biosystems ZoneGuard Reference Manual

Page 1

ZoneGuard

Single Channel Fixed Gas Detection System

Reference Manual

651 South Main Street Middletown, CT 06457 Tel (860) 344-1079 (800) 711-6776 Fax (860) 344-1068 Version 2.3 30SEPT2005 p/n 13-063

Page 2

THE ZO NEGUARD SINGLE CHANNEL FIXED GAS DETECTION SYSTEM HAS BEEN DESIGNED FOR THE DETECTION AND MEASUREMENT OF POTENTIALLY HAZARDOUS ATMOSPHERIC CONDITIONS

IN ORDER TO ASSURE THAT THE USER IS PROPERLY WARNED OF POTENTIALLY DANGEROUS CONDITIONS, IT IS ESSENTIAL THAT THE INSTRUCTIONS IN THIS MANUAL BE READ, FULLY UNDERSTOOD, AND FOLLOWED.

ZoneGuard Operat ion Manual

Version 2.3

Part Number 13-063

Biosystems

651 South Main Street

Middletown, Connecticut 06457

No page or part of this operation manual may be reproduced in any form

without written permission of the copyright owner shown above.

Page 1

Page 3

Table of Contents

SIGNAL WORDS .............................................................................................................4

WARNINGS......................................................................................................................4

CHAPTER 1. DESCRIPTION ........................................................................................5

1.1 ZONEGUARD CAPABILITIE S ------------------------------------------------------------------------------------------------------5

1.2 METHOD OF SAMPLING -----------------------------------------------------------------------------------------------------------5

1.2.1 Wiring recommendations _________________________________________________________5

1.3 SENSOR OPTIONS -----------------------------------------------------------------------------------------------------------------5

1.4 CALIBRATION-----------------------------------------------------------------------------------------------------------------------5

1.4.1 One Button Auto Calibration_______________________________________________________5

1.5 DISPLAYS AND CONTROLS -------------------------------------------------------------------------------------------------------6

1.6 ALARM LOGIC----------------------------------------------------------------------------------------------------------------------6

1.7 SPECIAL MICROPROCESSOR FEATURES ---------------------------------------------------------------------------------------6

1.8 RELAYS AND OUTPUTS -----------------------------------------------------------------------------------------------------------6

1.8.1 VAC relay contacts______________________________________________________________6

1.8.2 VDC outputs___________________________________________________________________6

1.8.3 Output operation________________________________________________________________7

1.9 CLASSIFICATION FOR USE IN HAZARDOUS LOCATIONS-----------------------------------------------------------------------7

1.10 ZONEGUARD DESIGN COMPONENTS --------------------------------------------------------------------------------------------7

1.10.1 ZoneGuard controller ____________________________________________________________7

1.10.1.1 LED alarm light indicators......................................................................................................... 7

1.10.1.2 Audible alarm ........................................................................................................................... 7

1.10.1.3 Detector display........................................................................................................................ 7

1.10.2 Remote detector assemblies ______________________________________________________7

1.10.2.1 Standard Detector housing ....................................................................................................... 7

1.10.2.2 Explosion-pr oof detector housing.............................................................................................. 7

CHAPTER 2. INSTALLATION AND BASIC OPERATION............................................8

2.1 INSTALLATION OVERVIEW --------------------------------------------------------------------------------------------------------8

2.2 ZONEGUARD CONTROLLER UNIT------------------------------------------------------------------------------------------------8

2.2.1 Controller PCBs ________________________________________________________________8

2.3 REMOTE DETECTOR ASSEMBLIES ----------------------------------------------------------------------------------------------8

2.3.1 Standard remote detector housing__________________________________________________8

2.3.2 Explosion-proof remote detector housing_____________________________________________8

2.4 SITING OF REMOTE DETECTORS ------------------------------------------------------------------------------------------------8

2.5 WIRING RECOMMENDATIONS ----------------------------------------------------------------------------------------------------9

2.5.1 Grounding_____________________________________________________________________9

2.6 CONNECTING REMOTE ALARM AND DETECTOR ASSEMBLIES WITH THE ZONEGUARD CONTROLLER -----------------9

2.6.1 Cautions______________________________________________________________________9

2.6.2 ZoneGuard controller connections __________________________________________________9

2.7 INITIAL SETUP ----------------------------------------------------------------------------------------------------------------------9

2.8 NORMAL OPERATION--------------------------------------------------------------------------------------------------------------10

2.8.1 Overview of ZoneGuard operation __________________________________________________10

2.8.2 Turning the ZoneGu ard on________________________________________________________10

2.8.3 Turning the ZoneGu ard off ________________________________________________________10

2.8.4 Start-up sequence ______________________________________________________________10

2.9 OPERATING MODES ---------------------------------------------------------------------------------------------------------------10

2.9.1 Text Only mode ________________________________________________________________10

2.9.2 Basic mode ___________________________________________________________________11

2.9.3 Changing operating modes________________________________________________________11

2.10 ENABLING OR DISABLING USE OF THE MODE BUTTON-----------------------------------------------------------------------11

CHAPTER 3 CALIBRATION.........................................................................................11

3.1 WARNINGS AND CAUTIONS CONCERNING VERIFICATION OF ACCURACY---------------------------------------------------11

Page 2

Page 4

3.2 CALIBRATION OVERVIEW---------------------------------------------------------------------------------------------------------11

3.3 VERIFICATION OF ACCURACY----------------------------------------------------------------------------------------------------11

3.3.1 Fresh air "zero" i n contaminated air _________________________________________________12

3.4 EFFECT OF CONTAMINANTS ON ZONEGUARD SENSORS --------------------------------------------------------------------12

3.4.1 Effects of contaminants on oxygen sensors___________________________________________12

3.4.2 Effects of contaminants on combustible sensors _______________________________________12

3.4.2.1 Effects of high concentrations of combustible gas on the combustible sensor...........................12

3.4.3 Effects of contaminants on toxic gas sensors__________________________________________13

3.5 FUNCTIONAL (BUMP) TEST -------------------------------------------------------------------------------------------------------13

3.6 AUTO-CALIBRATION ---------------------------------------------------------------------------------------------------------------13

3.6.1 Fresh air "zero" auto-calibration s equence____________________________________________14

3.6.1.1 Reading “Too High” or “Too Low” for zero adjust......................................................................14

3.6.2 “Span” auto-calibration sequence___________________________________________________14

3.7 MANUAL CALIBRATION PROCEDURE --------------------------------------------------------------------------------------------15

3.7.1 Manual Fresh air "zero" through keypad buttons _______________________________________15

3.7.2 “Manual” span calibration through keypad buttons ______________________________________15

3.7.3 Manual true zero span calibration for oxygen sensors ___________________________________16

CHAPTER 4. SETTING ALARM LEVELS.....................................................................17

4.1 ALARM ADJUSTMENT SEQUENCE -----------------------------------------------------------------------------------------------17

4.2 REST ORING THE FACTORY DEFAULT ALARM SETTINGS ---------------------------------------------------------------------18

4.3 ALARM TEST FUNCTION ----------------------------------------------------------------------------------------------------------18

CHAPTER 5. ADVANCED FUNCTIONS.......................................................................19

5.1 ZONEGUARD ADVANCED FEATURES OVERVIEW------------------------------------------------------------------------------19

5.2 RE-SET TING THE CALIBRATION GAS CONCENTRATION ----------------------------------------------------------------------19

APPENDICES...................................................................................................................20

APPENDIX A ZONEGUARD FIXED GAS DE TECT ION SYSTEM ORDERING INFORMATION----------------------------------------20 APPENDIX B ZONEGUARD FIXED GAS DE TECT ION SYSTEM TECHNICAL SPECIFICATIONS------------------------------------21 APPENDIX C ZONEGUARD DEFAULT ALARM SETTINGS ---------------------------------------------------------------------------22 APPENDIX D ZONEGUARD SENSOR RANGES ---------------------------------------------------------------------------------------22 APPENDIX E ZONEGUARD TOXIC SENSOR CROSS SENSITIVITY DATA-----------------------------------------------------------22 APPENDIX F ZONEGUARD DIMENSIONAL DRAWINGS, ELECTRICAL SCHEMATICS, AND WIRING DIAGRAMS ----------------23 APPENDIX G CALIBRATION FREQUENCY --------------------------------------------------------------------------------------------26

BIOSYSTEMS STANDARD WARRANTY GAS DETECTION PRODUCTS....................27

Page 3

Page 5

SIGNAL WORDS

The following signal words, as defined by ANSI Z535.4-1998, are used in the Zoneguard Reference Manual.

indicates an imminently hazardous situation which, if not avoided, will result in

death or serious injury.

indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

indicates a potentially hazardous situation, which if not avoided, may result in

moderate or minor injury . CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if

not avoided, may result in property damage.

WARNINGS

1. dangerous atmospheric cond itions. An alarm condition indicates th e presence of a potentially life-threatening hazard and sh ould be taken very seriously. Failure to immediately leave the area during an alarm condition may result in serious injury or death.

2. course of action is to immediately leave th e affected area, and to return only after further testing determines that the area is once again safe for entry. Failure to immediately leave the area during an alarm condition may result in serious injury or death.

3. calibration gas. Failure to check accuracy can lead to inaccurate and potentially dangerous readings.

