leak is not shut off, the ACM 150 monitor will most likely sense the alarm event each time it scans the leaking area(s).
  • Page 70 Since the monitor can detect multiple gases per port, the action plan can be tailored for each gas. Every user should have a plan of action for Alarm 1/Alarm 2 incidents. Refer to “Form 2: Plan for ACM 150 incidents” on page 76 for a suggested plan and format.
  • Page 71 Lock-on Mode can help ERT determine when it is safe for workers to re-enter an area. The Lock-on Mode is also used to introduce a test chemical while the ACM 150 monitor is locked onto the area. Lock-on Mode data is archived.
  • Page 72   ACM 150 Figure e 38. Lock-on mode menu buttons Once e selected, t this area is s scanned at the same ra ate as norm al scanning g. The displa Figure 3 39, identifies s the point (a area) numbe er selected.
  • Page 73   ACM 150 Figure 40. Demand scan menu After an area is selected, normal scanning is interrupted while two scans are collected. The results are displayed as shown in Figure 41. The concentration readings and status of each active gas at the sample point are displayed.
  • Page 74   ACM 150 In Demand Scan the infrared spectrum is displayed, and it may be expanded for viewing by touching the display. At the same time, the data and the spectrum are archived automatically. The archived spectra may allow an application chemist identify gases which were in the sampled area at the time but not actively monitored.
  • Page 75 ACM 150 Figure 43. Trend graph display Archive view The ACM 150 monitor stores the infrared spectrum data from all its modes for the past 30 days. The Archived View allows you to selectively review and identify these spectra. When you select Archive View, the menu shown in Figure 44 display.
  • Page 76 Every eight hours an average gas concentration for each point and gas is calculated and saved to a TWA file on the ACM 150 monitor hard drive. In addition, an MTD file may be created to calculate an average gas concentration for the last 30 days.
  • Page 77 Some malfunctions, such as a failure of the optional Line Leak Check, do not interrupt the operation of the ACM 150 monitor. It will continue to scan normally after this malfunction is detected. Other malfunctions, such as a “bench time-out”...
  • Page 78   ACM 150 Record all of the incidents on Form 3, “Details of alarms, problems or non-spec performance. Form 2: Plan for ACM 150 incidents Port # Active Points Sample Point Actions for Warn/ Name or Equip- Alarm 1/Alarm 2...
  • Page 79 559-40-0, ACGIH TWA 2.5 PPM) will absorb in RMS Noise Area 1, decreasing the SNR from over 500 to less than 10. Since 10 < SNR setpoint of 100, the ACM 150 monitor will ignore the 250 PPM reading of C and gas concentration readings of the other fourteen gases scanned at that point.
  • Page 80 Activation du rapport signal -sur-bruit sur des échantillons peut inhiber la détection de gaz . Honeywell Analytics ne recommande pas ce paramètre . Le client permet le rapport signal -sur-bruit sur des échantillons à leurs propres risques . Honeywell Analytics décline toute responsabilité découlant de clients permettant rapport signal sur bruit sur les échantillons .
  • Page 81: Setup Menus

