Gas Pup
®
Natural Gas &
Pressure Detection
Instruction 55-9002
Operation & Maintenance
Rev. 1 – December 2003
Product Leadership • Training • Service • Reliability
WARRANTY
Bacharach, Inc. warrants to Buyer that at the time of delivery this Product will be free from defects in material
and manufacture and will conform substantially to Bacharach Inc.’s applicable specifications. Bacharach’s
liability and Buyer’s remedy under this warranty are limited to the repair or replacement, at Bacharach’s
option, of this Product or parts thereof returned to Seller at the factory of manufacture and shown to
Bacharach Inc.’s reasonable satisfaction to have been defective; provided that written notice of the defect
shall have been given by Buyer to Bacharach Inc. within one (1) year after the date of delivery of this Product
by Bacharach, Inc.
Bacharach, Inc. warrants to Buyer that it will convey good title to this Product. Bacharach’s liability and
Buyer’s remedy under this warranty of title are limited to the removal of any title defects or, at the election of
Bacharach, to the replacement of this Product or parts thereof that are defective in title.
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED IN LIEU OF (I)
ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE: AND
(II) ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR
NOT ARISING FROM BACHARACH’S NEGLIGENCE, ACTUAL OR IMPLIED. The remedies of the Buyer
shall be limited to those provided herein to the exclusion of any and all other remedies including, without
limitation incidental or consequential damages. No agreement varying or extending the foregoing warranties,
remedies or this limitation will be binding upon Bacharach, Inc. unless in writing, signed by a duly authorized
officer of Bacharach.
A Instruction 55-9002
To Register Your Warranty, Visit
www.bacharach-inc.com
Notice:
Product improvements and enhancements are continuous, therefore the specifications and information
contained in this document may change without notice.
Bacharach, Inc. shall not be liable for errors contained herein or for incidental or consequential damages in
connection with the furnishing, performance, or use of this material.
No part of this document may be photocopied, reproduced, or translated to another language without the prior
written consent of Bacharach, Inc.
Copyright © 2001-2003, Bacharach, Inc., all rights reserved.
BACHARACH
®
and Pup® are a registered trademarks of Bacharach, Inc.
All other trademarks, trade names, service marks and logos referenced herein
belong to their respective companies.
Declaration of Conformity
Manufacturer’s name: Bacharach, Inc.
Manufacturer’ address: 621 Hunt Valley Circle
New Kensington, PA 15068-7074
European operations: Bacharach Europe
Sovereign House, Queensway
Royal Leamington Spa
Warwickshire CV31 3JR
United Kingdom
Product name: Gas Pup
conforms to the following specifications:
European Directive 89/336/EEC
EN 50081-1: 1992 (Emissions)
EN 50082-1: 1998 (Immunity)
EN 61000-4-2: 1995 (Electromagnet)
EN 61000-4-3: 1995 (Electromagnet)
i
Gas Pup
Instruction 55-9002
Contents
Contents
Safety Information ....................................................................... iii
Introduction..................................................................................... 1
General Description ................................................................................1
Components .............................................................................................2
Natural Gas Detection .......................................................................2
Pressure Detection .............................................................................2
Sample Pump .....................................................................................2
Batteries .............................................................................................2
Case.....................................................................................................2
Control Panel Description ......................................................................3
Gas and Pressure Fittings ......................................................................4
Technical Characteristics............................................................. 5
Operation .......................................................................................... 6
Operating Precautions (Please Read) ....................................................6
Battery Installation.................................................................................7
Turning ON the Gas Pup........................................................................8
Turning OFF the Gas Pup ....................................................................10
Backlighting ..........................................................................................11
Battery Voltage Check ..........................................................................11
Gas Operating Mode .............................................................................11
Auto-Ranging....................................................................................12
Fixed HI% Range..............................................................................12
PPM Range .......................................................................................13
LO% (Low Percent) Range ...............................................................13
HI% (High Percent) Range...............................................................14
Pressure Operating Mode .....................................................................14
Selecting the Pressure Mode............................................................14
High Pressure Mode.........................................................................16
Low Pressure Mode ..........................................................................16
Delta Pressure Mode ........................................................................16
Using the Probe’s Filter Chamber........................................................18
Foam Filter Element – Particulate Filtration.................................18
Charcoal Filter – Petroleum Vapors vs. Combustible Gases..........18
Water/Filter Trap ..................................................................................20
Error Messages......................................................................................21
ii
Gas Pup
Instruction 55-9002
Contents
Calibration ..................................................................................... 22
Gas Calibration Equipment Setup .......................................................22
Gas Calibration Procedure ...................................................................23
Pressure Sensor Check .........................................................................27
Maintenance................................................................................... 28
Batteries ................................................................................................28
Sampling Probe .....................................................................................28
Gas Inlet Filter Replacement ...............................................................29
Pump Replacement ...............................................................................29
Combustibles Sensor Replacement ......................................................30
Leak Check Basics ................................................................................30
Parts & Service.............................................................................. 32
Replacement Parts ................................................................................32
Accessories.............................................................................................33
Service Centers .....................................................................................34
Safety
Safety is essential in the use and maintenance of Bacharach equipment.