4. to contaminants by testing with known concentration test gas before further use. Failure to check accuracy can

lead to inaccurate an d potentially dangerous readings.

5. immediately. An instrument that fails calibration may not be used until testing with kn own concentration test gas

determines that accuracy has been restored, and the instrument is once again fit for use.

6. concent ration that differs from the one that is normally supplied by Biosystems for use in calibrating the Zoneguard. Use of inappropriate calibration gas may lead to in accurate and potentially dan g erous readings.

Customers are strongly urged to use only Biosystems calibration materials when calibrating the Zoneguard. Use of non-standard calibration gas and/or calibration kit components can lead to dangerously inaccurate readings and may void the stan dard Biosystems warranty.

7. Zoneguard can lead to inaccurate and potentially dangerous readings and may void the standard Biosystems warranty.

Biosystems offers calibration kits and long-lasting cylinders of test gas specifically developed for easy Zoneguard calibration. Customers are strongly urged to use only Biosystems calibration materials when calibrating the Zoneguard.

9. Read and un d erstand this reference manual before operating or servicing the Zoneguard.

10. combustible gas concen tration that exceeds the Zoneguard’s zero to 100 percent LEL detectionrange. The safest course of action is to immediately leave th e affected area, and to return only after further testing determines that the area is once again safe for entry.

The Zoneguard personal, portable gas detector has been designed for the detection of

In the event of an alarm condition it is important to follow established procedures. The safest

The accuracy of the Zoneguard should be checked periodically with known concentration

The accuracy of the Zoneguard should be checked immediately following any known exposu re

A sensor that cann ot be calibrated or is found to be out of tolerance should be replaced

Do not reset the calibration gas concentration unless you are using a calibration gas

Use of non-standard calibration gas and/or calibration kit components when calibrating the

Substitutio n of components may impair intrinsic safety. For safety reasons this equipment must be operated and serviced by qualified personnel only.

A rapid up-scale reading followed by a declining or erratic reading may indicate a hazardous

Page 4

Page 6

CHAPTER 1. DESCRIPTION

1.1 ZoneGuard capabilities

The ZoneGuard is a microprocessor based fixed gas detection system designed to accept the input from a single oxygen, combustible gas or toxic sensor. ZoneGuard systems are designed to provide continuous round-the-clock monitoring for a variety of common atmospheric hazards including ox ygen deficiency and/or enrichment, combustible gases and vapors, and specific toxic contaminan ts such as carbon monoxide (CO), hydrogen sulfide (H2S), sulfur dioxide (SO2), chlorine (Cl2), chlorine dioxide (ClO2), phosphine (PH3), and nitrogen dioxide (NO2). Sensors may be integrally mounted to the ZoneGuard controller housing, or located up to 50 feet away from the controller. Remote detector assemblies are available in explosion-proof or nonexplosion-proof versions. (Combustible sensors may onl y be mounted in explosion-proof sensor housings.) The unit is designed for operation via 120VAC 60 Hz. external power source.

Standard features in clude two independently adjustable alarm setpoints , built-in loud audibl e alarm (85 dB at 3-feet), easily -read, backlit LCD display, and bright LED alarm light indicators for OK / power on (green), low alarm (amber) and high alarm (red) conditions. Stan dard features also in clude DPDT relay contacts (rated 5A at 250V non- inductiv e load) for low and high alarm conditions . Optional accessories include externally mounted high intensity strobe lights and high intensity horn.

The ZoneGuard offers a choice of two modes of operation, Text Only (“OK”), and Basic (numeric readings) to provide the right amount of information for users with different skill levels and monitoring requirements. Biosystems’ “One Button” operating logic allows al l procedures necessary for normal day-to-day operation, including fully automatic calibration adjustment, to be made through the use of the single On/Off “Mode” button.

ZoneGuard sensors which are installed in explosion-proof remote detector housings are classified by Underwriters Laboratories, Inc. and the Canadian Standards Association as Explosion-Proof for use in Cl ass I, Division 1, Grou ps A, B, C, D, E, F and G hazardous locations.

Each ZoneGuard system includes the controller with all standard alarms, relays and electron ics installed in a NEMA 4X fiberglass housing; s ensor, mounting ears, calibration adaptor, Reference Manual, Quick Reference Card, and other standard accessories. Remote detector assemblies include the remote sensor housing, the appropriate amplifier board (installed in the remote detector housing), and sensor.

Note: Conduit, wire and other components necessary to connect the remote detector assembly with the instrument controller are not included and must be ordered separately.

The ZoneGuard design includes many user selectable features and is designed to be eas ily customized to meet specific customer requi rements. This chapter discusses some of these special features as well as basic capabilities used on a day-to-day basis.

1.2 Method of sampling

Once it has been connected to a power source and placed in normal operation, the ZoneGuard system continuously monitors for the hazard the sen sor is designed to detect. ZoneGuard sensors may be either integrally mounted to the controller housing, or remotely located u p to 50 feet away from the controller. The atmosphere being measured reaches the sensor by diffusing through a protective filter into th e sensor. Normal air movements are enough to car r y the sample to the sensor. The sensor r e acts to changes in the concentration of the hazard being measured. Values are constantly updated and di splayed on the ZoneGuard controller LCD.

1.2.1 Wiring recommendations

For oxygen remote detectors use (minimum) 22 gauge AWG, 6 conductor twisted-pair shielded with drain. For toxic remote detectors use (minimum) 22 gauge AWG, 4 conductor twisted-pair shielded with drain. For combustible remote detectors use 18 gauge AWG, 4 conductor twistedpair shielded with drain.

The maximum distance a ZoneGuard remote detector may be located from the controller is 50 feet.

1.3 Sensor options

ZoneGuard systems can be configured to monitor for a number of different atmospheric hazards. The hazard the system is configured to detect is determined by the type of sensor installed. The types of sensors currently available include a galvanic oxygen (O2) sensor, a catalytic-bead pellistor for LEL combustible gas, and substance-specific electrochemical sensors for carbon monoxide (CO), hydrogen sulfide (H2S), sulfur dioxide (SO2), chlorine (Cl2), chlorine dioxide (ClO2), phosphine (PH3), and nitrogen dioxide (NO2). Oxygen readings are given in percent-byvolume, combustible gas readings in percent LEL, and toxic gas readings in PPM (parts per million) or 0.1 PPM concentrations.

1.4 Calibration

ZoneGuard systems have been designed for easy verification of accuracy .

The accuracy of the Zoneguard should be checked periodically with known concen t ration calibration gas. Failure to check accuracy can lead to in accurate and potentially dangerous readings.

1.4.1 One Button Auto Calibration

Biosystems’ “One Button” logic means that all normal dayto-day operating procedures, including automatic calibration adjustment, may be made through the use of the single On/Off Mode button.

Calibration procedures are discussed in detail in Chapter 3.

Page 5

Page 7

1.5 Displays and controls

ZoneGuard systems include an 8-character LCD readout located at the controller which is used to display gas readings and other messages. Built-in LED alarm lights are used to indicate “OK” / Power-on (green), “Low Alarm” (amber), and “High Alarm” (red) conditions.

The On/Off “Mode” button is to initia te the automatic calibration sequence and to control most other day-to-day procedures. The button is l ocated on the exterior of the controller housing, on the underside of the case. Four additional push-bu tton controls (“-”, “+”, “Alarm” and “Cal”) are located on the inside of the controller housing door. These buttons are used for advanced procedures such as changing operating modes, changing alarm setpoints, adjusting calibration gas values, making optional setup choices, an d other advanced procedures.

1.6 Alarm Logic

The Zoneguard personal, portable gas detector has been design ed for the detection of dangerous atmospheric condit ions. An alarm condition indicates the presen ce of a potentially life-threatening hazard and sh ould be taken very seriously. Failure to immediately leave the area during an alarm condition may result in serious injury or death.

In the event of an alarm condition it is important to follow established procedures. The safest course of action is to immediately leave the affected area, and return only after further testing together with other appropriate safety procedures determine that the area is once again safe for en try.

ZoneGuard alarms are user adjustable and may be set anywhere within the range of the specific sensor. When an alarm set point i s exceeded the audible alarm sounds, the appropriate bright LED alarm light indicator are turned-on, and (if equipped) the optional external strobe light(s) and/or remote high intensity audible alarm are activated. (Any extern al alarm devices controlled by means of the ZoneGuard alarm relay contacts will also be activated.)

ZoneGuard alarms are normally of the self-resetting type. When readings drop back below the pre-set alarm levels, the instrument returns to normal operation, and the visual and audible alarms cease.

It is possible to set ZoneGuard alarms so that they "latch". In the latched condition, once an alarm occurs both visual and audible alarms will continue to sound even after the atmospheric hazard has cleared. The instrument must be manually reset before the alarms are silenced.

Procedures for latching ZoneGuard alarms are given in Chapter 4.

ZoneGuard systems equipped with toxic or combustible gas sensors are provided with two levels of gas alarm: “Low” (warning) and “High” (danger). Toxic and combustible alarms are configured as “ascending”, meaning that they are triggered when gas concentrations exceed the al arm setpoints.