    Setup Menus Accessing the setup View setup Any user can view the setup program menus for the ACM 150 monitor. The setup menu screens show how the ACM 150 monitor is currently configured. Change setup Only authorized users with an access code are permitted to change the setup program.
  • Page 82   ACM 150 Figure 46. Point configuration Active Indicates the point is configured and active. The scan has been enabled. It may be enabled in the Order of Scan. Inactive Indicates the point is configured but not active. Scan must be enabled before the point can be included in the scan cycle.
  • Page 83 When you select an unconfigured point, all of the available methods are displayed. If the ACM 150 monitor monitors only a short list of gases, you may have only one method. If you have a large number of gases, you will have multiple methods installed.
  • Page 84   ACM 150 Figure 48. Editing the configuration Configure each point using the steps listed in the table below: Table 2. Point configuration steps  Enter a name for the sample point that identifies the specific equipment or location in your facility. Form 1 may be used as your master list of sample point names. Scroll down the list of methods and select one that includes all of the gases you want to monitor at that point.
  • Page 85 Gases that are not selected are not monitored on that point by the ACM 150 monitor. Enter a value for the Alarm 1 and the Alarm 2 set points. Alarm 1 is the lower value and can not be set higher than the Alarm 2 value.
  • Page 86 Decide on the scan sequence you want to use before you make any changes. Note that points may be scanned in any sequence. If you want the ACM 150 monitor to spend more time scanning one or more critical points, you can repeat the point(s) in the sequence.
  • Page 87 Composite Point groups have only one advantage. They shorten the scan cycle. Since the ACM 150 monitor typically monitors air having no target gases present, the readings are zero most of the time. Composite sampling enables the ACM 150 monitor to increase its rate of scan until a gas leak occurs.
  • Page 88 Alarmes 1 et 2 ensemble des points Programmable relays The ACM 150 monitor has 80 programmable relay outputs. The functions and uses of the relays are described in section Alarm 1/Alarm 2 incidents and actions.
  • Page 89   ACM 150 Figure 52. Review programmable relays - default Selecting the relay program Follow the steps in Table 4 when assigning levels, points and gases to a relay.  ...
  • Page 90 Form 2:, “Plan for ACM 150 incidents” may be used to record your plan. After you login, the relay numbers change to selection buttons. This enables you to select any of the relays.
  • Page 91 Virtual relay setup. You can connect the ACM 150 monitor to a PLC or facility computer without hard- wired relays. Virtual relays are available for this purpose. They are accessed using the advanced key, which brings up the SQL Direct Entry display as shown below.
  • Page 92 A Master Code is created by Honywell Analytics in the configuration software and given to the person in charge of the ACM 150 monitor. That code must be entered when Access Login is selected to pull up the setup menu as shown below. The Master Code may be changed by the user and that code may be used for multiple monitors in the same facility.
  • Page 93   ACM 150 Figure 56. Access codes Default Access Level Functional range Level “0” View most screens Demand Scan (2 successive scans on one point) Level “1” Level “0” + Reset Alarms +Reset Service Events + Lock-On Scan Level “2”...
  • Page 94 “OK”. NOTE If the Master Code on the target ACM 150 differs from that on the source ACM 150, you will have to manually change the Master Code on the target ACM 150 directly after importing the password there.
  • Page 95 Figure 57. Method files Save / load configuration After you setup the ACM 150 monitor and each time you change the setup, you want to save the configuration to the ACM 150 monitor hard disk. Also, you should backup the configuration to a USB flash drive. Then, if the software should get corrupted or the hard disk fail, you can save hours of work by loading the configuration from your storage drive.
  • Page 96 Alarm Simulation For testing communication links to external devices via Modbus/TCP output, such as a PLC connection, the ACM 150 monitor Software v2.10 and higher features Alarm Simulation. For security reasons this screen is password protected and may only be activated with the ACM 150 monitor in Manual Mode.
  • Page 97   ACM 150 Figure 60. Alarm simulation • Select the point you want to simulate alarms on and hit Next. • Select the gases for simulating alarms and hit Next. • On the next screen click either Go to activate the alarms or Cancel to abort.
  • Page 98: Shutdown Procedure

    Automatic Mode, all simulated alarms will be cleared. Shutdown Procedure Emergency shut down Immediately turn off the Main Power Switch located on top of the ACM 150 monitor to disconnect power to all of the internal circuits. Figure 62. Main power switch...
  • Page 99   ACM 150 Under these conditions you should close the external shut off valves: • The system is shut down for an extended period, taken out of service or relocated. • The venturi pumps or gas cell are serviced. •...
  • Page 100: Technical Specifications

      ACM 150 Technical Specifications Performance Specifications Analysis Method Continuous scan FT-IR analyzer (FT-IR = Fourier transform infrared) Gas 5.0 m path length Cell Path Gases Monitored Organic, PFC, CFC, HFC, Metal Organic, NF3 and a wide variety of other...
  • Page 101   ACM 150 Interfaces Web based user interface (e-Diagnostics) Ethernet: HTML viewing / control; ODBC access Touchscreen user friendly interface (point and click) Optional Outputs and Communications via Gateways Interface LonWorks®, Allen Bradley®, Modbus®, Profibus®, OPC drivers others on request Options and Accessories  ...
  • Page 102: Maintenance