Therefore this manual and any marking on the instrument provide
important safety information concerning the operation, care, and maintenance of this instrument.
All operating and maintenance personnel should read and understand the
contents of this manual before operating or maintaining the instrument.
Observe all of the safety information provided.
Safety Alert Symbol
This symbol together with the word WARNING or CAUTION is used to
call a user’s attention to hazards or unsafe practices that could result in
injury or property damage. The message that follows provides information for preventing or avoiding the hazard.
WARNING: Informs the user of hazards or unsafe practices that
if not avoided could result in severe personal injury or death.
CAUTION: Informs the user of hazards or unsafe practices that
if not avoided could result in personal injury or property damage.
Purpose of Manual
This instruction manual is intended to familiarize all personnel with the
safe operation and maintenance procedures for the Bacharach Gas Pup.
Please retain this manual for future reference.
Gas Pup Safety
iii
Instruction 55-9002
Notes:
iv Instruction 55-9002
Gas PupSafety
Instruction 55-9002 1
Gas Pup
Introduction
Introduction
General Description
The Bacharach Gas Pup (Figure 1)
is a natural gas detection instrument designed for general leak
detection, barholing operations,
regulator pressure checks, and line
pressure integrity operations. It
offers measurement of natural gas
(as methane) in the following three
ranges:
• PPM (Low) Range: Gas level
displayed in 0 to 2500 ppm as a
bar graph, allowing visual indication of the peak reading. Useful
for locating leaks in piping.
• LO% (Mid Percent) Range:
Measures natural gas in the
range of 0.2–5.0% by volume,
which corresponds to the lower
explosive limit (LEL) of methane.
• HI% (High Percent) Range: 0–100% by volume is useful in “pin
pointing” leaks in underground piping through barhole testing
The Gas Pup also features three pressure modes: High (0 to 99 psig);
Low (–9.9 to 9.9 psig); and Delta (displays a pressure change in the range
of ±9.9 psig from any reference pressure between 0 and 90 psig).
Three ‘AA’ batteries power the instrument. Pressing the key for at
least 1 second turns the instrument ON; after which, the battery voltage
is briefly displayed, followed by the gas and pressure sensors being
zeroed, and then followed by the display of the detected gas level.
The Gas Pup’s gas display is auto ranging, automatically switching
between its PPM, LO%, and HI% ranges as the detected gas level rises
and falls. The Gas Pup’s pressure-operating mode is selected by pressing
the key while the word “GAS” is being displayed during the
instrument’s warm-up period.
Figure 1. Gas Pup shown with
Probe and Coiled Tubing
Gas Pup
2 Instruction 55-9002
Introduction
Components
Natural Gas Detection
The instrument’s PPM and LO% ranges use a catalytic-bead detection
circuit, which is the most widely accepted method of detecting combustible gases. The HI% range uses the thermal-conductivity method of
detection, which is a reliable method for measuring the concentration of
one gas in a second gas (methane in air).
Pressure Detection
The instrument contains a solid-state pressure sensor that supports the
instrument’s three pressure modes (High, Low & Delta). The optional
Pressure Hose Kit accessory with fittings (P/N 55-0038) can be used to
connect the instrument’s quick-connect pressure fitting to the pressure
source.
Sample Pump
An internal sample pump draws a gas sample into the instrument for
analysis. This is a convenience in the LO% and HI% gas ranges, providing
a more reliable and accurate test of gas levels. It is also important in the
PPM range to achieve a stable gas reading at low gas concentrations.
The sample pump includes a flow-failure function. If the flow is blocked
(e.g., clogged filter or crimped hose), the display will blink the letters
“F P” in the READING window. When the pump returns to normal
operation, the display stops blinking.
Batteries
Three ‘AA’ alkaline batteries supply power to the instrument. A fresh set
of batteries will typically last 6–8 hours, depending on how the instrument is used. The batteries are housed in a battery block internal to the
instrument, and are protected with a metal cover and retained by two
thumbscrews. This design allows the batteries to be quickly replaced in
an area known not to contain explosive gases.
Case
The instrument is housed in an anodized extruded aluminum case. The
instrument is rugged, resistant to water and electromagnetic interference. Rubber-bumper guards provide impact protection on both ends of
the instrument.
Instruction 55-9002 3
Gas Pup
Control Panel Description
Two pushbutton controls and a large LCD are conveniently located at the
top of the instrument. The backlit LCD provides highly readable indications of natural gas or pressure in any lighting condition ranging from
direct sunlight to total darkness.
The control panel consists of the following three windows and two
pushbutton keys:
• READING Window: A two-digit display that is used to primarily display
the concentration of natural gas in the LO% and HI% gas ranges. The
READING window also displays pressure readings when the instrument is operating in any one of its three pressure modes.
Introduction
Figure 2. Controls and Indicators
Bar Graph Window
(active only in the HI%
and ppm ranges,
showing 25% gas)
READING Window
(showing 25% gas)
RANGE Window
(range pointer showing
that instrument is in its
HI% range)
Range Identifiers
Function Key
Power ON/OFF Key,
plus Backl ight ON/OFF
Gas Pup
4 Instruction 55-9002
• Bar Graph Window: Provides a real time moving display of the natural
gas concentration to give a better ‘feel’ of when the gas level has
reached a peak. The bar graph is active only in the PPM and HI%
ranges.
• RANGE Window: Identifies the range in which the instrument is
currently operating. This is accomplished by means of a pointer, which
in conjunction with range-labels printed on the display overlay, define a
range for the gas reading.
• Key: Turns the instrument, and also the backlight, ON and OFF.
• Key: Changes the instrument’s function as determined by its current
operating mode, thus allowing a variety of functions to be selected with
just one pushbutton. Refer to text in this manual’s Operating section for
details.
Gas and Pressure Fittings
Two quick-connect fittings (Figure 3) provide convenient connections to
the gas probe and pressure hose assemblies.
The gas fitting mates with a quick-connect female plug, while the pressure fitting mates with a quick-connect male plug.
Introduction
Figure 3. Gas and Pressure Fittings
Gas
Fitting
Pressure
Fitting
Instruction 55-9002 5
Gas Pup
Technical Characteristics
Measurement Ranges:
Natural Gas ........................... PPM: 0 to 2500 ppm
LO%: 0.2 to 5.0% volume gas
HI%: 0 to 100% volume gas
Pressure:
High .................................... 0 to 99 psig
Low...................................... ±9.9 psig referenced to atmospheric
pressure
Delta.................................... ±9.9 psig from any reference pressure
point between 0 and 90 psig
Accuracy:
Natural Gas ........................... PPM: (not applicable)
LO%: ±0.3% gas
HI%: ±3% gas
Pressure: ................................ ±5% of Reading
Warm Up Time ........................ 1 minute
Response Time:
Gas.......................................... <20 seconds to 95% of final value
Pressure ................................. <5 seconds to 95% of final value
Operating Environmental Conditions:
Temperature .......................... –4 to 122 °F (–20 to 50 °C)
Humidity ................................ 10 to 95% R.H. (non-condensing)
Air Pressure........................... 1 Standard Atmosphere, ±10%
Position .................................. Any
Storage Environmental Conditions:
Temperature .......................... –22 to 122 °F (–30 to 50 °C)
Humidity ................................ 10 to 95% R.H. (non-condensing)
Position .................................. Any
Size............................................ 4.7 x 2.3 x 3.7 in. (11.9 x 5.8 x 9.4 cm)
Weight ...................................... 25 oz (712 g)
Batteries .................................. Qty 3, ‘AA’ alkaline
Battery Life............................. Typically 6–8 hours of continuous opera-
tion, and well over a week of operation
when used from 50 to 60 minutes a day
Agency Approvals ................. MET lab certified to UL913 and CSA
C22.2-157, intrinsically safe for use in
Class I, Division 1, Groups A, B, C & D
hazardous areas
Technical Characteristics
Gas Pup
6 Instruction 55-9002
Operation
Operating Precautions
(Please Read)
To ensure that the gas sensor is properly zeroed at startup, the Gas Pup
must be turned on in fresh air (free of combustible gases or vapors).
Before using the Pup to detect gas, ‘bump test’ the instrument by applying a known concentration of gas to the instrument’s gas inlet port, and
then observing that the instrument responds to the applied gas in a
positive manner. The optional Response Check Gas bottle (P/N 51-1816) is
recommended for this purpose.
Calibrate the instrument about every 30 days to assure its accuracy. The
frequency of calibration, however, may change depending on how often
the instrument is used and the amount of gas that was sampled. Create a
maintenance log to keep track of when an instrument was calibrated, and
then use this log to help develop a calibration schedule. For example, an
instrument that fails its calibration after only being calibrated a single
time should be calibrated more often.
Avoid sampling leaded gasoline vapors, or gases or vapors containing
silicones or sulfur compounds. Tetraethyl lead, silicones, and sulfur
compounds can form contaminating compounds on the sensor element
(poison the sensor), with resulting loss in sensitivity.
Always purge the instrument with fresh air after completing a test. This
removes combustibles from the sensor chamber and prolongs the life of
the sensor.
Operation
Instruction 55-9002 7
Gas Pup
Operation
Battery Installation
WARNING: Explosion hazard:
• To reduce the risk of igniting a flammable atmosphere,
batteries must only be changed in an area known to be
non-flammable.
• To maintain agency approval, use only the following types of
‘AA’ alkaline batteries: Energizer E91; Duracell MN1500 or
MX1500; Rayovac 815; and Panasonic AM-3PI.
1. Loosen the two thumbscrews on battery cover and remove cover.
2. Insert three ‘AA’ batteries into the Pup, observing polarity as shown
in Figure 4.
3. Reinstall battery cover and tighten its thumbscrews.
Figure 4. Battery Installation
LOOSEN BOTH BATTERY
COVER THUMBSCREWS
‘AA’ BATTERIES
Gas Pup
8 Instruction 55-9002
Turning ON the Gas Pup
Important! To assure that all detectors are properly zeroed, the
Gas Pup must be turned on in a gas-free environment (no
combustibles), and that no pressure is being applied to the
instrument’s pressure port.
It is also recommended that the probe and hose assembly be
connected to the instrument before turning it on.
Refer to Figure 5. The Gas Pup is turned ON by momentarily pressing the
key for 1 second. Listen for the pump to start and observe that all
segments of the display are momentarily turned on. After all segments
have been displayed the word “UEr” (Version) is displayed followed by the
instrument’s software version number. Next, the letter “b” appears in the
RANGE window along with the battery voltage momentarily appearing in
the READING window. The instrument will quickly move to display the
word “GAS”, indicating that the instrument is operating in its gas mode.
After several seconds, the READING window will display a flashing “AS”
(Auto Start). This is the Auto Start portion of the instrument’s operation,
and is used to stabilize the gas sensor in order to establish ‘zero’ gas
readings. Without additional operator intervention, the auto start portion of
the start-up routine will finish, leaving the instrument in its PPM gas range.
Operation
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