ZoneGuard systems equipped with oxygen sensors have four levels of gas alarm, two “ascending” alarms (“Warning” and “Danger”) for oxy gen enrichment, an d two “descending” (“Warning” and “Danger”) alarms for oxygen deficiencies. Descending alarms are activated when oxygen concentrations drop below the alarm setpoints for oxygen deficiency.

Note: “Warning” level alarms may be manually acknowledged and silenced for a period of 10 minutes by pressing the Mode button. If the alarm condition continues to exist after 10 minutes h as elapsed, the “Warning” alarms will be reactivated. If t he alarm condition reaches the “Danger” level during this 10 minute period, the “Danger” level alarms will immediately be activated regardless of whether or not the “Warning” alarm has been silenced. “Danger” level alarms may not be manually silenced.

The procedures for adjusting alarm setpoints are given in Chapter 4.

1.7 Special microprocessor features

Several automatic programs prevent tampering and misuse of the ZoneGuard by unauthorized persons. Each time the detector is turned on, an electronic self-test is performed that assures the user of proper performance.

Optional setup choices include latching alarms, changing the concentrati o n of the gas that is used during Auto Calibra tion adjustment, as well as changing or restoring the factory alarm settings by using the 4 pus h-buttons on the instrument keypad. It is also possible to enable or dis able use of the extern al Mode button.

ZoneGuard software also incl udes an “Alarm Test” function that can be used to automatically “ramp” readings throughout the full range of the sensor. The “Alarm Test” function is used to verify alarm setpoints as well as the proper activation of the audible alarm, LED alarm light indicators, optional s tr obe lights or horn, as well as other alarm devices or peripheral equipment controlled by means of the ZoneGuar d r e lay contacts.

Chapters 4 and 5 describe how to use these advanced technical features and setup choices in greater detail.

1.8 Relays and outputs

See Appendix F for ZoneGuard electrical schematics and wiring diagrams.

1.8.1 VAC relay contacts

ZoneGuard systems include DPDT relay contacts for warning (low) and danger (high) gas alarm conditions. ZoneGuard rela y contacts are rated at 5 Amp at 250 VAC, non-i nductive l oad.

1.8.2 VDC outputs

ZoneGuard systems also include +12 VDC outputs rated at

0.5 Amp for warning (low) and danger (hi gh) gas alarm conditions.

Page 6

Page 8

CAUTION: ZoneGuard +12 VDC outputs may only be

used to provide power to remote alarm devices which have been approved by Biosystems for use with the ZoneGuard system. Use of non-approved devices may cause damage to the ZoneGuard system, and void the Biosystems Standard Warranty for Gas Detection Products. Contact Biosystems Technical Service Department at (860) 344-1079 for additional information on approved remote alarm devices.

1.8.3 Output operation

ZoneGuard alarms are normally of the “self-resetting” type, and will cease when readings drop back below the pre-set alarm levels. ZoneGuard alarms may als o be configured to “latch” so that the alarms remain activated even after the alarm condition has ceased. Once activated, a latched alarm will continue to sound until the instrument is manually reset by pressing the mode button.

The procedure for changing the alarm latch setting is given in Chapter 4

If the gas concentration causes the activation of the low (warning level) alarm, the audible alarm is activ ated, the low level (amber) alarm LED illuminates, and the low alarm relay is activated. Warning level alarms may be silenced and the relay deactivated for a period of 10 minutes by pressing the Mode button.

If the gas concentration causes the activation of the high (danger level) alarm, the audible alarm is activated, the high level (red) alarm LED illuminates, and the high alarm relay is activated. High level alarms may not be manually silenced by pressing the Mode button.

ZoneGuard systems are supplied with relays and outputs preset with the following standard factory setup:

VAC relays: Warning (low) alarm Normally energized (fail s afe) Danger (high) alarm Normally energized (fail s afe) 12 VDC outputs: Warning (low) alarm Normally de-energized Danger (high) alarm Normally de-energized

1.9 Classification for use in hazardous locations

ZoneGuard remote detector assembli es are available in both explosion-proof and non-expl osion-proof versions. Explosion-proof version remote detector assemblies have been su bmitted to Underwriters Laboratories, Inc. for Classificati on per ULC as Explosion-Proof for use in Class I, Division 1, Groups A, B, C, D, E, F, and G explosive atmospheres.

1.10.1 ZoneGuard controller

The ZoneGuard controller unit is enclosed in a durable, gasketed, fiberglass NEMA 4X case. The On/Off Mode button i s located on the exterior of the controller housing, on the underside of the case. Four additional push-button controls (“-”, “+”, “Alarm” and “Cal”) are located inside the door of the controller housing.

1.10.1.1 LED alarm light indicators

ZoneGuard controllers include 3 bright system status and alarm condition LED indicators; green for “OK” / Power On, amber for “Warning”, and red for “Danger”.

1.10.1.2 Audible alarm

A loud (85 dB at 3 feet) built-in audible alarm is provided to warn us ers of hazardous conditions. Optional remote audible alarms and high intensity horns are also available.

1.10.1.3 Detector display

An 8-character LCD readout is used to displ ay gas readings and other information.

Readings, messages, and modes of operation are discussed in Chapter 2.

1.10.2 Remote detector assemblies

Remote detector assemblies include sensor, sensor specific amplifier board (installed in the remote detector housing), and remote detector hous ing. Oxygen and toxic gas remote detector assemblies are available in both “standard” (nonexplosion-proof) and “ex plosion-proof” versions. Remote detector assemblies for combustible gas are only available in explosion-proof housings.

Installation procedures are discussed in Chapter 2.

1.10.2.1 Standard Detector housing

“Standard” remote detector assemblies are housed in a heavy-duty, ni ckel-coated, molded junction box. Not for use in hazardous locations.

1.10.2 . 2 Explosion-proof detector housing

“Explosion-proof” remote detector assemblies are housed in a heavy duty steel explosion-proof (Class I, Divi sion 1, Groups A, B, C, D, E, F, G) junction box with threaded lid.

1.10 ZoneGuard design components

See Appendix F for dimensional drawings, mounting schematics, and wiring diagrams for the ZoneGuard controller and remote detector assemblies.

Page 7

Page 9

CHAPTER 2. INSTALLATION AND BASIC OPERATION

2.1 Installation overview

Biosystems gas detection systems are fully tested and calibrated before they leave the factory. However, after installation we strongly recommend that full testing and verification of proper operation is carried out before the system is placed in normal service. Make sure all ZoneGuard system elements and/or peripheral alarm, notification, or con trol devices are properly installed before connecting the system to a power source!

Make sure that th e ZoneGuard system is disconnected from the external po wer source before installing, replacing, or handling ZoneGuard system components!

Repair of system components damaged as a result of improper installation can be expensive! ZoneGuard installation, initial setup, and / or system modification should only be undertaken by individuals who are qualified and authorized to do so. Call Biosystems’ Service Department at (860) 344-1079 if you need help or have any questions.

2.2 ZoneGuard controller unit

The ZoneGuard controller unit is designed for wall mounting in any convenient non-hazardous location where a suitable power supply is available. ZoneGuard control ler units are designed for use with 120VAC, 60Hz. external power.

Note: ZoneGuard controller housing accessories include a set of 4 external mounting brackets. Use of these mounting brackets is optional. The controller hous ing may be mounted directly to the wall or other mounting surface by use of screws inserted throu gh apertures in 4 mounting wells located on the back of the controller case, or by means of the external mounting brackets, whichev e r is more convenient.

ZoneGuard controller housing accessories also include a ½” NPT galvanized cable grab “gland”. If the cable connecting the remote detector housing with the controller is run through conduit, it will be necessary to remove the cable grab gland and replace it with a threaded ½” NPT conduit bushing (not provided). When making use of ZoneGuard relay contacts to control or actuate external alarm devices it will be necessary to remove the “hole-seal” from the bottom of the controller case, and install the appropriate glands or bush ings. To prevent dust and water ingress all cabl e entries and knockouts must be checked and sealed as necessary.

2.2.1 Controller PCBs

The ZoneGuard controller includes a displ ay PCB located underneath the hinged controller cas e cover, and the relay PCB located on a mountin g plate inside the controller case. In the case of ZoneGuard systems with integrally mounted sensors, a sensor specific amplifier board is mounted onto the relay PCB. In the case of ZoneGuard systems with

remote sensors, the amplifier board is located in the remote detector housing.

The four push-buttons (“+”,“-”, “Alarm”, and “Cal”) us ed to make use of advanced features and setup choices are located on the display PCB on the inside of the con troller hous ing door.

2.3 Remote detector assemblies

Oxygen and toxic gas remote detector assemblies are available in both “standard” (non-explosion-proof) and “explosion-proof” housi ngs. Remote detector assemblies for combustible gas are only available in explosion-proof housings.

ZoneGuard re mote detector as semblies may be located up to 50 feet away from the controller. Power is provided to the remote detector by the Zo neGuard controller.

The ZoneGuard remote detector assembly contains a factory installed, sensor specific amplifier PCB. The remote detector assembly is labeled as to the type of hazard it is designed to measure (i.e. H2S, CO, O2, etc.).

2.3.1 Standard remote detector housing

Sensors for the measu r emen t of oxygen and toxic gas may be installed either in explosion-proof or “standard” remote detector housings.