    A means of disconnecting line power at the source is necessary to allow safe access to the power terminals at the ACM 150 monitor. An external Lockout / Tagout switch must be installed for this purpose. Follow your company’s Lockout / Tagout procedure, shutting off and locking this switch when required.
  • Page 103 Wear appropriate Personal protective Equipment. Standard Nitrile gloves are recommended. 1. Disconnect all gas sample lines from the fittings on the top of the ACM 150 monitor. 2. Allow the ACM 150 monitor to run in automatic sampling mode for 60 minutes to purge any residual gases in the system.
  • Page 104 It is highly recommended to reboot the ACM 150 monitor computer monthly. This ensures proper operation and avoids unexpected behaviour. Quarterly inspection It is recommended that the ACM 150 monitor be inspected every 3 months (more frequently, if desired) and that service be performed, if any problems or failures are found.
  • Page 105   ACM 150 Annual PM services Inspect and service the ACM 150 monitor in accordance with Service inspections procedures. If you have not already done so during the course of the past 12 months, replace these expendable items: • Cabinet filters •...
  • Page 106 Access Code (refer to Access codes). NOTE When you are ready to exit the Diagnostc Mode and return the ACM 150 monitor to normal scan operation, remember to Logout. This prevents unauthorized access to the restricted Setup and Diagnostics menus.  ...
  • Page 107 Figure 63. Menu options Service Log: This is a list of all the service incident messages stored by the ACM 150 monitor. You can review the time period of interest from the current day to any number of past days.
  • Page 108   ACM 150 Software Servicing: May be used to analyze and control the database on the ACM 150 monitor and is designed for our Fieldservice Engineers. Manual Mode Op: When selected, the manual mode menus appear on the right. Mode Control: Users with an access code may change the mode from automatic to manual or frontpanel.
  • Page 109 ACM 150 Figure 64. Service log View valve cycles This mode displays the ACM 150 monitor flow schematic with the current activation state of each Cycle Valve, as shown in Figure As the ACM 150 monitor progresses through its sampling sequence, you can observe the changing activate states.
  • Page 110   ACM 150 Figure 65. View valve cycles ZPD trends The ZPD Trends indicate changes in the FTIR detector signal, which is the relative intensity of the infrared radiation on the detector (refer to ZPD Value and Location a complete explanation).
  • Page 111 ‘Background’. S/N determines the lower detection sensitivity of the FTIR analyzer, the higher the value the better. If the S/N degrades below preset limits, the ACM 150 monitor generates an incident message. A degraded S/N indicates the need for service before it reaches unacceptable levels.
  • Page 112   ACM 150 Figure 67. Background, S/N, and drift Acquire background You can obtain a background spectrum on demand by selecting ‘Acquire Background’. As shown in Figure 68, the background spectrum is displayed for evaluation. In this mode it is also possible to ‘Save New Factory Background’ Scan’, which would replace the prior reference background.
  • Page 113 WDT timeout. Perform an entire line leak test Any authorized user can perform this test, provided your ACM 150 is configured for automatic line leak tests. Typically, this test is initiated because one or more line failed its automatic test. If services were performed to resolve the failure, this test verifies successful corrective actions.
  • Page 114 Database Statistics The screen “Software Servicing” may be used to analyze and control the database on the ACM 150 monitor and is designed for our Field Service Engineers. Figure 70. Software Servicing Clicking “Get Database Statistics” will load a list of key parameters describing the database size and composition.
  • Page 115   ACM 150 Figure 71. Database Statistics The same data will additionally be written to the comma-separated text file “db_ stats.csv”. You may save this file to a USB stick (or to your Desktop PC if you are operating remotely). Every time the statistics are generated, the complete data is appended to the end of the existing file.
  • Page 116 ACM 150 monitor touchscreen or from a remote computer. 2. If you are at the ACM 150 monitor, it may be easier to run tests from the local control panels. To do so, select ‘Switch to Frontpanel Mode’ and perform the tests from these control panels: •...
  • Page 117   ACM 150 bar at the top of the display changes to show it is ‘Being Serviced’ until you exit this mode. The Operating Mode also changes in the greyed-out status bar from Automatic Mode to Manual Mode. NOTE While in the Manual Mode, normal point scanning is halted. When you finish the manual testing, switch back to the Automatic Mode to resume point scanning.
  • Page 118   ACM 150 ACM manual control This mode displays the ACM 150 monitor flow schematic. It is the same schematic displayed in automatic mode, View valve cycles, except you have control over each valve. When you enter this mode, all valves are inactive. Turn a valve on by selecting the blue circle area.
  • Page 119 Figure 76. Sample valves manual control Relays All of the output relays may be controlled manually. The ACM 150 monitor has 40 programmable relays. The figure below shows only the first row of the menu, programmable relays 1-10. No relays are activated when you enter this mode. Select the relay you want to activate to open it.
  • Page 120 To minimize the time for repair, it is recommended that spare parts be stocked by the ACM 150 monitor user. You should review this with your local HA service representative to determine which of these spares should be stocked at your facility to support service.
  • Page 121 12, located in the lower pump cabinet. Replace it according to the recommended schedule or more frequently if required. The ACM 150 monitor should be taken off-line for this service. If not, expect to generate a Service Status message when temporarily interrupting the sample flow.
  • Page 122   ACM 150 During scheduled PM services or following any Service Status messages that might indicate a pump problem, use the manual tests to check the pumps, Cycle valve tests. Servicing the venturi pumps The Bypass Venturi and Gas Cell Venturi are shown in Figure 11.
  • Page 123 2 mm diameter detector. To get the best performance from the ACM 150 monitor, the path through these optics must be clean and clear, and the optics must be in alignment.
  • Page 124 Servicing the line leak test. 2. If the ACM 150 monitor failed one or more evaluations and/or if you have other problems, e.g. related Service Status messages, proceed to Servicing the gas cell (unless the problem is a ZPD value that is too high).
  • Page 125 Servicing the line leak test This applies only if your ACM 150 utilizes the optional Line Leak Test. There are no scheduled services. This daily test will generate a Service Status message and identify any sample point(s) failing the test. If you experience any failures, isolate and...
  • Page 126: Manual Tests And Evaluations

    Most likely, the in-line filter on that point needs to be replaced. To make sure the problem is not inside the ACM 150 monitor, disconnect the sample tube(s) from the problem point(s). If you observe that the Fill Cycle goes to 0 psig in 1-2 seconds with the line disconnected, assume the restriction is at the in-line filter or the sample tubing (or the check valve if the line leak option is used).
  • Page 127 View Valve Cycles, Figure Continue to observe the Sample Vacuum as the ACM 150 monitor scans through all of its active points. Minor fluctuations from one point to the next are normal. If you notice a significant increase in vacuum above normal at one or more point, suspect a flow restriction.
  • Page 128 Points either pass or fail the test. In order to pass, a pressure has to build up in the sample line that is sufficient to exceed the set point of the sample pressure transducer. If one or more line fails the leak test, go to the ACM 150 monitor to identify the problem, as follows: •...
  • Page 129   ACM 150 Evaluating/resolving spectral balance You evaluate the spectral balance using a Background spectrum. A Background spectrum is provided in “Acquire Background” Figure 68. It should look like Figure 78, having the same overall shape and peaks. Figure 78. Correct background spectrum Figure 79.
  • Page 130   ACM 150 4. The spectrum in Figure 79 has a dip in the region around 3000 to 3500cm . This indicates that there is a chemical coating on the gas cell. It needs to be cleaned or replaced. 5. The ratio of energies at 5000cm...
  • Page 131   ACM 150 Service and setup instructions Solenoid valves Sample valves To service the valves, remove one 10-port manifold at a time. First, disconnect the inlet tube fittings, Figure 6, and remove the pair of screws at each end. Use the handles to lift the manifold up and out.
  • Page 132 15. Using the 2 new O-Rings from the kit screw in and tighten both End Caps. Throw away the Felt Filters in the kit. No filters are used in the ACM 150 monitor pump. 16. Tighten the bolts attaching the Muffler Box to the End Plate.
  • Page 133   ACM 150 Figure 80. Backup vacuum pump diagram Table 5. Backup vacuum pump parts list Item Service Part Quantity Body Vane* Shroud End plate Gasket* Muffler box O-Ring* Felt* (Do not use) End cap End cap arm Nipple Plate bolt Service Kit  ...
  • Page 134 Prepare for test and setup Disconnect a few sample tubes at inlet fitting, e.g. points 1 thru 4. Make sure that you have CDA supplied to the ACM 150 monitor and that you have installed check valves at all of the sample point inlets.
  • Page 135: Troubleshooting

    Utilizing daily inspections As a backup to monitoring the output relays, a quick daily inspection of the ACM 150 monitor is recommended. It will help you identify problems, and it provides you with an inspection record.
  • Page 136 ACM 150 Resolving problems Table 6 lists service messages that might be generated by the ACM 150 monitor software. Troubleshoot the problems by following the recommended actions. Use ‘refer to’ for guidance, additional information and/or step-by-step procedures. Table 6. Service request messages...
  • Page 137: Appendix A: Kbr Msds

      ACM 150 Appendix A: KBr MSDS Trade name: Potassium Bromide 1 Identification of the substance/mixture and of the company/undertaking Product details Article number: 09934418 Trade name: Potassium Bromide Application of the substance / the preparation: Laboratory chemicals Manufacturer/Supplier: PerkinElmer Life and Analytical Sciences...
  • Page 138   ACM 150 Trade name: Potassium Bromide General information: • Seek immediate medical advice. • No special measures required. After inhalation: Supply fresh air; consult doctor in case of complaints. After skin contact: Generally the product does not irritate the skin.
  • Page 139   ACM 150 Trade name: Potassium Bromide General protective and hygienic measures: The usual precautionary measures for handling chemicals should be followed. Breathing equipment: Not required. Protection of hands: • The glove material has to be impermeable and resistant to the product/ the substance/ the preparation.
  • Page 140   ACM 150 Trade name: Potassium Bromide Primary irritant effect: • on the skin: No irritant effect • on the eye: No irritating effect Sensitization: No sensitizing effects known. Additional toxicological information: When used and handled according to specifications, the product does not have any harmful effects according to our experience and the information provided to us.
  • Page 141   ACM 150 Trade name: Potassium Bromide Cancerogenity categories EPA (Environmental Protection Agency): Substance is not listed. IARC (International Agency for Research on Cancer): Substance is not listed. NTP (National Toxicology Program): Substance is not listed. TLV (Threshold Limit Value established by ACGIH): Substance is not listed.
  • Page 142: Appendix B: Znse Msds

      ACM 150 Appendix B: ZnSe MSDS Trade name: Zinc Selenide 1 Identification of the substance/mixture and of the company/undertaking Product details Trade name: Zinc Selenide Article number: 09934409B Application of the substance / the preparation: Laboratory chemicals Manufacturer/Supplier: PerkinElmer Life and Analytical Sciences...
  • Page 143   ACM 150 Trade name: Zinc Selenide Hazard-determining components of labelling: zinc selenide Hazard statements: • H301 Toxic if swallowed. • H331 Toxic if inhaled. • H373 May cause damage to organs through prolonged or repeated exposure. H410 Very toxic to aquatic life with long lasting effects.
  • Page 144   ACM 150 Trade name: Zinc Selenide General information: • Immediately remove any clothing soiled by the product. • Remove breathing equipment only after contaminated clothing have been completely removed. In case of irregular breathing or respiratory arrest provide artificial respiration.
  • Page 145   ACM 150 Trade name: Zinc Selenide Precautions for safe handling: • Thorough dedusting. • Ensure good ventilation/exhaustion at the workplace. Open and handle receptacle with care. Information about fire and explosion protection: Keep respiratory protective device available Storage (conditions for safe storage, including any incompatibilities) Requirements to be met by storerooms and receptacles: No special requirements.
  • Page 146   ACM 150 Trade name: Zinc Selenide Appearance • Form: Solid • Color: Dark brown • Odor: Characteristic • Odour threshold: Not determined pH-value: Not applicable. Change in condition • Melting point/Melting range: >1100°C • Boiling point/Boiling range: Undetermined. Flash point: Not applicable.
  • Page 147   ACM 150 Trade name: Zinc Selenide Acute toxicity Primary irritant effect: • on the skin: No irritant effect • on the eye: No irritating effect Sensitization: No sensitizing effects known. Toxicity Aquatic toxicity: No further relevant information available. Persistence and degradability No further relevant information available.
  • Page 148   ACM 150 Trade name: Zinc Selenide IMDG, IATA • Class: 6.1 Toxic substances. Packing group • ADR: I Environmental hazards: • Marine pollutant: No • Special marking (ADR): Symbol (fish and tree) Special precautions for user Warning: Toxic substances.
  • Page 149   ACM 150 Trade name: Zinc Selenide Precautionary statements • P260: Do not breathe dust/fume/gas/mist/vapours/spray. • P261: Avoid breathing dust/fume/gas/mist/vapours/spray. • P273: Avoid release to the environment. • P264: Wash thoroughly after handling. • P270: Do no eat, drink or smoke when using this product.
  • Page 150: Appendix C: Glossary

    Nearly all chemicals have an IR absorbance spectrum, which is always the same and unique for each chemical. The FTIR spectra have a high resolution which enables the distinct identification of one chemical from the another. The ACM 150 monitor only monitors for chemicals in their gas (vapor) phase.
  • Page 151 Pounds per square inch gauge, pressure relative to atmospheric pressure at sea level. The ACM 150 monitor reports concentration values for gases in parts per million (PPM) and parts per hundred thousand (PPHT) (water vapor only). A pure gas would have a value of 100% concentration (by volume). One part in one million (1 PPM) is 0.0001% or 100% divided by 1 million.
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  • Page 156   ACM 150 Air Composition Monitor Revision 2, ECO# HAA150063 December 2015 ©Honeywell Analytics...

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