onguard 3000 users manual

2654 Weaver Way Doraville, Georgia, 30340, U.S.A. tel: (770) 662-8545 (800)-222-6367 www.purafil.com

USER ’S MANUAL FOR THE

ONGUARD 3000 (OG3 )

© Purafil 2010 User’s Manual - OG_3000 - 01

FIRSTIN CLEANAIR

www.pu ra f i l . com

REAL -T IME ENV IRONMENTAL MONITOR ING

i2654 Weaver Way Doraville, Georgia, 30340, U.S.A. tel: (770) 662-8545 (800)-222-6367 www.purafil.com


TABLE OF CONTENTS

Preface ........................................................................................................................................1

OnGuard Technology ....................................................................................................................2

How The OnGuard Works ............................................................................................................3

Upacking and Inspection ..............................................................................................................5

Installing and Powering the OnGuard 3000 ..................................................................................6

Communication............................................................................................................................8

Configuration ..............................................................................................................................9

Calibrate Temperature & Humidity ..............................................................................................10

Logging and Viewing Data ........................................................................................................11

Replacing Corrosion Sensors ......................................................................................................12

Current Outputs ........................................................................................................................12

OnGuard 3000 LCD Menus ........................................................................................................13

Purafil OG3 Connect PC Software Block Diagram........................................................................14

OnGuard PC Software (OG3) Connect ........................................................................................15

Information on Setting Corrosion Classifications ........................................................................17

OnGuard 3000 (OG3) 4-20 mA Calibration ................................................................................18

Relative Humidity and Temperature Specifications ......................................................................20



PREFACE Rev 2.2

Airborne gaseous contaminants, as well as fluctuations in temperature and relative humidity, have always posed a threat toeverything from modern electronic equipment to centuries-old artwork and archives. In recent years attention has beenfocused on how we can monitor and control these variables in our environment, creating a new key term: Indoor Air Quality(IAQ).

Purafil, Inc., the industry leader in air filtration systems, anticipated the need to merge technology with IAQ and created theOnGuard atmospheric corrosion monitor. After thorough testing and development, Purafil introduced the patented OnGuardAtmospheric Corrosion Monitor. For OnGuard’s development, Purafil received the 1992 R&D 100 Award, recognizing the top100 technologically significant products that year.

OnGuard has been installed to protect the environment in worldwide facilities such as: Santa Maria delle Grazie (housingda Vinci’s Last Supper), Italy; the English Channel Tunnel, U.K. and France; Haindl Papier, Germany; British Nuclear Fuels, U.K.;Honeywell, Yokogawa, and Georgia Pacific, USA.

Purafil thanks you for your purchase and we know you will be as pleased with your OnGuard unit as we are with itsdevelopment. For additional information or questions on the product contact:

Purafil, Inc. 2654 Weaver Way

Doraville, Georgia 30340USA

Phone: (800) 222-6367 or (770) 662-8545E-mail: [email protected]

Web: www.purafil.com and www.purafilonguard.com



THE ONGUARD TECHNOLOGY

INTRODUCTIONMetal strips have been used to quantify the effects of the atmosphere on similar metal surfaces for decades. Originally, theanalysis of the reactive metal strips relied on simply determining the weight gain due to atmospheric gases reacting with thebase metal. Later, more involved laboratory analyses gave some additional information on what compounds made up theresulting corrosion film that collected on the metal strips.

As good as this technique is, it requires that the metal strips be placed in the environment from 30 to 90 days and can onlyreport the total corrosion that has occurred during the test period. Corrosion, however, is most often an isolated event, andseldom occurs at an equal rate over the 30-to-90-day testing period. The method allows no way to pinpoint when any ofthe corrosion occurred, or to determine the severity of any particular corrosion event. Likewise, it cannot detect whatdramatic atmospheric changes, such as wind, temperature and humidity, have had on the corrosive activity within indoorenvironments.

It is important to take corrective action at the time these dangerous atmospheric shifts occur instead of after damage fromcorrosion has taken place. Getting information “real-time” gives users this advantage.

The OnGuard 1000 was the first instrument to provide real-time monitoring of environmental corrosion that can affect thereliability of industrial electronics, computers, and control equipment. The OnGuard 1000 has also been used extensively inmuseums and archives to monitor the environmental conditions that could irreparably damage precious artwork, artifacts andarchives. The OnGuard 2000 and related models are patented, second-generation instruments that provide the same basiccapabilities as the OnGuard 1000, with significant improvements in user interface, accuracy, and application flexibility. TheOnGuard 3000 implements the most desired features of the OnGuard 2000, adding battery operation as an option. Inaddition, the OnGuard 3000 is housed in an attractive enclosure that can address a variety of markets.

The OnGuard provides real-time measurements of the amount of corrosion forming on copper and silver surfaces by corrosivegases present in the local environment. It also measures the temperature and relative humidity of the environment, both ofwhich can affect the corrosion rate of these metals.

All of the OnGuard measurements for corrosion rates, temperature, and relative humidity can be related to the InternationalSociety for Measurement and Control (ISA) Standard S71.04-1986: Environmental Conditions for Process Measurement andControl Systems: Airborne Contaminants and ISA S71.01-1986: Environmental Conditions for Process Measurement andControl Systems: Temperature and Humidity, except for the silver corrosion rate. The silver corrosion rate measured by theOnGuard is reported in an environmental classification that has the same corrosion rate ranges as ISA Standard S71.04-1986has for the copper corrosion rate. Similarly, the OnGuard measurements can be related to various archive and museumstandards being utilized around the world. The ranges for both the copper and silver corrosion rates can be customized bythe OnGuard user for specific applications if desired.

All of the OnGuard units are equipped with the standard sensor set (temperature/relative humidity, copper corrosion, silvercorrosion). All OnGuard units are also capable of logging the sensor measurements in internal memory at user-selectableintervals, and this information is uploadable from the OnGuard to a personal computer (PC) for viewing, graphing orarchiving.



HOW THE ONGUARD WORKS

TECHNOLOGYCorrosion on electronic components and contacts and on precious and semiprecious metal artifacts is characterized by thebuildup of various chemical reaction products (films) which form when corrosive gases come into contact with the base metal.The sources of these gases often result from the types of processes being operated at the industrial site, chemicals in useand/or general atmospheric contamination. They may also be transported from an adjacent facility so careful attention shouldbe given to potential sources of atmospheric corrosion outside the facility boundaries as well.

Typical corrosive gases are: hydrogen sulfide (H2S); chlorine (Cl2); oxides of sulfur and nitrogen (SO2, SO3, NO. NO2, etc.);ozone (O3); ammonia (NH3); and hydrogen fluoride (HF). Therefore, corrosion films may be composed of reaction productssuch as copper sulfide and oxide (Cu2S and Cu2O) on copper, and silver sulfide and chloride (Ag2S and AgCl) on silver. Thesereaction products cause an associated mass gain which can be directly correlated to the average corrosion film thickness, inangstroms (Å), on the metal surface.

Measuring atmospheric corrosion on metallic surfaces has been done with a variety of techniques. The simplest and mostreliable is the measurement of the mass gain on a metal sample strip (often referred to as a “coupon”). The OnGuard 3000uses a patented technology to measure the corrosion that will occur on copper and silver surfaces using quartz crystalmicrobalance sensors plated with either copper or silver. The plated crystal has a natural resonance frequency based uponits mass. As corrosion films are formed, the sensor mass increases by the mass of the contaminant gases that have reactedwith the base metal plating. As a result, the crystal’s resonance frequency decreases.

By applying the proper conversion factors contained in the software of the OnGuard units, the corrosion buildup that occursover the life of the corrosion sensor can be determined. This is referred to as Cumulative Corrosion. The rate of corrosionbuildup over a given time period can also be determined. This is termed Incremental Corrosion.

CUMULATIVE CORROSIONCumulative Corrosion is the total amount of corrosion that has accumulated on a metal surface. Corrosion is an ongoingprocess, occurring when the conditions are correct for additional reaction of the contaminant gases with the base metal. Forsurfaces like copper and silver, the onset of corrosion is evidenced by the appearance of a slight tarnish, which is the actualcorrosion film. Progressively, this tarnish gets darker and thicker. Cumulative Corrosion is reported to the OnGuard in termsof angstroms (Å), which is 10-12 meters.

The OnGuard corrosion sensors have the capability to accumulate 4000 Å of Cumulative Corrosion. At this stage ofCumulative Corrosion, the base metal copper and silver corrosion sensors will be completely black. If the OnGuard is beingused to monitor the effects gases have on other metallic surfaces, whether they are precious artifacts or electrical circuitcontacts, either visual tarnishing or electrical failures will have occurred prior to the OnGuard’s corrosion sensors reachingtheir 4000 Å limit.

The Cumulative Corrosion information is logged in the OnGuard memory module, and it can be recalled and reviewed toanalyze the buildup of corrosion that the OnGuard has detected.

INCREMENTAL CORROSIONIncremental Corrosion is the amount of corrosion that has accumulated on a metal surface over a specific time period.Incremental Corrosion can also be referred to as the rate of corrosion buildup. The OnGuard reports Incremental Corrosionin terms of Angstroms per twenty-four hours (Å/24 hours). The Incremental Corrosion is an indication of the severity, or lackof severity, of a corrosion-causing event. In the OnGuard, the Incremental Corrosion is recalculated every 15 minutes for theprevious 24-hour period. Because Incremental Corrosion is updated every 15 minutes, significant changes in the rate ofcorrosion can often be determined within a 15-minute time period. Less significant changes in the rate of corrosion may takelonger to detect.

In certain applications, Incremental Corrosion of less than 10 Å/24 hours has been determined to be within safety limits. IfIncremental Corrosion of greater than 10 Å/24 hours is detected, alarms within the OnGuard can be activated. IncrementalCorrosion is logged within the OnGuard memory module, and this information can be recalled for review and analysis.Reviewing the Incremental Corrosion is especially useful in determining the time that corrosion-causing events begin or end.

TEMPERATURE EFFECTS ON CORROSIONIncreases in Temperature can accelerate the rate of corrosion by increasing chemical reactions. Using the OnGuard to monitorand record Temperature, increases or decreases in Cumulative Corrosion and Incremental Corrosion can be correlated toTemperature effects. The Temperature sensor is read continuously, and the data is averaged over a one-minute time period.This information can be logged within the OnGuard unit and reviewed for analysis to determine if increased Temperature wasa factor in a corrosion event.

RELATIVE HUMIDITY EFFECTS ON CORROSIONVarying levels of Relative Humidity can significantly affect the rate of corrosion. Changes in the Relative Humidity can resultin condensation on surfaces within a space, and should corrosive gases be present, they can dissolve into this water layer.Many corrosive gases are often referred to as “acid gases” in that when they are dissolved in water, the resulting mixture isan acid. For instance, chlorine (Cl2) gas dissolved in water creates hydrochloric acid (HCl). Therefore, Relative Humidity oftenneeds to be carefully monitored and controlled in computer control rooms. The OnGuard monitors and records RelativeHumidity for correlation to events that are associated with increased rates of Cumulative Corrosion and IncrementalCorrosion. The Relative Humidity sensor is read continuously and the data is averaged over a one-minute time period. Thisinformation can be logged within the OnGuard unit and reviewed to determine if Relative Humidity was a factor in acorrosion event.

STANDARDSStandards can be used to define the limits of acceptable performance. These limits may be formally set by a committee actingon behalf of an organization or informally set by an individual based upon a particular application.

The OnGuard is capable of containing one preloaded formal corrosion standard, which the OnGuard unit will default to oninitial start-up. The OnGuard units are also capable of having a user-defined corrosion standard input. Similarly, theacceptable limits for Temperature and Relative Humidity can be selected from the formal, default standard, or an informalstandard more applicable to a particular application.

Initially, the OnGuard has been set up with industrial standards for corrosion written by the Instrument Society of America(ISA). These standards are ISA S71.04-1985: Environmental Conditions for Process Measurement and Control Systems:Airborne Contaminants and ISA S71.01-1985: Environmental Conditions for Process Measurement and Control Systems:Temperature and Humidity. They were written by a panel of experts in the corrosion field, ranging from manufacturers ofsophisticated electronics and gas-phase filtration to professional engineers and end users in the industrial marketplace. Thestandards have been globally accepted and used in areas where sensitive electronics are housed in industrial complexes.

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UNPACKING AND INSPECTIONDO NOT REMOVE THE ONGUARD UNIT FROM THE SEALED PLASTIC BAG UNTIL TIME OF INSTALLATION

1. Verify that the following items are included in the shipping box. If any item is missing, notify Purafil, Inc. immediatelyat (770) 662-8545 or 800-222-6367.

• OnGuard unit• Installation and operation manual on CD• Digital data cable• OnGuard control software (OG3 Connect) on CD• Warranty Registration Card

2. Make a visual inspection of the OnGuard unit. Do not remove it from the sealed plastic bag for extended periodsuntil the time of installation. This insures that the corrosion sensors are not exposed to air contaminantsprematurely, which may shorten sensor life.

3. Examine the OnGuard unit for any damage that may have occurred during shipment. If any obvious damage is foundnotify the carrier immediately and call Purafil.

4. Fill out the Warranty Registration Card and return it to Purafil immediately. Failure to send in the WarrantyRegistration Card may result in delayed receipt of future updates to OnGuard control software and may limittechnical support.

5. Check the packaging for any additional documentation that may have been included.

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INSTALLING AND POWERING THE ONGUARD 3000

Although the OnGuard is designed to withstand corrosive industrial environments, the unit contains sensitive electroniccircuitry. Therefore, care should be taken to insure that it is not dropped or handled roughly during installation.

MECHANICAL MOUNTING OF THE ONGUARD UNITThe OnGuard is designed to be mounted on a secure flat vertical surface. Use the screws provided and install in a levelorientation. There are two “keyhole-shaped” mounting holes on the rear of the OnGuard 3000. The two mounting screwscan be positioned and installed using the mounting template provided in the appendix, which should be photocopied andused for installation. The screws should be driven into the mounting surface until the bottom surface of the head of the screwis approximately 0.1 inches (2mm) from the wall. The OnGuard 3000’s mounting holes are then placed over the screws andlowered into place. Adjust the screws for a firm fit.

BATTERY OPERATIONOPENING THE ONGUARD 3000 FOR BATTERY INSTALLATIONRemove the OnGuard 3000 from the protective bag it was shipped in. Remove the two screws that hold the front half andthe back half of the case together. These are located in the middle on each side of the unit. With these screws removed thecase will come apart, providing access to the battery holders.

IMPORTANT! The batteries must be installed correctly! In both battery holders, the outline image of a battery is molded into each locationwhere a battery is to be installed. Please orient the batteries as indicated.

INSTALLING THE CLOCK BATTERYA standard lithium battery (CR123) must be installed for proper clock operation. Install this battery, noting the properpolarity, in the small battery holder inside the OnGuard 3000. The time displayed will be invalid until it is set via the OG3Connect program.

INSTALLING THE MAIN BATTERIESThe OnGuard is designed to operate on four standard “AA” alkaline batteries. The unit will begin operation when the last ofthe four batteries is installed. For longest operating life, use “high capacity” batteries like the Duracell Ultra or EnergizerMax. When the batteries are installed reassemble the case by installing the two screws that were removed to open the case.

Battery Life

Log Interval

(Minutes) X/Hr % On mAHr WHr Hours Days

1 60 96.7% 18.38 0.0607 158 6.6

2 30 48.3% 9.39 0.0310 310 12.9

5 12 19.3% 4.00 0.0132 728 30.3

10 6 9.7% 2.20 0.0073 1324 55.1

15 4 6.4% 1.60 0.0053 1820 75.8

30 2 3.2% 1.00 0.0033 2911 121.3

60 1 1.6% 0.70 0.0023 4158 173.2

120 0.5 0.8% 0.55 0.0018 5291 220.5



EXTERNAL POWERThere are two ways to provide external power to the OnGuard 3000.

1. EXTERNAL DC POWER SUPPLYThe OnGuard 3000 can be powered by an externally supplied DC voltage between 9VDC and 30VDC. The powersource should be able to supply at least 300mA of current. This voltage is applied to pins 9 and 10 of the 10-pinterminal block on the bottom of the OnGuard. Pin 1 of the terminal block is on the left when viewed from the front,pin 10 on the right. The negative lead of the power source is connected to pin 9, and the positive lead is connectedto pin 10.

When operating from an external power supply the OnGuard will operate continuously and will not power down into“sleep mode” as it does when powered from the batteries. If the external power supply fails or is turned off theOnGuard 3000 will continue to operate from the internal batteries if they are installed. This allows continuousoperation even during power outages.

2. POWERED FROM A PC USB PORTThe OnGuard 3000 can also be powered by connecting the OnGuard 3000 to a PC via the USB port on the bottomof the unit. All functions are available and the OnGuard 3000 will operate the same as if it is powered from anexternal power supply.

COMMUNICATION

The OnGuard 3000 is designed to communicate with a Windows-based PC via a USB port, using the OG3 Connect software.The OG3 Connect software application provides a convenient way to configure the OnGuard 3000 and extract measureddata. The most reliable results have been obtained with computers containing a USB 2.0 compatible USB port and WindowsXP or XP Pro operating system. The USB cable must have a standard “type A” plug on one end and a “mini-B” plug on theother. A travel-type cable is supplied with the OnGuard 3000.

Here is the procedure to establish communication between the OnGuard and the PC:

1. Plug the USB cable into the PC’s USB port.

2. Start the OG3 Connect software on the PC.

3. Apply power to the OnGuard. If operating on batteries, “wake” the unit by pressing the ENTER key on the OnGuard 3000.

4. Plug the USB cable into the small USB connector on the bottom of the OnGuard 3000. Be sure to orient the connector correctly and do not force a connection that does not appear to fit. If your PC sound is not muted and the volume adjusted so it can be heard, you should hear the familiar USB “connect beeps” from the PC indicating aconnection has been made.

5. In the lower left corner of your PC screen you should see the word “Connected” after a few seconds. You can now interact with the OnGuard 3000.

NOTES: Always unplug the USB cable after closing the OG3 Connect program.

Wait at least 20 seconds after last data communication (configuration or data download) before closing the OG3 Connect program.

If the OG3 Connect program is connected to the OnGuard 3000 and the USB cable is accidentally unplugged, just close the program. The program may take up to 30 seconds to close.

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CONFIGURATION

The OnGuard 3000 may need to be configured to operate properly in your location, and provide the data desired. Theconfiguration includes setting up the data logger, the date and time, corrosion sensors, and temperature and relative humiditylimits. The OG3 Connect software is used for configuration. On the main menu bar click on “Device”, then “Configure”. Asummary of the available functions is listed below:

DATA LOGGER TABThe data logger can be enabled and disabled from this screen. You can also set the logger interval from 1 to 120 minutes.You can maximize battery life by setting the logger interval to a higher value (15+ minutes) as the OnGuard 3000 uses morepower during readings than between readings, when it “sleeps”. The most power is used when interfacing with an operatorvia the keypad and LCD display. Batteries can be made to last several months with proper setup and minimal operatorintervention.

The OnGuard 3000 can store over 21,000 readings in its logger memory.

LOGGER MEMORY CAPACITY

CLOCK/CALENDAR TABThe date and time must be set. Make sure the OnGuard is connected to the PC and communication is established. Fromthe configuration screen, click on the “Clock/Calendar” tab. Enter the time and date in the spaces provided and click the“Apply Changes” button.

SENSORS TABThe OnGuard is shipped with copper and silver sensors installed. Copper is on top and silver is on the bottom. From theconfiguration menu, click on the “Sensors” tab. Click on the “Read Device” button to see the current setting for the sensors.By default the Classification Level will be set for “Std (Fixed)”. The table of values selected by this choice corresponds tothe ISA standards. Custom levels may be entered by setting the “Range” to “Custom”. You can then enter the upper valuefor each range. The lower value is automatically set. See the appendix for additional information on the Classification Levels.

TEMP & HUMIDITY TABThe OnGuard 3000 allows you to set high limit, low limit, and rate-of-change limits for temperature and relative humidity.When limits are exceeded, the red LED will flash.

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Log Interval Hours Days1 Minute 350 142 Minutes 700 295 Minutes 1750 7215 Minutes 5250 21830 Minutes 10500 43260 Minutes 21000 864120 Minutes 42000 1728



CALIBRATE TEMPERATURE & HUMIDITY

The temperature and relative humidity sensors can be calibrated from the PC. Under the “Device” menu, there are selectionsfor “Calibrating Temperature” and “Calibrating Humidity”. A reference instrument is required to provide a point to calibrateto. The temperature can be calibrated in Celsius or Fahrenheit. See Appendix A for sensor accuracy on temperature andrelative humidity.

INITIALIZING SENSORSWhen the OnGuard 3000 is shipped from the factory, it is enclosed in a protective bag designed to minimize contaminantaccess to the corrosion sensors. When batteries are installed and the unit begins to operate, the first function it performs isthe initialization of the copper and silver corrosion sensors. This process is initiated automatically and takes two hours andshould not be interrupted until it is completed. This process establishes the initial state of the sensors and sets the referencefor future operation. During this period the LCD display will turn off and the red LED will flash on and off at about a 1 secondrate.

NORMAL OPERATIONOnce the OnGuard 3000 has been installed, configured, and the sensors initialized, it is ready for normal operation. Mostof the time the unit will be in “sleep” mode with no visible sign of activity except a flash from one of the LEDs once a minute.If the green LED flashes it means the unit is operating properly and no limits have been exceeded. When the unit is takinga reading, the green LED will flash once per second for about a minute. If there is an alarm condition, the red LED will flashat a one second “on”, one second “off” rate. At any time, the user can press the ENTER key to wake the unit and view thecurrent readings or any alarm conditions.

ALARM CONDITIONSThere are two LED indicators on the OnGuard 3000 just to the right of the LCD display. The green LED will light if there areno “Alarm Conditions”. If an alarm condition is detected, the red LED will flash. The conditions that can cause an alarmcondition are:

• One or both sensors in the two-hour initialization mode

• Sensor 1 (copper) or Sensor 2 (silver) failure

• Temperature above or below user-set limits

• Temperature rate-of-change above limit

• Relative Humidity above or below user-set limits

• Relative Humidity rate-of-change above limit

• Battery level below 10%

If there is an alarm condition active, and the unit is in “sleep” mode, the red LED will flash once per minute. If the unit isawake (during reading), the red LED will flash one second on, one second off. If there is no alarm condition the green LEDwill flash on the one minute interval and will flash at one second intervals during the reading period. To disable the red LEDfrom lighting due to temperature or relative humidity limits being exceeded, set those limits to values the unit will notexperience.

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LOGGING AND VIEWING DATA

There are two ways to view and/or save the OnGuard 3000 data. The first way is to use the “Capture Live Data”, and thesecond is to download data already logged. In both cases, the file is saved as a “.csv” text file, which can be read byMicrosoft Excel for additional analysis. The data files are saved in the same directory as the application program unlessanother location has been specified.

CAPTURE LIVE DATAThis function is used to view readings as they are obtained by the OnGuard 3000. The readings are transmitted to the PCat the logger interval and saved in a file on the PC. The OG3 Connect software will place each received record in a table andgraph the result in real-time. It is also saving this data to the file that was created when the function was initiated.

DOWNLOAD LOGGER DATAThis function is used to download data from the OnGuard 3000’s logger memory. This function does not require connectionto a PC until the moment you want to download all of the readings stored in the OnGuard.

DATA SAVED IN FILE (filename.csv)The data file consists of nine columns of numbers. Here is a description of each column.

Sample: (this is just a reference number and doesn’t correspond to the absolute sample number)

Time: This is the time the sample was taken in 24-hour format.

TempC: This is the temperature in Celsius.

TempF: This is the temperature in Fahrenheit.

Humidity: This is the relative humidity in %.

CopperC: This is the copper cumulative value.

CopperI: This is the copper incremental value.

SilverC: This is the silver cumulative value.

SilverI: This is the silver incremental value.

When viewing the graphed data the Zoom+ can be used in conjunction with the lower scroll bar to enlarge any area ofinterest. The Zoom- key can be used to zoom back out. The left vertical axis of the graph is the scale for temperature andrelative humidity. The temperature can be scaled to 0-100 degrees C or 0-100 degrees F. The humidity scale is 0-100%.

REPLACING CORROSION SENSORS

When a corrosion sensor reaches its end of life, which happens when it reaches 4000 Angstroms of corrosion accumulation,it will cease to function and must be replaced. When a replacement sensor is obtained, install it on the OnGuard 3000 inthe same place as the sensor that failed. The upper sensor location is for Copper sensors and the lower position is for Silversensors. The OnGuard 3000 will recognize that a new sensor has been installed and will begin an initialization procedure.The LCD display will display a message indicating that the initialization sequence is in process. This process takes two hours,and during this time the information received from the OnGuard 3000 for that sensor is not valid. When the initializationsequence is complete the LCD message will be replaced with valid sensor readings.

CURRENT OUTPUTS

The OnGuard 3000 has four 4-20mA current outputs that correspond to Copper Cumulative, Silver Cumulative, Temperature,and Relative Humidity. The current outputs are accessible in the large 10-pin terminal block on the bottom of the OnGuard3000. Pin 1 and Channel 1 is located on the left end of the terminal block as viewed from the front. There is no LCD screenon the OnGuard 3000 that deals with the Current Loop Outputs. These outputs are disabled when the OnGuard 3000 isbattery operated.

• Channel 1, Copper Cumulative, Pin 1 (-), Pin 2 (+), 4-20mA = 0-4000 Angstroms

• Channel 2, Silver Cumulative, Pin 3 (-), Pin 4 (+), 4-20mA = 0-4000 Angstroms

• Channel 3,Temperature, Pin 5 (-), Pin 6 (+), 4-20mA = 0-100C

• Channel 4, Relative Humidity, Pin 7 (-), Pin 8 (+), 4-20mA = 0-100%

• OnGuard External Power, Negative Input, Pin 9

• OnGuard External Power (+12-30VDC), Positive Input, Pin 10

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ONGUARD 3000 LCD MENUS

The OnGuard 3000 contains a backlit graphic LCD Display. The primary information screen is the “Main Menu”. Additionalscreens are available to display alarm conditions, data logger settings and the OnGuard 3000’s firmware revision. These arethe “Alarm Menu”, the “Logger Menu”, and the “Version Menu”. The user can sequentially cycle through all these screensby pressing the “Menu” key.

MAIN MENUWhen the OnGuard 3000 is powered up, the Main Menu Screen appears as shown above. Thisscreen displays the measured results from the on-board sensors, which include copper andsilver corrosion sensors, temperature, and relative humidity.

• The first line shows the screen title and the remaining battery life.• The second line shows the copper sensor “classification” (G1) and the current

cumulative value (3).• The third line shows the silver sensor “classification” (P1) and the current cumulative

value (2).• The fourth line shows the current temperature in Celsius and Fahrenheit.• The fifth line shows the current value for Relative Humidity.• The sixth line shows the date and time in 24 hour format.

ALARM MENUThe Alarm Menu shows the status of the OnGuard 3000 sensors and the main power batteries.The status of each will be shown as “OK” unless there is a problem with one of them. When analarm condition occurs the red LED will light. The temperature (TEMP) and relative humidity (RELH)sensors will show an “L” for “low”, “H” for “high”, or “R” for “rate of change” limit exceeded.The SENS will show a “1” for copper, a “2” for silver, or “1/2” for both if any sensor has failed orreached end-of-life. The BATT entry shows “FAULT” when the battery level falls below 10%.

LOGGER MENUThe Logger Menu shows the log interval. The value may be changed by pressing the UP orDOWN arrows on the keypad. Cycling through the interval values will present options forenabling and disabling the logger, and clearing the logger memory. When the desired option isdisplayed, pressing the ENTER key will implement that option.

VERSION MENUThe Version Menu displays the current revision of the software in the OnGuard 3000.



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ONGUARD PC SOFTWARE (OG3 CONNECT)The OG3 Connect software application provides a convenient way to configure the OnGuard 3000 and extract measureddata. The software is a Microsoft Windows application that utilizes the computer’s USB port for communication. The mostreliable results have been obtained with computers containing a USB 2.0 compatible USB port and Windows XP or XP Prooperating system. The USB cable supplied with the OnGuard 3000 has a standard PC-compatible USB port on one end forconnection to the computer, and a USB Mini-B connector on the other end to connect to the OnGuard. The OnGuardconnection is located on the bottom of the unit to the left of the 10-pin terminal block connection. Be sure to orient theconnector correctly and do not force a connection that does not appear to fit.

The following is a description of the functions and capabilities of the OG3 Connect software. Refer to the PC Software BlockDiagram to view the location of these functions.

FILE > OPEN DATA FILEAny OnGuard 3000 log file that has been previously downloaded and saved on the PC can be opened and viewed with theOG3 Connect program. To open a previously saved file, click on “File” on the Windows menu bar and then select “OpenData File”. A standard Windows “open file” dialog box will open with the default directory being the directory where theOG3 Connect program is installed. Any desired directory can then be located by browsing. The OnGuard 3000 logger fileshave a “.csv” extension. This is a particular form of “text file” and can be opened in Microsoft Excel if additional data analysisis desired.

DEVICE > CONNECTThis function initiates a connection between the PC and the OnGuard 3000 via the PC’s USB port. For best results, the PCshould be “booted up”, but not running any other application programs, including OG3 Connect. With the OnGuard 3000powered up and “awake” (if operating from battery power), plug the USB cable into the OnGuard and then into the PC’sUSB port. If your PC sound is not muted and the volume adjusted so it can be heard, you should hear the familiar USB“connect beeps” from the PC indicating a connection has been made. Now start the OG3 Connect software. On the“Device” menu pull-down, click on “Connect”. In the lower left corner of your PC screen you should see the word“Connected” after a few seconds. You can now interact with the OnGuard 3000.

DEVICE > CAPTURE LIVE DATAThis function opens the OG3 Connect graphing program and data collection table. Data points are graphed and logged asthey are transmitted from the OnGuard at one minute intervals. The resulting graph and data can be saved to a file for laterreview. When this function is selected you will be prompted to enter a filename and location where the data will be saved.Each reading transmitted from the OnGuard 3000 will be displayed and saved to the file.

DEVICE > DOWNLOAD LOGGER MEMORYThis function downloads the stored logger data from the OnGuard 3000 and opens the OG3 Connect graphing program anddata collection table. Data points from the downloaded file are displayed in a table and graphed. The resulting graph anddata file can be saved to the PC.

DEVICE > ERASE LOGGER MEMORYThis function is used to clear the logger memory.

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DEVICE > CONFIGUREThis function is used to configure the OnGuard 3000. This includes the data logger, the date and time, corrosion sensors,and temperature and relative humidity limits. A summary of the available functions is listed below:

Logger TabLogger On/OffLogger Interval (1, 2, 5, 10, 15, 30, 60, 120 minutes)Buttons: Read Device, Apply Changes

Clock/Calendar TabTime: HH:MM:SSDate: Month, Day, YearButtons: Read Device, Apply Changes

Sensors TabSensor TypeRange: Std (Fixed) or CustomLevels (G1, G2, G3, GX, P1, P2, P3, PX)Buttons: Read Device, Apply Changes

Temp & Humidity TabTemp: Low, High, Rate, (Scale: Celsius or Fahrenheit)Humidity: Low, High, RateButtons: Read Device, Apply Changes

DEVICE > CALIBRATE TEMPERATUREThis function is used to calibrate the temperature sensor in the OnGuard 3000. Set the scale to “degF” or “degC”, enter thecurrent temperature and click “OK”

DEVICE > CALIBRATE HUMIDITYThis function is used to calibrate the relative humidity sensor in the OnGuard 3000. Enter the current relative humidity andclick “OK”.

WINDOWThis function shows what OG3 Connect program modules are currently active.

ABOUTThis function provides the version of the OG3 Connect software.

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INFORMATION ON SETTING CORROSION CLASSIFICATIONSCorrosion Classifications can be set to establish parameters for measuring the rate of corrosion against either formalcorrosion standards or user-developed standards.

To set Corrosion Classifications using the OG3 Connect software, select “Device”, then “Configure”, then the “Sensors” tab.

There are two Corrosion Classifications available for copper: ISA and Copper Custom.

The ISA Table conforms to ISA S71.04-1985 and cannot be altered. To view the ISA Table, click the pull-down menu beside“Range” and select “Std(Fixed)”. The ISA values will fill the table for that sensor.

The second choice for the Range is “Custom”. The custom table allows the user to set the maximum limit for each corrosionclass. Once “Custom” has been selected, fill in the “Max” value for each classification level. The minimum value for the levelwill be chosen automatically by the OnGuard 3000. The values will be saved when the “Apply Changes” button is pressed.

There are also two Corrosion Classifications available for silver: Purafil and Silver Custom.

Because silver is not addressed in the ISA Standard, Purafil created a classification for silver, which has the same range limitsas the copper standard. This table, listed as “Std(Fixed)”, cannot be altered.

The silver custom table allows the user to set the maximum limit for each corrosion class in Å per 24 hrs. To select the customtable for the silver sensor select the “Custom” entry in the “Range” pull-down menu. The minimum value for the level willbe chosen automatically by the OnGuard 3000. The values will be saved when the “Apply Changes” button is pressed.

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ONGUARD 3000 (OG3) 4-20 mA CALIBRATIONINTRODUCTIONOG3 air monitors equipped with version “F” hardware and version 2.2 firmware (or later) are capable of 4-20 circuitcalibration via OG3_Connect PC software (version 2.22 or later).

The 4-20 circuits are set by firmware default values such that the current loop levels will be very close to 4 and 20 milliampson average. However, due to slight performance differences in electronic components, the firmware default levels may not beclose enough for a particular application. Each of the four circuits may be individually calibrated by the end-user. It should benoted that even though the calibration adjustments can set the levels to within 0.005 mA, the circuits may drift slightly aftercalibration due temperature change or other external forces.

PREPARATION1. Connect the OG3 to external power. Refer to Table 1 below for connector information. The OG3’s 4-20 circuits will

not operate under battery or USB power and will operate only when external power is applied.

2. Connect a suitable ammeter to a selected channel on the OG3. Refer to Table 1 below for connector information.At this point, the current displayed on the ammeter will represent the selected channel’s output (e.g. humidity onchannel 4).

Table 1, Connector Pin Assignments

3. Attach the OG-3 to the PC with an appropriate USB cable and run the OG_Connect PC Application.

4. On the PC Application, select Configure from the Device option onthe menu as shown in Figure 1:

5. In the Device Configuration window, select the far right tab labeled4-20 Calibration. At this point, the current displayed on theammeter will represent the output channel (1-4) and level (min ormax) as selected on the 4-20 calibration window.

The OG3 will hold the selected level, bypassing normal 4-20functionality, for a period of 60 seconds every time an adjustmentselection from this window is chosen.

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Signal Positive GND/CommonChan 1 (Copper) 2 1Chan 2 (Silver) 4 3

Chan 3 (Temperature) 6 5Chan 4 (Humidity) 8 7External Power 10 9

Figure 1, Accessing device configuration options

Figure 2, Calibration window operation

OPERATION

OUTPUTSelecting any of the output (Channel 1 through Channel 4) will force the currently selected level (Minimum or Maximum) tobe output on the selected channel.

LEVELSelecting either option (Minimum or Maximum) will force the currently selected channel to its minimum or maximum level.

ARROW KEYS Selecting these will adjust the current on the selected channel up or down by an amount corresponding to the level shownin the drop-box immediately below.

STEP AMOUNT This defines the step size affected by the arrow keys. The steps are roughly as follows:

X-Fine 0.005 mAFine 0.05 mAMedium 0.15 mACourse 0.50 mA

UNDOReset will undo any adjustments made since the last time Store Changes was selected for the selected channel and selectedlevel. For example, if Channel 1 and Minimum are selected, clicking Reset will clear changes made to channel 1 minimum.Channel 1 Maximum and other channels will not be affected.

STORE CHANGESThis stores the changes for the currently selected channel and level. For example, if Channel 1 and Maximum are selected,clicking Store Changes will store the changes made to the maximum level of channel 1, channel one’s minimum level andthe other channel calibrations will not be stored. This allows the user to change any single attribute of all channel’s minimumand maximum levels; however, Store Changes must be selected for each channel and that is level intended to be calibratedbefore exiting the calibration window.

PROCEDURE:1. Follow the setup steps listed in the Preparation section above. 2. Familiarize yourself with the operation of the calibration window controls as shown above. 3. For each channel:

a. Connect a suitable ammeter to the channel’s output pinsb. Select the desired channel in the calibration window. c. Select Minimum (4 mA)d. Verify that the ammeter reads 4.00 mA. Adjust up or down using the arrow keys until the desired level is

obtained while using the step amount control to achieve an appropriate adjustment size. e. Select the Store Changes button to store the calibration adjustment.f. Select Maximum (20 mA)g. Verify that the ammeter reads 20.00 mA. Adjust up or down using the arrow keys until the desired level is

obtained while using the step amount control to achieve an appropriate adjustment size. h. Select the Store Changes button to store the calibration adjustment.

4. Exit the calibration window and disconnect the ammeter. The OG3 will continue normal 4-20 circuit operation 60seconds after the most recent (calibration window) button-press.

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onguard 3000 users manual

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