Sensors that are hou sed in “standard” remote detector housings may not be installed in hazardous locations requiring an “Explosion-Proof” classification.

2.3.2 Explosion-proof remote detector

housing

Explosion-proof remote detector housin gs can be installed in Class I, Division 1 Groups A thro ugh G hazardous locations.

Explosion-proof remote detectors are installed in a heavy duty stainless steel explosion-proof (Class I, Division 1, Groups A through G) junction box with threaded lid.

ZoneGuard sensors for the measurement of combustible gas may only b e installed in ex plosionproof remote detector housings.

2.4 Siting of remote detectors

The specific placement of remote detector assemblies should be a function of the type of area being monitored, the type and source of atmospheric hazard being measured, prevailing wind patterns, and other information.

Call Biosystems Technical Service Department at (860) 344-1079 for additional advice.

In general, for gases lighter than air, the detector should be placed at a level slightly above the area where leaks are likely to occur. For gases which are heavier than air the detectors should be located close to floor level or in inspection pits or ducts into which heavier than air gases may collect or flo w.

There are many circumstances which may modify this general advice. For example, the molecular weight of nitrogen (MW ≅ 28) is very close to that of air (MW ≅ 29).

Page 8

Page 10

When nitrogen is at the same temperature as the air into which it is introduced, it mixes readily, and tends to spread evenly through the affected atmosphere. On the other hand, if the nitrogen is under pressure, and then suddenly released into the atmosphere, as the gas expands (going from higher pressure to a lower pressure) it cools. Because the cooler gas is now denser than the air in to which it is being introdu ced, it no longer mixes in as readily. Instead, the nitrogen tends to fall to floor level, then spread l aterally. In this case remote detectors being used to monitor for oxygen deficiency should be located n ear floor level in order to detect the deficiency as quickly as possible.

The nearer in density to air a gas is, the more easily it will flow with air due to draughts, ventilation etc. A compromise approach for placement of detectors used to measure gases whi ch are only s lighter lighter (such as carbon monoxide) or heavier (such as hydrogen sulfide) than air is to mount the detectors at a height as close as possible to the breathing area of personnel being protected.

When installing detector assemblies it is important to ensure that the sensor is not exposed to liquid or du st contamination which would interfere with th e passage of gas through the protective filter into the sensor. Remote detector assemblies shoul d be placed so that the axis of the sensor points straight downward. Splash deflectors should be used when water or other liquid is chronically present in the area where the detectors have been located.

2.5 Wiring recommendations

For oxygen remote detectors use (minimum) 22 gauge AWG, 6 conductor twisted-pair shielded with drain. For toxic remote detectors use (mini mu m) 22 gau ge AWG, 4 conductor twisted-pair shielded with drain. For combustible remote detectors use 18 gauge AWG, 4 conductor twistedpair shielded with drain.

The maximum distance a ZoneGuard remote detector may be located from the controller is 50 feet.

Due to the relatively low signal levels carried by wiring between gas detectors and their control unit, it is essential not to run wire near high power electrical equip men t. When ZoneGuard systems are installed in environments which contain high power electrical equipment it is usually best to install the wire in conduit.

2.5.1 Grounding

Wire used to connect ZoneGuard remote detector assemblies with the controller shou ld always be with drain lead. In order to reduce the chances for electromagnetic interference (EMI), the screen (drain) of the wire should be connected to the ground plate of the detector head (l ong reach glands and/or the screen terminals should be us ed for this purpose). Ground loops must be avoided! Grounding is done through the normal circuit ground of the system.

2.6 Connecting remote alarm and

detector assemblies with the ZoneGuard controller

2.6.1 Cautions CAUTION: Make sure that the ZoneGuard system is

disconnected from the external power source before installing, replacing, or handling installed ZoneGuard system components!

CAUTION: Make sure the remote detector housing is

properly connected to the correct controller terminal block connector as discu ssed below.

CAUTION: +12 VDC outputs may only be used to

provide power to remote alarm devices which have been approved by Biosystems for use with the ZoneGuard system. Use of non-approved devices may cause damage to the ZoneGuard system, and void the Biosystems Standard Warranty for Gas Detection Products. Contact Biosystems Technical Service Department at (860) 344-1079 for additional information on approved remote alarm devices.

2.6.2 ZoneGuard controller connections

Electrical connections and wiring diagrams for the ZoneGuard controller are shown in Appendix F.

Full wiring sch ematics are available on the Biosystems website or by contacting Biosystems directly.

Connectio ns are by screw terminal blocks located on the mounting plate and relay PCB located in the ZoneGuard controller. Warning (Low) and Danger (Hi gh) VAC output relays are DPDT, are isolated from the system power supply, and are rated at 5 Amp, 250VAC, non-inductive. Warning (Low) and Danger (High) VDC outputs (+12 VDC at 0.5 Amp) may only be us ed to provide power to remote alarm devices which have been approved by Biosystems for use with ZoneGuard systems.

2.7 Initial setup

1. Make sure the controller is not con nected to any other

peripheral or external equipment or alarm devices.

2. Disconn ect the built-in “loud” 85 dB audible alarm.

3. Make sure any other alarm or notification devices

controlled by mean s of the ZoneGuard relay contacts are disconnected or turned off.

4. Connect mains power to the controller.

5. Connecting the ZoneGuard system with mains power

will cause the detector to turn on in normal operation. The green “OK / Power On” LED indicator should be lit and the LCD disp lay should be on. The LCD disp lay shou ld show a sequence of start-up screens as the detector goes through a self test sequ ence, followed by the curren t gas level readings. The low or high LED alarm indicators, optional strobe lights, remote audible alarms, and other devices connected to may be activated while the sensor is stabilizing.

Page 9

Page 11

Note: The ZoneGuard system is designed so that in the event of a power interruption, the instrument will automatically turn itself back on. To turn the system off it will be necessary to hold down the Mode button until the display goes blank. When the Mode button is released the display will ind icate “OF F”.

6. Allow the readings to stabilize fully.

Note: Combustible and oxygen sensors may take up to an hour after power is applied to the system to stabilize fully. Carbon monoxide, hydrogen sulfide, sulfur dioxide and phosphine may take up to 2 hou rs. Chlorine, chlorine dioxide, and nitrogen dioxide sensors may take up to 12 hours.

7. If readings are still in alarm, the ZoneGuard should be fresh air zeroed. Since the amount of adjustment required at the time of initial setup may be large, it is usually better to make a “manual” fresh air zero adjustment. To do a manual fresh air zero, make sure the sensor is currently located in fresh air, then press the “Cal” button to enter the “Zero Adjust Mode”. The display should show the message “Zero Gas ” . Press the Cal button once more to automaticall y make a fresh air zero adjustment. (The complete procedures for

zero and span calibration are discussed in Chapter

3.)

8. Reconnect the 85dB audible alarm and any other alarm devices which were turned off or disconn ected prior to “powering up” the ZoneGuard system.

The ZoneGuard system must be properly calibrated as discussed in Chapter 3 at the time of initial installation before the system is put into normal service.

2.8 Normal operation

2.8.1 Overview of ZoneGuard operation

The ZoneGuard offers a choice of two modes of operation, Text Only, (“OK”) and Basic, (numeric readings). Mode selection should be determined based on how much information is required, the skill level of the user, and the nature of the environment in which the ZoneGuard system is installed.

2.8.2 Turning the ZoneGuard on

The black switch located on the bottom of the exterior of the ZoneGuard con troller housing is cal led the Mode button. It is used to turn the ZoneGuard on and off, as well as to control most other operations of the instrument. Press and hold th e Mode button for one second to turn the ZoneGuard on.

2.8.3 Turning the ZoneGuard off

Turn the ZoneGuard off by pressing and holding the Mode button until the LCD goes blank. When the button is released the LCD will display the message “OFF”.

2.8.4 Start-up sequence

After the ZoneGuard has been turned on, it will automatically go through an electronic self test and start-up sequence that takes approximately twenty seconds. During start-up the

LCD display will show several messages or "screens" in sequence. The first screen displays the software version number: The second shows the type of sensor installed. Additional screens will briefly appear indicatin g the current low (warning) and high (danger) alarm setpoints. For instance, a ZoneGuard for carbon monoxide being operated in the Basic mode would show the following sequ ence of factory installed (default) alarm set points when the instrument is first turned on. (Note: The software version installed in your ZoneGuar d may differ with that shown below.)

→

At the conclusion of the startup sequence, the screen will cycle back and forth between the current gas readings screen and the sensor identification screen.

↔

Note: LCD screens indicating readings or alarm setpoints include the measurement u nits being used. In the case of toxic gas the last three ch aracters will indicate “PPM” (parts-per-million). In the case of combustible gas (LEL) and oxygen the last three display characters will indicate “PCT” (percen t ) .

The alarm set-point screens are omitted when the instrument is tu r ned on while in the “Text Only” mode.

→

2.9 Operating modes

Two operating modes provide ZoneGuard users with the right amount of information to meet their monitoring needs. The ZoneGuard is designed to be as simple or as sophisticated as the job that needs to be done.

2.9.1 Text Only mode

The simplest mode of operation i s the “Text Only” mode. In this mode, during normal operation the LCD screen dis plays an “OK” message rather than numerical readings as long as no alarms are present. The “OK” screen alternates with th e sens or identification screen.

↔ During an alarm condition (when the sensor readings exceed a pre-set alarm level), the ZoneGuard will show readings as a numerical value, activate the appropriate LED alarm light, soun d the audible alarm, and (if equipped) activate the optional high intensity strobe light(s), remote audi ble alarm,

Page 10

Page 12

and/or other alarm or notification devices controlled by the ZoneGuard rela y contacts.

↔ ZoneGuard alarms are normally self-resetti ng. When readings drop back below the pre-set alarm levels, the screen returns to the "OK" in dication, and visual and audible alarms cease.

2.9.2 Basic mode

Basic mode provides numerical readings during normal operation.

↔

2.9.3 Changing operating modes

To change operating modes, with the instrument running open the door of the con troller housing to access the four mini-push-buttons, and simultaneously press and hold the "+" and "-" buttons until the word “MODE” is displayed. Each time the operatin g mode is changed the display screen will briefly indicate which operating mode “TEXT” or “BSIC” (Basic) has been selected.

Note: Shifting modes or otherwise reprogramming the instrument should only be done by employees who are authorized to do so.

2.10 Enabling or disabling use of the

Mode button

Most day-to-day operati ng procedures (such as automatic calibration adjustment) are normally made by using the On/Off Mode button. It is possible to disable the u se of the Mode button. Once disabled, the Mode button may no longer used for any purpose. To res tore normal functions, the Mode button must be re-enabled.

To enable or disable use of the Mode button press and hold down the “+” key while the ZoneGuard system is in normal operation. The display will show the message “MODE OFF” or “MODE ON” to indicate when the procedure of enabling or disabli ng the Mode button is complete.

CHAPTER 3 CA LIBRATION

3.1 Warnings and cautions concerning verification of accuracy

The accuracy of the Zoneguard should be checked immediately following any known exposure to contaminants by testing with known concentration test gas before further use. Failure to check accuracy can lead to inaccurate and potentially dangerous readings.

A sensor that cannot be calibrated or is found t o be out of tolerance should be replaced immediately. An instrument that fails calibration may not be used until testing with known concentration test gas determines that accuracy has been restored, and the instrument is once again fit for use.

Do not reset the calibration gas concentration unless you are using a calibration gas concentration that differs from the one that is normally supplied by Biosystems for use in calibrating the Zoneguard. Use of inappropriate calibration gas may lead to in accurate an d potentially dangerous readings.

Use of non - st andard calibration gas and/or calibration kit components wh en calibrating th e Zoneguard can lead to inaccurate and potentially dangerous readings and may void the standard Biosystems warranty.

3.2 Calibration overview

The ZoneGuard gas detection system has been designed for easy calibration. A single button, th e on / off Mode button, is used to initiate the “Au to-Calibration” sequence, and automatical ly make all calibra tion adjustments.

It is also possible to manually calibrate the instrument by using simple pus h-button controls located on the inside of the door of the ZoneGuard controller housing.

“One-Button Auto-Cal” procedures are discussed in Section 3.6. Manual calibration procedures are discussed in Section 3.7.

3.3 Verification of accuracy

To verify accuracy, first place the Zoneguard in Basic Mode so that readings are given in numbers. See section 2.9.3 for instructions on changing operating modes.

Page 11

Page 13

Verification of accuracy for a Zoneguard equipped with an O2 sensor is a one-step procedure. Si mply provide the sensor with a known source of fresh air and veri fy that the display reads 20.9% oxygen. If the display shows anything besides 20.9% while exposed to a known source of fresh air, it must be fresh air calibrated as discussed below in section 3.6.1.

Verification of accuracy for a Zoneguard equ ipped with either a combustible gas / LEL sensor or any tox ic sensor is a two-step procedure.

Step one is to provide the sensor with a known source of fresh air and verify that the display shows “0 PCT” for LEL units or “0 PPM” for toxic units. If an instrument equipped with an LEL or toxic sens or shows anything besides “0” while exposed to a known source of fresh air, it must be fresh air calibrated as discussed bel ow in section 3.6.1. If the ZoneGuard is located in an area in which the air may not be fresh, see section 3.3.1 below for instructions on fresh ai r “zero” calibrations in contamin ated air.

Step two is to test sensor response by exposing the sensor to appropriate test gas of known concentration. This is known as a functional (bump) test. Readings are considered to be accu rate when the display shows a reading between 90% and 120% of the expected values as gi ven on the calibration gas cyli nder. If readings are accurate, there is no need to adjust your gas detector. See section 3.5 for explicit functional/bump test instructions.

If the readings are inaccurate, th e instrument must be calibrated before further use as discussed in section 3.6.

Biosystems offers calibration kits and long lasting cylinders of test gas specifically developed for easy ZoneGu ard calibration . Customers are urged to use Biosystems calibration materials when calibratin g their ZoneGuard detectors.

3.3.1 Fresh air "zero" in contaminated air

The fresh air "zero" for all types of sensors must be done while the sensor i s located in fresh, uncontaminated air. In this procedure the instrument automatically adjusts its readings to match the concentrations present i n fresh air. Fresh air should contain 20.9% oxygen, 0% LEL combustible gas, and 0 parts-per-million toxic gas.

If the atmosphere in which the ZoneGuard sensor is located is not fresh, or if it is not certain whether or not the air is contaminated, speci al procedures are required. In this case, the zero adjustment must be made while the sensor is exposed to contaminant free atmosphere by means of a cylin der of “Zero Air” which contains 20.9% oxygen, 79.1% nitrogen and no contaminants. This gas is supplied to the sensor and the instrument may then be fresh air “zero” calibrated as discussed i n section 3.6.1.

3.4 Effect of contaminants on ZoneGuard sensors

The atmosphere in which th e ZoneGuard monitor is being used can have an effect on the sensor. Sensors may be poisoned or suffer degraded performance if exposed to certain substances.

Caution: The accuracy of the ZoneGuard should be checked immediately following any known exposu re to contaminan ts by testing with known concentration test gas before further use.

The ZoneGuard is avail able with three basic types of sensors: oxygen, combustible gas (LEL), and electrochemical toxic. Each type of sens or uses a slightly different detection principle. The kinds of conditions that affect the accuracy of the sensors vary from one type of sens or to the next.

3.4.1 Effects of contaminants on oxygen sensors

Oxygen sensors may be affected by prolonged exposure to "acid" gases such as carbon dioxide. The oxygen sensors used in Biosystems instruments are not recommended for continuous use in atmospheres which contain more than 25 % CO2.

3.4.2 Effects of contaminants on combustible sensors

Combustible sensors may be affected by exposure to substances containing silicone (found in many lubricants and hydrau lic fluids), the tetra-ethyl-lead in "leaded" gasoline,

and halogenated hydrocarbons (Freons®, or solvents such as trichloroethylene and methylene chloride). High concentrations of hydrogen s ulfide may also damage the sensor.

For a comprehensive list of known LEL sensor poisons, see the last paragraph of the Biosystems Standard Warranty at the end of this manual.

If sensitivity of the combustible sensor is lost due to poisoning, it tends to be lost first with regards to methane. A partially poisoned sensor might still respond accurately to propane while showing a dangerously reduced response to methane.

Biosystems’ “Equivalent” calibration gas mixtures have been developed to eli minate this potentially dangerous source of calibration error. Biosystems’ “Equivalent” mixtures are based on methane, so any loss of sensi tivity to methane is detected (and can be corrected) immediately. Biosystems offers several different “Equivalent” combustible calibration gas mixtures for use in various monitoring applications. Please contact Biosystems’ Service Department at (800) 711-6776 for help in deciding which calibration gas mixture to specify for use.

Using Biosystems brand calibration gas insures that proper sensitivity is maintained over the life of the sensor.

3.4.2.1 Effects of high concentrations of

combustible gas on the combustible sensor

The accuracy of combustible sensors may also be affected by exposure to high concentrations of combustible gas. To minimize the chance for damage or loss of sensitivity to the combustible sensor, the ZoneGuard system is designed to

Page 12

Page 14

"alarm latch" whenever the concen tration of combustible gas exceeds 100 percent LEL. Under these conditions the combustible gas reading will show an “X” to indicate an overlimit condition. The audible and visual alarms will sound continuously until the instrument is manually reset by turning it off, then turning the instrument back on.

A combustible sensor overrange alarm indicates a potentially explosive atmosphere. Failure to leave th e area immediately may result in serious injury or death!

Note: If the over limit condition still exists at the time the instru ment is turned back on, the ZoneGuard system will revert to the over-limit alarm-latch condition.

truly cleared before attempting to make an auto-zero adjustment. Auto-zero adjustments may only be made when the ZoneGuard sensor is located in air that is known to be fresh . Accuracy of the combustible gas sensor should be verified by exposure to known concentration test gas before further use.

Note: The combustible sensor used in the ZoneGuard design requires the presence of oxygen in order to detect combustible gas. The accuracy of the combustible sensor may be affected if the instrument is used in oxygen deficient atmospheres.

by a rapid declining or erratic reading may indicate a gas concentration beyond the u pper scale limit which may be hazardous.

Make sure the alarm condition has

Any rapid up-scale reading followed

3.4.3 Effects of contaminants on toxic gas

sensors

Biosystems “substance-specific” electrochemical sensors used to measu r e toxic gases such as CO, H2S, SO2, Cl2, ClO2, PH3, and NO2 have been carefully designed to minimize the effects of common interfering gases. “Substance-speci fic” sensors are designed to respond only to the gases they are supposed to measure. The higher the specificity of the sensor the less likely the sensor will be affected by exposure to oth er gases which may be incidentally present. For instance, a “substance-specific” carbon monoxide sensor is deliberately designed not to respond to oth er gases which may be present at the same time, such as hydrogen sulfide or methane.

Even though care has been taken to reduce cross sensitivity, some interfering gases may still have an effect on toxic sensor readin gs. In some cases the interfering effect may be “positive” and result in readings wh ich are higher than actual. In some cases the interference may be negative and produce readings which are lower than actual.

Cross sensitivity of ZoneGuard toxic sensors to common interfering gases is listed in Appendix E.

toxic gas sensor. For further details on verifying the accuracy of an instrument with an O2 sensor, see section 3.3.

To perform a Functional (bump) test,

1. Place the Zoneguard in Basic Mode so that readings are given in numbers.

2. Make sure the sensor is located in fresh air. If you are not certain the air is fresh, use a cylinder of Zero Air to supply atmosphere to the sensor.

3. Verify that the readings match the con centrations present in fresh air. Instruments equipped with an LEL sensor or any of the toxic gas sensors should read “0”. If necessary, fresh air “zero” calibrate the ins trument using the procedures discussed in Section 3.6.1.

4. Screw the regulator into the cylinder and connect it to the detector using the short section of tubing and the calibration adapter. The regulator will automatically begin flowing calibration gas at the correct flow rate as soon as it is screwed into the cylinder of gas.

5. The instrument will display the sensor readings as they rise. When they have stabilized at their highest value, note the readings. Readings are considered to be accurate when the display is between 90% and 120% of the ex pected values as given on the calibration gas cylinder. If readings are accurate, there is no need to span calibrate the detector.

Readings that are considered inaccurate indicate the instrument must be adjusted using the “span” calibration procedures discussed in Section 3.6 before further use.

3.6 Auto-calibration

Biosystems “One-Button Auto-Calibration” mode may be used to verify accuracy any time du ring normal operation while the instrument is being used in the Basic operating mode. Press the Mode button 3 times in rapid sequence to initiate the “Auto-Calibration” sequence. Sensor adjustments are made automatically in Auto Calibration mode.

Auto-calibration is a one step procedure for instruments equipped with an oxygen sensor. If the detector doesn’t read 20.9 PCT in a known fresh air environment, perform the fresh air “zero” calibration as described in section 3.6.1.

Auto-calibration is a two step procedure for instruments equipped with either a combustible gas / LEL sensor or a toxic gas sensor. In the first step the sensor is ex posed to fresh air and a "zero" adjus tmen t is made automatically as discussed below in section 3.6.1. The second step is th e sensor response or "span" calibration adjustment. In this step the accuracy of the ZoneGuard sen sor is established by exposing it to known concentration calibration gas as discussed below in section 3.6.2. The sensitivity or “span” is automatically adjusted.

3.5 Functional (bump) test

Note: The functional (bu mp) test is only used on instruments equipped with a combustible gas / LEL or

Page 13

Page 15

3.6.1 Fresh air "zero" auto-calibration sequence

The “One Button” fresh air zero procedure may only be done while the ZoneGuard system is being operated in the Basic operating mode.

1. Make sure gas readings are given in numbers. If the

display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode simul taneously hold down th e "+" and"-" keys as discussed in section 2.9.3.

2. Make sure the ZoneGuard system has been turned on

and operating for a sufficient period of time for the sensor readings to have stabilized fully before initiating auto-calibrati on procedures.

If the sensor has just been replaced, the ZoneGu ard should be turned on and allowed to stabilize for the following period of time prior to performing any of the calibration options.

Sensor Stabilization Period

Oxygen 1 hour LEL 5 minutes All Toxic sensors

available for ZoneGuard

3. Make sure the sensor is located in an area where the air

is known to be fresh or provide fresh air to the sensor with a cylinder of “Zero Air”. See section 3.3.1 for more details on using a “Zero Air” cylinder during the Fresh Air “zero” calibration.

4. Press the Mode button 3 times within two seconds. This

will "wake up" the instrument from normal operation, and put it into the “Auto-Calibration” mode. A screen will briefly display the message “ZERO MODE”.

5. Press the Mode button withi n five seconds to initiate the

fresh air adjustment. (If the Mode button is not push ed within 5 seconds, the instrument will return to normal operation.)

6. The screen will show the message “ZERO WAIT” while

the adjustment is being completed.

7. After successful completion of the “zero” auto-

calibration, the display will prompt you with the message “SPAN MODE” to cont inue with a span calibration adjustment.

Span calibration is covered in detail below in section

3.6.2.

3.6.1.1 Reading “Too High” or “Too Low” for

zero adjust

To reduce the chances of the ZoneGuard being inadvertently zeroed in contaminated air, only small

15 minutes

↔

adjustments are allowed through the use of the “One Button” auto-zero sequence. If the necess ary adjustments are too large the display will indicate that the ZoneGuard “CANT ZERO”. In this case the instrument mu st be fresh air zeroed using the “Cal” button on the instrument keypad and procedures discussed in Section 3.7.1.

Once the instrument has been successfully zeroed using the “Cal” button, subsequent calibration adjustments may be made using the Mode button and “One Button Auto Cal” logic discussed in this section.

3.6.2 “Span” auto-calibration sequence

After successful comple tion of the FRESH “zero” autocalibration adjustment, instruments equipped with either a combustible gas / LEL sensor or a toxic gas sensor will automatically move on to “SPAN MODE”.

↔

1. Press the Mode button within 5 seconds to initiate “span” auto-calibration. The screen will show “FLOW GAS” and will continue to display this screen until it determines that calibration gas has been applied. If the Mode button is not pushed within five seconds a span calibration adjustment will not be made, and the instrument will be returned to normal operation.

Note: It is possible to exit t he auto-calibration mode at any time prior to completion by pressing and holding down the Mode button to turn th e instrument off.

↔

2. Screw the regulator into the cylinder and connect it to the detector using the short section of tubing and the calibration adapter. The regulator will automatically begin flowing calibration gas at the correct flow rate as soon as it is screwed into the cylinder of gas.

Make sure the regulator, cylinder seating surfaces and threads are clean and dry before attaching the regulator to the cylinder of gas. Introduction of contaminants th rough the regulator fittings may alter or degrade the concentration of the gas contained in the cylinder and may lead to inaccurate and potentially dangerous gas readings.

3. The instrument will display the sensor readings as they

rise. When they have stabilized at their highest value, the instrument will note the response and, if necessary, adjust the readings to match the concentration of gas being used to calibrate the detector . (The instrument will beep as the adjustment is being made.)

and/or calibration kit components wh en calibrating th e ZoneGuard may lead to dangerously inaccurate readings and may void the standard Biosystems warranty.

4. When span adjustment has been completed, the di splay

will show the message “DONE”.

Use of non-standard calibration gas

Page 14

Page 16

Note: Make sure the calibration adaptor and all other fittings have been removed from the detector before it is returned to service.

3.7 Manual calibration procedure

It is also possible to calibrate the ZoneGuard manually using the four buttons on the instrument keypad.

3.7.1 Manual Fresh air "zero" through keypad buttons

1. Make sure gas readings are given in numbers. If the

display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, simultaneously hold down the "+" and"-" keys as discussed in section 2.9.3.

2. Make sure the ZoneGuard system has been turned on

and operating for a sufficient period of time for the sensor readings to have stabilized fully before initiating manual calibration procedures.

If the sensor has just been replaced, the ZoneGu ard should be turned on and allowed to stabilize for the following period of time prior to performing any of the calibration options.

Sensor Stabilization Period

Oxygen 1 hour LEL 5 minutes All Toxic sensors

available for ZoneGuard

3. Make sure the sensor is located in fresh, contaminant

free atmosphere or use a cyl inder of Zero Air to supply atmosphere to the sensor.

4. Press the keypad button marked "Cal". The “GAS

ZERO” calibration message will appear on the instrumen t LCD.

5. Press “Cal” to automatically zero the instrument. The

LCD will show the message “ZERO WAIT” while the adjustment is being made.

6. After completion of the zero adjustment the ZoneGuard

will automatically return to the current gas readings screen.

7. The manual fresh air zero adjustment can be canceled

at any time prior to completi on by pressing the Mode button. Pressing the Mode button causes the calibration values in the memory to remain unchanged from the last time a fresh air adjustment was made. An information screen is displayed briefly which verifies that

↔

15 minutes

the zero values have not been changed. The instrument will then return to normal operation.

↔

3.7.2 “Manual” span calibration through keypad buttons

Span calibration procedures using buttons on the instrument keypad are only necessary when the adjustment necessary to restore accuracy is outside the permissible window of adjustment for “One Button Auto Calibration” pr ocedures. Span calibration using the keypad buttons may onl y be done while in the Basic operating mode.

1. Make sure gas readings are given in numbers. If the

display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, simultaneousl y hold down the "+" and"-" keys as discussed in section 2.9.3.

2. Make sure the ZoneGuard system has been turned on

and operating for a sufficient period of time for the sensor readings to have stabilized fully before initiating manual calibration procedures .

If the sen sor has just been replaced, the ZoneGuard should be turned on and allowed to stabilize for the following period of time prior to performing any of the calibration options.

Sensor Stabilization Period

Oxygen 1 hour LEL 5 minutes All Toxic sensors

available for ZoneGuard

3. Turn the instrument off by pressing and holding the

Mode button.

4. While holding down the "Cal" bu tton, press the Mode

button to turn the ZoneGuard back on. A screen sh owing the message “SPAN” will be displayed which alternates wi th the sen sor readings.

Press the Mode button at any time to cancel the calibration.

5. Screw the regulator into the cylinder and connect it to

the detector using the short section of tubing and the calibration adapter. The regulator will automatically begin flowing calibration gas at the correct flow rate as soon as it is screwed into the cylinder of gas.

6. Allow the readings to stabilize. When the readings

stabilize, use the "+" and "-" keys to raise or lower the readings to match the concentration printed on the calibration cylinder label.

7. Make sure the correct cylinder of gas is attached before

attempting to adjust the span! If the concentration of gas reachi ng the sensor is too low to al low the instrument to be adjusted, or if the wrong type of gas i s applied to the sensor being adjusted, the alarms will be

↔

15 minutes

Page 15

Page 17

activated and a screen will be displayed indicating that the ins trument “CANT SPAN”. Pressing the Mode button cl ears the “CANT SPAN” message and returns the instrument to normal operation.

↔

In the event t hat a “CANT SPAN” message is displayed, verify the type and concentration of the gas being used is correct for the sensor being calibrated, and replace the cylinder if necessary. Verify that the flow rate of the regulator is 1.0 lpm. If the "CANT SPAN" message is repeated it may indicate that the sensor is unresponsive, or dead, and requir es replacement.

8. When span calibration has been completed, press and hold th e "Cal" button down until the LCD s creen indicates that calibration is complete by showing the message “DONE”. The ZoneGuard will then turn itself off.

Caution: The “Cal” button must be held down until

the screen in dicates that span calibration has been successfully completed.

If the button is released before this message is displayed, span values will not be updated, and remain unchanged from the last time a span calibration was successfully completed.

Pressing the Mode button at any time cancels the manual span calibration procedure. A screen will announce “NO SAVE” after which the instrument will turn itself off.

↔

A sen sor that cannot be calibrated or is found to be ou t of tolerance should be replaced immediately. An instrument that fails calibration may not be used until test ing with known concentration test gas determines that accuracy has been restored, and the instru ment is once again fit for use.

Pressing the Mode button at any time during the span adjustment cancels the procedure, and causes the calibration values in memory to remain unchanged from the last time a span calibration adjustment was made.

3.7.3 Manual true zero span calibration for

oxygen sensors

Note: During normal operation of a ZoneGuard system for the detection of oxygen, the only calibration adjustment necessary is the automatic fresh air “zero” procedure as discussed in Section 3.6.1.

Following reinitialization of the instrument, or in cases where the ZoneGuard is being used to monitor oxygen lev e ls that are close to 0.0%/volume and increased accuracy near 0 is required, th e ZoneGuard may be manually span adjusted. A

cylinder of calibration gas containing 100% nitrogen and no oxygen is ne cessary for this calibration routine.

If the ZoneGuard is not span adjusted following reiniti alization, message screens will indicate “NEED CAL” when the instrument is next turned on.

↔

1. Make sure gas readings are given in numbers. If the display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, si mu ltaneously hold down the "+" and"-" keys as discussed in section 2.9.3.

2. Make sure the ZoneGuard system has been turned on and operating for a sufficient period of time for the sensor readings to have stabilized fully before initiating manual calibration procedures . If the oxygen sensor has just been replaced, the ZoneGu ard for oxygen should be turned on and allowed to stabilize for one hour pri o r to performing any of the calibration options.

3. Turn the instrument off by pressing and holding the Mode button until Off is displayed.

4. While holding down the "Cal" bu tton, press the Mode button to turn the ZoneGuard back on. Release the button when the word “ SPAN” appears. The display sh ould alternate between “SPAN” and the c urrent oxygen reading (20.9 in fresh air). Pressing the Mode button at any time cancels the span calibration.

↔

5. Screw the regulator into the cylinder and connect it to the detector using the short section of tubing and the calibration adapter. The regulator will automatically begin flowing calibration gas at the correct flow rate as soon as it is screwed into the cylinder of gas.

6. Allow the reading to stabilize. If the reading is a positive number, use the “+” and “-“ keys to bring the value to zero.

7. When finished, press and hold down the “Cal” key until the display reads “DONE”.

8. Perform a fresh air zero adjustment as discussed in section 3.6.1 when the instrument is next turned on.

Page 16

Page 18

CHAPTER 4. SETTING ALARM LEVELS

ZoneGuard alarms are user adjustable and may be set anywhere within the range of the sensor channel. When an alarm set point i s exceeded a loud audible alarm sounds, the appropriate LED is activated, and (if equipped) the optional strobe light(s) and/or remote audible alarms are activated. In addition, any other alarm devices controlled by means of the ZoneGuard relays will also be activated.

ZoneGuard alarms are normally self resetting. When readings drop below the alarm setpoint, the alarm ceases. It is possible, if desired, to se t ZoneGuard alarms so that they “latch”. In the latched condition, once an alarm occurs both visual and audi ble alarms continue to sound even after the atmospheric hazard has cleared. The instrument must be manually reset by pressing the Mode button. Pressing the Mode button s ilences th e alarms and restores n ormal operation. Procedures for latching ZoneGuard alarms are given in the next section.

6. Press the “Cal” button again to advance the display to the next available alarm adjustment option, enabling or disabling the warning level (Low) audible alarm. The display alternates between a screen which shows the message “AUD” and the status of the warnin g level alarm, either “ON” or OFF”. Use the “+” or “-” buttons to enable or disable this feature.

↔

7. Press the “Cal” button again to advance the display to the next available alarm adjustment option, “latching” the warning alarm. In the latched condition, the warning alarms will continue to sound even after the alarm condition has cleared. Latched alarms will continue to sound until they are manually silenced by pressing the Mode button. The display alternates between a screen which shows the mess age “ L OCK” and the status of the alarm latch condition, either “ON” or OFF”. Use the “+” or “-” buttons to enable or disable th is feature.

4.1 Alarm adjustment sequence

It is necessary to be in the "Alarm Adjust" mode to change alarm settings.

ZoneGuard default alarm settings are listed in Appendix C.

Note: The order of these screens may be different depending on software version and sensor type. Instruments equipped with a toxic or combustible gas sensor are equipped with a low “warning” alarm and a high “danger” alarm. Instruments equipped with an oxygen sensor include ascending and descending low “warning” alarms and high “danger” alarms (a total of four alarm settings).

To enter the alarm adjust mode:

1. Make sure gas readings are given in numbers. If the display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, simultaneously hold down the "+" and"-" keys as discussed in section 2.9.3.

2. Turn the ZoneGuard off by pressing and holding the Mode button until the LCD goes blank. When the button is released the LCD will display the message “OFF”.

3. With the unit turned off, press and h o ld down the "Alarm" button.

4. While holding down the "Alarm" button, press the Mode button to turn the ZoneGuard back on.

5. A screen will appear showing the first alarm point to be adjusted, the “Low” (warning level) al arm set point. Use the "+" and "-" keys to raise or lower the Low al arm set point.

↔

→

↔

8. Press the “Cal” button again to advance the display to the next availabl e alarm adjustment option, the high level (Danger) alarm setpoint. Use the “+” and “-” keys to raise or lower the High alarm set point.

↔

9. Press “Cal” again to advance to the enable/disable option for the Danger level alarm. Set as discussed in Step 6.

10. Press “Cal” agai n to advance to the alarm latching option for the “Danger” (high) alarm. Latching the Danger level alarm is in the same way as latching the warning level alarm (see step 7).

11. When all alarm adjustments have been completed, press and hold the "Alarm" button down until an information screen indicates that alarm adjustment is DONE.

Caution: The “Alarm” button must be h e ld down until the screen in dicates that alarm adjustment has been successfully completed.

Failur e to pr ess and hold the “Alarm” button down until the “DONE” message is displayed will cause the alarm settings to revert to the way they were the last time the adjustment was successfully completed.

Pressing the Mode button at any time cancels the alarm adjustment mode, and returns the instrument to the gas reading screen. A screen will announce “NO SAVE” after which the instrument will turn itself off.

↓

→

Page 17

Page 19

↔

4.2 Restoring the factory default alarm settings

ZoneGuard al arm settings are set conservatively at the factory. (See Appendix C) It is possible to restore these default settings at any time by doing the following.

1. Make sure gas readings are given in numbers. If the

2. Press the "Alarm" button on the instrument key-pad.

The display will briefly show the default alarm message, and the ty pe of sensor currentl y installed.

audible alarm, LED alarm light indicators, optional strobe lights or horn, as well as other alarm devices or peripheral equipment controlled by means of the ZoneGuard relay contacts.

To use the “Alarm Test” function:

1. Make sure gas readings are given in numbers. If the display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, simultaneousl y hold down the "+" and"-" keys as discussed in section 2.9.3.

2. Simultaneously press the “Alarm” and “Cal” buttons to begin the test. The displ a y will show the message screens, “ALRM TEST”, followed by numerical readings.

→

3. This screen will be followed by several more showing the specific default alarm settings. These screens will be shown in continuous r o tation. In the case of a ZoneGuard with a hydrogen sulfide sensor installed, the following sequence of screens would be shown.

→

4. Push and hold the "Alarm" button to restore the factory default alarm setting s. The display indicates when the settings have been restored:

5. If the Mode button is pushed, the current alarm settings remain unchanged, and the display shows the following screen:

→

3. The readings shown on the ZoneGuard display will slowly “ramp” up from zero to 10% above the high alarm setpoint, then back down again. The audible an d visual alarms will be activated as the readings exceed the pre-set alarm levels. (In the case of ZoneGuard systems equipped with an oxygen sensor, readings will both ramp up through the “ascending” warning and danger alarms for oxygen enrichment, as well as ramp “down” in order to test the “descending” warning and danger alarms for oxygen deficiency.)

4. The ZoneGuard will automatically return to normal operation when the Alarm Test function has been completed.

5. The Alarm Test can be terminated at any time by pressing the Mode button.

↔

6. After selection of the default or current alarm settings has been made, the display reverts to the current gas reading screen.

4.3 Alarm Test function

ZoneGuard s oftware in cludes an “Alarm Test” function that can be used to automatically “ramp” readings throughout the full range of the s ensor. The “Alarm Test” function is used to verify alarm setpoints as well as the proper activation of the

Page 18

Page 20

CHAPTER 5. ADVANCED FUNCTIONS

5.1 ZoneGuard Advanced features

overview

The ZoneGuard microprocessor circuitry makes possible a number of advanced features and capabilities. The four push buttons located on the inside of the controller housin g door are used to program advanced ZoneGuard functions. The techn ique for usin g these buttons requires several buttons to be pressed and h e ld at the same time.

Caution: Do not use this technique with any other

combination of buttons than those listed below. Doing so may result in unintended changes to the instrument setup.

5.2 Re-setting the calibration gas

concentration

During auto calibration adjustment the ZoneGuard adjusts the sensitivity of the sensor to match the concentration of the gas used to calibrate the sen sor. The value the instrument uses to adjust the reading is the calibration gas concentration stored in the instrumen t memory.

For instance, Biosystems normally supplies 50 ppm carbon monoxide calibration gas for use in calibrating CO ZoneGuard detectors. This is the default calibration gas concentration stored in the instrumen t memory. When gas is appli ed to the sensor during auto calibration, the instrument automaticall y adjusts the calibration constants to produce readings which match th is 50 ppm concentration.

Sensor Gas us ed

to calibrate

sensor Oxygen Zero Air 20.9% 20.9% Combustible

gas Carbon

monoxide Hydrogen

sulfide Sulfur

dioxide Chlorine Cl2 5 ppm 5 ppm Chlorine

dioxide Phosphi ne PH3 5 ppm 5 ppm Nitrogen

dioxide

Table 5.2. Default calibration gas concentrations used

It is necessary to r e-set the calibra tion gas concentration stored in instrument memory before making use of a different calibration gas concentration.

Propane

Equivalent

CO 50 ppm 50 ppm

H2S 25 ppm 25 ppm

SO2 10 ppm 10 ppm

Cl2 5 ppm 1.7 ppm

NO2 5 ppm 5 ppm

during auto-calibration adjustment

True cal gas concentration

50% LEL 50% LEL

Value us ed by ZoneGuard to adjust readings

Do not reset the calibration gas concentration unless you are using a calibration gas concen t ration which dif f e rs from that normally supplied by Biosystems for use in calibrating your instrument. Non-matching calibration gas and calibration gas value settings will lead to inaccurate and potentially dangerous readings.

Customers are strongly urged to use only Biosystems calibration materials when calibrating their ZoneGuard detector. Use of non-standard calibration gas and/or calibration kit components can lead to dangerously inaccurate readings and may void the standard Biosystems warranty.

Use the following procedure to re-set the calibration gas concentration:

1. Make sure gas readings are given in numbers. If the

display shows “OK”, then the ZoneGuard is currently being operated in the “Text Only” mode. To change over to Basic mode, simultaneousl y hold down the "+" and"-" keys as discussed in section 2.9.3. 2. Turn the instrument off by pressing the Mode button until the display blanks.

3. While holding down the “+” button, press the Mode

button to turn the ZoneGuard back on.

4. The ZoneGuard LCD will display alternating “CAL” and

“GAS” messages for 4 seconds. The display will then alternate between the current concentration stored in memory and the “GAS” message screens.

5. Use the “+” and “-” buttons to change the concentration.

6. Once the proper new concentration has been selected,

press and hold down the “Alarm” button for three seconds . Do not release the “ Alarm” button until the LCD displays the message “DONE” to indicate that the new value has been successfully entered.

7. Pressing the Mode button at any time cancels the

procedure. The LCD will show the message “NO SAVE” to i ndicate that the calibration gas concentration values have not been changed.

Page 19

Page 21

Chapter 6. ZoneGuard Condensed Operating Instructions

Operation Procedure

Turn on Press Mode. Turn off Press and hold Mode until ZoneGuard shuts off. Change operating mode Turn Zon eGuard on. Simultaneou sly press “+” and “-” to switch between

TEXT ONLY and BASIC operating modes.

Enable/disable use of Mode button Turn ZoneGuard on. Press and hold “+” to disable the Mode button. Press

and hold “+” to re-enable the Mode button.

Auto calibration Turn ZoneGuard on. In fresh air, press Mode 3 times to enter “Auto

Calibration Mode”. Press Mode to do Auto-Zero. When complete press Mode to do Auto Span. Attach calibration adapter. Apply span gas. Remove fittings when Auto Cal complete.

Manual fresh air calibration Turn ZoneGuard on. In fresh air, pres s CAL to enter fresh air “zero” mode.

Press CAL to do the fresh air zero; or press Mode to exit without doin g “zero”.

Manual span calibration Hold CAL down and tur n ZoneGuard on. Attach calibration adapter. Apply

span gas. Wait for the ZoneGu ard’s reading to stabilize. Use “+” and “-” to adjust the reading to the value printed on the span gas con tainer. Press an d hold CAL to save the span adjustment; or pr ess Mode to exit the manual span without saving.

Set default alarms Turn ZoneGuard on. Press ALARM to enter “Default Alarm Mode”.

ZoneGuard will display the default alarm settings. Press and hold ALARM to restore the factory defaul t alarm settings; or press Mode to exit without setting the alarm levels to the default values.

Alarm adjustments Hold ALARM down and turn ZoneGuard on. Press CAL to switch to the alarm

option to be changed. Use “+” and “-” to adjust the alarm option to the desi r ed value. Press and hold ALARM to save the changes to the ZoneGuard; or press Mode to exit alarm adjustment mode without saving any changes.

Alarm test Turn ZoneGuard on. Press ALARM and CAL simultaneously to do an alarm

test. Press Mode to return ZoneGuard to normal operation.

APPENDICES

Appendix A ZoneGuard fixed gas detection system ordering information

ZoneGuard system for:

Part No. Part No. Part No.

Oxygen 54-16-90 54-16-900 54-16-901 LEL combustibl e NA NA 54-16-801 Carbon monoxide 54-16-01 54-16-010 54-16-011 Hydrogen sulfide 54-16-02 54-16-020 54-16-021 Sulfur dioxide 54-16-03 54-16- 030 54-16-031 Chlorine 54-16-08 54-16-080 54-16-081 Chlorine dioxide 54-16-12 54-16- 120 54-16-121 Phosphine 54-16-13 54-16-130 54-16-131 Nitrogen dioxide 54-16-09 54-16-090 54-16-091

With integrally mounted sensor

With remote sensor i n standard housing

With remote sensor in explosionproof housing

Page 22

Accessories

Part No. Description

54-17-A0101 Single integrally mounted external strobe (red) 54-17-A0102 Dual integrall y mounted external strobes (red and amber) 54-17-A0201 Remote programmable (volume adjustable) audible alarm 54-17-A0202 Remote high intensity audi ble alarm 54-17-A0301 Splash guard for sensors inst al led in explosion-proof remote housings 54-17-A0302 Splash guard for sensors installed in standard housings 54-17-A0401 Wire, 22 gauge, 6 conductor, twisted pair, shielded with drain, used to connect oxygen remote detectors

with ZoneGuard controller, 50 feet

54-17-A0402 Wire, 22 gauge, 4 conductor, twisted pair, shielded with drain, used to connect toxic remote detectors

with ZoneGuard controller, 50 feet

54-17-A0403 Wire, 18 gauge, 4 conductor, twisted pair , shi elded with drain, used to connect combustibl e remot e

detectors with ZoneGuard controller, 50 feet

Calibration Materials

54-17-K0301 Calibrati on ki t for ZoneGuard fixed detection systems. Includes foam l ined carrying case with room f or

up to 3 cylinders of gas, one standard 1. 0 LPM fi xed flow rate regulator , calibration adapt or s, and 3 f eet

of tubing. