USER MANUAL JEROME® J405 MERCURY VAPOR ANALYZER July 2014 Firmware Version 1.34 ARIZONA INSTRUMENT LLC 3375 N Delaware Street | Chandler, AZ 85225 USA 800.528.7411 | 602.470.1414 | f 602.281.1745 www.azic.com Email: General – azi@azic.com International – intl@azic.com Customer Service – support@azic.
JEROME® J405 Mercury Vapor Analyzer Operation Manual PROPRIETARY RIGHTS NOTICE This manual contains valuable information and material developed by Arizona Instrument LLC for use with the Jerome® J405 Mercury Vapor Analyzer. No part of this manual can be reproduced or transmitted in any form or by any means, electronic, mechanical or otherwise.
Table of Contents 1. 2. 3. 4. UNPACKING THE INSTRUMENT ...........................................................................5 INTRODUCTION .........................................................................................................7 JEROME® J405 TECHNICAL SPECIFICATIONS.................................................9 PRINCIPLE OF OPERATION ...................................................................................10 Zero Air Filter (AZI P/N Z2600 3905) .........................
Functional Test Procedure ............................................................................................... 60 J405 FTK Instrument Response Chart ............................................................................ 61 Functional Test Troubleshooting..................................................................................... 62 12. WARRANTY ................................................................................................................
1. UNPACKING THE INSTRUMENT This manual contains details that will optimize the results and the life of your instrument. Read and refer to the manual for complete details on operation, maintenance and troubleshooting, special voltage inputs and data output. The Jerome® J405 is easy to operate and ready for use upon receipt from the factory. • Remove the instrument from the packing material. Retain all packaging materials for any future shipment of the instrument.
• • • • • • • Perform a sensor regeneration by following these steps: Connect the AC power supply/charger between the matching (DIN) connector on the back of the J405 and an AC power outlet or connect the external battery pack to the back of the J405. If the J405 is turned off, press the I/O power button to turn the instrument on. Press the RIGHT arrow button (►) to enter the main menu. Press the DOWN arrow button (▼) to move the cursor to Regen.
2. INTRODUCTION The Jerome® J405 Mercury Vapor Analyzer is an ambient air analyzer with a range of 0.5 to 999 micrograms of mercury vapor per cubic meter (µg/m3 Hg). CAUTION: The Jerome® J405 is for gaseous vapor use only. DO NOT allow the probe or the instrument's intake to be exposed to any liquid, dust or other foreign material. The J405 is designed to be easy to operate for quick and accurate analysis of mercury vapor levels. It has few maintenance requirements.
Applications • • • • • • • • • Regulatory detection compliance Regulatory clean up compliance Ambient air analysis Quality control Scrubber efficiency testing Accuracy check for other mercury vapor monitors and control systems Mercury vapor source detection Leak detection Portable mercury vapor detection. (The Jerome® J405 is operated from an internal 12V battery source. For charging the batteries, an external AC power supply/charger is included.
JEROME® J405 TECHNICAL SPECIFICATIONS 3. Display Range* Resolution Response time-sample mode Response time-survey mode Flow rate Power requirements Fuse Internal battery pack Operating environment Case construction Dimensions Weight Digital meter display Data storage capacity Output Certifications Units: µg/m3 Units: mg/m3 0.5 μg/m3 to 999 μg/m3 0.001 mg/m3 to 0.999 mg/m3 0.01 μg/m3 Hg 0.001 mg/m3 Hg 16 seconds 2 seconds 750 ± 50 cc/min (0.75 ± 0.
4. PRINCIPLE OF OPERATION The heart of the J405 is the well-proven gold film sensing technology. A thin gold film, in the presence of mercury vapor, undergoes an increase in electrical resistance proportional to the mass of mercury vapor in the sample. When the SAMPLE button is pressed, an internal pump pulls ambient air through a scrubber filter (AZI P/N: 600-0262) and into the flow system. After three seconds, the sample solenoid bypass opens, closing off the scrubber filter from the flow system.
The instrument’s microprocessor automatically re-zeroes the digital meter at the start of each sample cycle and holds the meter reading until the next sample cycle is activated, thus eliminating drift between samples. During the sample mode cycle, a sensor saturation meter on the LCD represents the percentage of sensor saturation, or adsorbed mercury collected on the gold film. With use, the sensor becomes saturated and needs to be cleaned.
5. INSTRUMENT OPERATION J405 Main Screen Display The J405 Main Screen is depicted below, followed by explanations of the labeled items. SYSTEM TIME – As set in the SYSTEM menu. (See SYSTEM menu on page 20). BATTERY – Indicates current charge level and charging status (See Charging Internal Battery on page 28) SOUND ICON – Indicates if the audible alarm is turned on or muted, as set in the SYSTEM menu. (See SYSTEM menu on page 20). SYSTEM DATE – As set in the SYSTEM menu. (See SYSTEM menu on page 20).
J405 Back Panel Connections The above-labeled connections are available from the back panel of the J405. If the USB option has not been activated, the USB ports will not be present. Contact your AZI Sales Representative for information on the USB option. POWER CONNECTOR – Connect the supplied AC power supply/charger, the optional external battery pack (AZI P/N: 990-0214), or the optional car accessory jack (AZI P/N: 200-0170) here to provide power to the instrument or to recharge the battery.
J405 User Interface Main Menu Structure NOTE: The main menu also contains a selection labeled “Factory.” This option is for AZI factory use only and is not accessible by the end user.
A USB keyboard (AZI P/N: 990-0230) can be used to navigate the menu system and for data entry for items such as Location Names. Connect the USB keyboard to one of the two USB Type “A” ports on the back of the instrument. Either upper or lower case characters may be entered when using a USB keyboard, while only upper case letters are available from the J405 keypad. SAMPLE menu SAMPLE MODE The Sample Mode setting provides the choice between auto-sampling and manual sampling.
Interval Samples on the: Examples: 1 minute 1-minute marks 12:00, 12:01, 12:02, 12:03, 12:04, 12:05, 12:06, etc. 2 minutes 2-minute marks 12:00, 12:02, 12:04, 12:06, 12:08, 12:10, 12:12, etc. 5 minutes 5-minute marks 12:00, 12:05, 12:10, 12:15, 12:20, 12:25, 12:30, etc. 10 minutes 10-minute marks 12:00, 12:10, 12:20, 12:30, 12:40, 12:50, 1:00, etc. 15 minutes Quarter hour 12:00, 12:15, 12:30, 12:45, 1:00, 1:15, 1:30, etc.
REGEN menu The sensor saturation meter on the main screen (to the right of s. sat) indicates the current level of saturation of the sensor with mercury. Clean/Regenerated Sensor Partially Saturated Sensor Saturated Sensor – Regen Required When the sensor becomes saturated with mercury, as indicated by the sensor saturation meter, a regeneration (regen) must be performed on the sensor to release the accumulated mercury, before additional samples can be taken.
SET INTERVAL If auto-sampling is being used (as set in SAMPLE MODE above), the J405 can be configured to automatically perform sensor regenerations at a predetermined interval. Use the ▲and ▼arrows to scroll through the available intervals of 6, 12, 24 and 48 hours and Saturation, and press ENTER/START to save the selected interval.
SAVE TO USB DRIVE Before selecting SAVE TO USB DRIVE, connect the target USB memory drive to either USB TYPE “A” PORT on the back panel of the J405. When ENTER/START is pressed, all of the stored data on the J405 will be transmitted to the target drive as a comma-delimited text file. See Retrieving Data on page 29 for more information. NOTE: The J405 is NOT compatible with USB memory drives that have the U3 program pre-installed. Do not use USB memory drives that have the U3 program with the J405.
SYSTEM menu The SYSTEM menu is password protected to prevent unwanted or accidental changes to operating parameters. The default initial password is AZI, but should be changed to something unique if restricted access to the SYSTEM menu is desired. The password can be up to 10 characters long. When the SYSTEM menu is selected from the Main Menu, the J405 will prompt for the password. Input the password using ▲ and ▼ to change the alphanumeric character, and ► and ◄ to move between characters.
VIEW SENSOR STATS Use VIEW SENSOR STATS to display the current saturation level of the sensor, the number of regenerations performed on the sensor, and the total number of samples read by the sensor. Press any key to exit the screen when finished. SET SYSTEM TIME The J405 maintains the system time using a 24-hr clock format. Use the ▲and ▼arrow keys to change the value in the field where the cursor is flashing.
Daily Operations Before each day's use of the Jerome® J405, perform the following steps to verify proper instrument operation: • Press the power I/O button. The display will light up and show instrument serial number and software revision. If necessary, press ESC to clear any calibration reminders. Call AZI Customer Service at 800-528-7411 or 602-470-1414, or e-mail support@azic.com, to schedule instrument calibration. The digital meter displays 0.00 μg/m3.
Sensor Regeneration Sensor regeneration is needed to clean the J405 sensor of any accumulated mercury vapor and to prolong the life of the sensor. This simple procedure should be done: • At the beginning of the day on which the instrument is to be used. • During the day when the sensor becomes saturated. • At the end of the day before storing the instrument. • At a minimum of 30-day intervals while the instrument is in storage.
Sample Mode This mode, used for standard operation, produces optimum accuracy with the Jerome® J405. See JEROME® J405 TECHNICAL SPECIFICATIONS on page 9 for the accuracy specifications. • • • • • • Press the power I/O button. The display will light up and briefly show the instrument serial number and software revision. If necessary, press ESC to clear any calibration reminders. Next, the digital meter displays 0.00 µg/m3. If the battery meter is empty and flashing, recharge the battery.
Survey Mode The survey mode takes samples and displays the result every 2 seconds automatically. Use this mode to locate mercury spills or to assess areas of potentially high mercury concentrations. Sampling in the survey mode is not as accurate. • • Press the power I/O button. The display will light up and show the instrument serial number and software revision. If necessary, press ESC to clear any calibration reminders. Next, the digital meter displays 0.00 μg/m3.
Operating on AC Power or Generator • For stationary use, the J405 may be operated on AC power. Operating the instrument on AC power at all times eliminates the need for the battery pack and its necessary maintenance. The battery may be disconnected internally or removed completely whenever the instrument is operating on AC power. Operating on Internal Battery Power For portable use, the J405 may be operated on battery power.
Medium Frequency user: Once per month usage. For this type of user, the instrument should be plugged in for a minimum of three (3) hours prior to use. Otherwise, the instrument can be left unplugged. Infrequent user: Greater than one month between uses or long term storage. For this type of user, the instrument should be fully charged and the battery should be disconnected. Make sure nothing is plugged into the back of the J405, then remove the front 2 screws near the intake and open the instrument.
When operating using the external battery pack, the J405 will shut down after twenty (20) minutes of non-usage. However, if the instrument is running in Survey Mode or Auto-Sampling mode, the instrument will not shut off after twenty minutes. If the J405 is reading low levels of mercury in Survey or Auto-Sampling mode, it will continue to sample until the battery runs out.
Retrieving Data On instruments that have the USB Communications option, sample data can be transmitted from the J405 for analysis using the USB connections on the back panel of the J405. Data may be transmitted directly to a PC, saved to a USB drive plugged into the J405 or printed to an AZI printer connected to the J405. See the DATA menu section on page 18 for the specific data transmission options available. If the USB Communications option has not been purchased, the USB ports will not be present.
Instrument I/O Interface The J405 I/O port is a DB-25F connector on the back of the instrument that provides numerous specialized functions for specific industrial applications and for factory use. System integration utilizing the 4-20mA output feature is the most common use of the I/O port. NOTE: This is NOT a printer connection. It is a specialized interface. Connecting any non-AZI authorized device to this connector may damage both the device and the J405 and may void the warranty on the J405.
To utilize the 4-20mA output, connect the positive wire of your 4-20mA system to pin 19 of the I/O port on the J405, and the negative wire to pin 20. The number of each pin of the I/O port is labeled on the port itself, and the locations of pins 19 and 20 can also be seen in the diagram below. The 4-20 mA connection is passive and must be powered by an external 12 V DC power supply. An example setup is shown below. In this example, the 5.
6. MAINTENANCE Preventive Maintenance Schedule To keep the Jerome® J405 operating at peak performance, follow the maintenance schedule below as a guide. Since maintenance is more a function of application and amount of use rather than time, your requirements may be different from the listed schedule. Call AZI Customer Service at 800-528-7411 or 602-470-1414, or e-mail support@azic.com for additional guidance for your environment and operation. PART/COMPONENT Charge battery Change .
Flow System The Jerome® J405's flow system is the crucial link between the sensor and the sample. For the instrument to perform correctly, the flow system must be properly maintained. The user maintainable components of this system are the intake filter (.25 inch fritware), an AG Filter, two scrubber filters and connecting tubing. NOTE: Make sure nothing is plugged into the back of the instrument before opening the instrument case.
AG Filter Check The increased sensitivity of the Jerome® J405 requires the replacement of the AG filter (6000293) every 500 samples to ensure the accuracy of the readings. If your application will require in excess of six (6) months to reach 500 samples, the AG filter should still be changed every six months along with the other internal filters. To check the AG filter: • Take 5 samples with Zero Air Filter (Z2600-3905) connected to front of instrument.
#1 #2 #3 Internal Filters 1. Scrubber Filter (1 elbow, 1 straight barb) 2. Scrubber Filter (2 elbow barbs) 3. AG Filter Part Number Z2600 3930 600-0262 600-0293 Internal Filters • • • • • • • • • • Replace the internal filters after six (6) months of use, or as needed. The AG filter should be replaced every six (6) months or every 500 samples, whichever comes first, based on your instrument usage schedule. Press the I/O button to turn the power OFF and unplug the power cord.
Replacing the Battery Pack • • • • • • • • • • • Press the I/O button to turn the power OFF. Unplug the power cord. Use a Phillips screwdriver to remove the four (4) screws securing the battery panel as shown above. After removing the screws, carefully set the panel to the side. Note that it is still connected to the instrument via the power connector. Slide the battery pack out of the J405. Disconnect the battery connector to detach the old battery.
7. CALIBRATION Factory Calibration Service The Jerome® J405's gold film sensor is inherently stable and does not require frequent calibration. The interval between calibrations depends upon the application and frequency of use; however, the recommended interval is every 12 months. The Jerome® J405 has been factory calibrated using laboratory equipment containing NIST traceable permeation tubes.
8. J405 TROUBLESHOOTING Symptom Possible Cause Solution Instrument does not turn ON. Discharged battery or Recharge battery for a minimum of 3 hours. Refer to page 28. Battery will not hold a charge. Dead battery. Replace battery. Refer to page 36. Instrument does not turn on when connected to AC power supply/charger. Open fuse. Wait for fuse to automatically reset itself. Insufficient power. Use a voltmeter to verify there is power to the AC outlet. Internal component failure.
Symptom Possible Cause Solution Low response or erratic readings after a long period of non-use. May need a second regeneration 1. Wait 30 minutes and perform cycle. another sensor regeneration. 2. Test with FTK. Refer to page 57. 3. If still unresponsive, call AZI Customer Service at 800-5287411 or 602-470-1414 for assistance. False readings Extremely cold or extremely warm air sampled into unit. If sampling under these conditions, install Zero Air Filter in intake.
Symptom Possible Cause No USB Drive is connected or USB USB drive not connected or Drive is full. USB drive full Battery Fault Solution Make sure space is available on USB drive and drive is connected. 1. Turn off the J405, then disconnect the AC power supply/charger from the J405. 2. Turn the J405 back on, then reconnect the AC power supply/charger to the J405. Calibration due soon Call AZI Customer Service at 800-528-7411 or 602-470-1414 to schedule factory calibration.
Potential Interferences Potential interferences to the Jerome® mercury vapor analyzers are rare and most of these can be eliminated with proper maintenance procedures. However, erroneously high readings can sometimes occur.
9. ACCESSORIES & MAINTENANCE PARTS PART # ITEM DESCRIPTION Y405-0901 J405 Accessory Kit, Communications Package Instruments (See pictures beginning on page 43) 1400 2002 Probe 1400 3010 Tubing Adapter, 1/4” to 1/8” 2600 3039 Filter, Fritware, 0.25” (1 pack of 20 fritware filters) Z2600 3905 Filter, Zero Air Filter 200-0165 USB Cable, Type A to Type B, 6 ft.
990-0217 Hard Side Carry Case Includes a molded case with die cut foam rubber inserts to hold the Jerome® J405 and accessories. 990-0220 Soft Side Carry Case Includes a shoulder strap for easy carrying, a clear plastic window over the instrument display, and pockets to hold supplies or accessories.
200-0143 Battery Pack Assembly 200-0170 Car Accessory Cable 990-0225 10-to-1 Dilution Module 990-0214 External Battery Pack 600-0293 Filter, AG Filter 990-0193 Filter, Ammonia Filter AZI Customer Service 800-528-7411 or 602-470-1414 Page 44 of 64
Z2600 3940 Filter, Chlorine Filter 2600 3039 Filter, Fritware, .
A2600 0902 Stopper Assembly A2600 0903 Syringe Assembly 2600 0022 Syringe Needles, 22 Ga. 1400 3010 Tubing adapter 345-0050 Tygon® tubing 1/8" I.D. (1 foot) 200-0165 USB Communication Cable (Type A to Type B) 990-0230 USB Keyboard For current prices and delivery information, call AZI Customer Service at (800) 528-7411 or (602) 470-1414.
10. APPENDIX A – USB/HYPERTERMINAL SETUP Installing the J405 USB Driver Note: The AZI USB Driver is compatible with Windows® XP (32-bit), Windows® Vista (64-bit) and Windows® 7 (32 and 64-bit). However, the HyperTerminal program is only included in Windows® XP. If the Jerome® J405 CD is available: • Insert the CD in the PC’s CD-ROM drive. • Use Windows® to browse to the CD, locate the driver file (AZI_USB_Driver.zip), and copy it to your desktop.
3) Windows® may display one or more messages indicating that the driver has not passed Windows® Logo Testing. This driver being installed is a generic Communications Port driver that is part of Windows® (usbser.sys), so it is safe to ignore this warning. Click “Continue Anyway” to install the driver. 4) Click Finish.
5) Power on the J405 and connect it to the target computer using the included USB cable (AZI P/N: 200-0165). Windows® will detect the J405 and its Communications Port and automatically start the New Hardware wizard. The following pictures and descriptions correspond to a Windows® XP installation. (If using Windows® Vista or Windows® 7, this process is abbreviated and requires minimal user interaction. Watch for the two info balloons to appear and then proceed to page 52.
7) Select “Install the software automatically”, and click Next. 8) Windows® may display a message indicating that the driver has not passed Windows® Logo Testing. This driver being installed is a generic Communications Port driver that is part of Windows® (usbser.sys), so it is safe to ignore this warning. Click “Continue Anyway” to install the driver.
9) Windows® will copy a file and finish the wizard. Click Finish. 10) Windows® will then indicate that the driver has been successfully installed.
Using HyperTerminal to receive data from the J405 1) The J405 should be connected to the PC’s USB port and powered on before HyperTerminal is launched or HyperTerminal may not see the COM port in use. 2) Start HyperTerminal (Start All Programs Accessories Communications HyperTerminal). If prompted to make HyperTerminal the default telnet application, click No. 3) When prompted for a name for this connection, enter J405 and click OK.
5) Next, a window labeled Connect To will be displayed. Find the last dropdown list in the dialog box labeled Connect using:. Select the last COM port from the list and click OK. 6) Next, HyperTerminal will prompt for Port Settings. These settings do not apply to USB ports, so the default values do not need to be changed. Continue by clicking OK.
7) A blank HyperTerminal screen will be displayed. On the status bar in the lower left hand corner it should say Connected. 8) Select Capture Text... from the Transfer menu on the main HyperTerminal window.
9) HyperTerminal will prompt for a file to save the data to. It is recommended that the data be saved to either the Desktop or My Documents. 10) Go to the J405 and navigate to the DATA menu, then highlight Send to PC and press ENTER/START. 11) You should see your data scrolling in the HyperTerminal window. If you do not see anything in the HyperTerminal window, go to step 13).
12) When the J405 stops sending data, Click HyperTerminal's Transfer menu again and click Capture Text, then Stop 13) If you did not receive any text from the J405: • • • Go to the Call menu, click Disconnect Go to the File menu, click Properties You will see the same window as in step 4) above. Try selecting a different COM port and continue from step 4). Keep trying each COM port in the list.
11. APPENDIX B – J405 FUNCTIONAL TEST KIT If your application requires frequent verification of instrument functionality, this test will benefit you. If the test results fall within the expected range, you may assume the instrument is functioning properly. THIS IS A FIELD CHECK OF THE FUNCTIONALITY OF THE INSTRUMENT. THIS TEST DOES NOT CALIBRATE THE INSTRUMENT. Testing with the Functional Test Kit (FTK) should always be done with the instrument set to display in micrograms per cubic meter (µg/m3).
Mercury Transfer • • • • CAREFULLY pour the mercury into the center of the functional test kit vessel’s opening. ENSURE that no mercury residue is on the outside of the vessel. See the supplier’s Material Safety Data Sheets (MSDS) or call AZI Customer Service at 1-800-528-7411 or 1-602-470-1414 for clean-up instructions. INSTALL the stopper assembly into the functional test kit vessel carefully, to prevent breakage of the thermometer. PRESS the stopper assembly into the vessel to achieve a good seal.
Syringe Technique • • • • • Pull and hold the syringe plunger against the bar-stop. Verify that the black mark on the syringe plunger aligns with the 1cc mark on the syringe barrel. If it does not, the holder assembly must be adjusted. Call AZI customer service at 602-470-1414 or 800-528-7411 for assistance. Insert the needle into the needle-guide of the bottle stopper. Operate the plunger two or three times to pump mercury vapor into the syringe.
• • When “Purging” disappears from the display, release the plunger and allow gravity to feed the mercury vapor into the airstream. If the plunger stops, gently press it completely closed. Remove the syringe needle from the septum. Functional Test Procedure NOTE: Perform the functional test ONLY after sensor regeneration. • • • • • • • • • • Allow the FTK vessel to remain stable at room temperature for at least 2 hours. The temperature range for the test is 16 °C- 24 °C.
• • Repeat the instructions for mercury injection three more times. The readings obtained for the last three 1cc injections should be within ± 5% of each other. Refer to the J405 FTK Instrument Response Chart, below, for the acceptable range. The average of the last three readings should fall within the range shown on the chart. If the average is within range, the JEROME® J405 is functioning properly. • If the last three readings are not within ± 5% of each other, Perform sensor regeneration.
Functional Test Troubleshooting If you do not achieve good results with the functional test procedure, check the following: Results Solution Typically too high Ensure the FTK vessel temperature is stable. Be sure to inject the Hg vapor ONLY after “Purging” disappears from the display (approximately 2 seconds after SAMPLE is pressed). Too Low Ensure there is no oxidation on the mercury drop in the vessel. Gently swirl the mercury drop in the vessel. Replace if necessary.
12. WARRANTY Arizona Instrument LLC (seller) warrants to buyer that Jerome® products delivered pursuant to this agreement shall, at the time of delivery, and for a period of one (1) year thereafter (the Internal Battery Pack, where applicable, is warranted for a period of ninety [90] days only), be free from defects in material or workmanship and shall conform to seller's specifications or such other specifications as seller has agreed to in writing.
TRADEMARK AND COPYRIGHT PROTECTION Jerome®, Arizona Instrument®, AZI® and the stylized AZI are all registered trademarks of Arizona Instrument LLC. Instrument firmware is copyright protected. All specifications subject to change without notice. © Copyright 2006-2014 Arizona Instrument LLC. All Rights Reserved. Sofnolime™ is a trademark of Molecular Products Limited Resisorb® is a registered trademark of Avantor Performance Materials.
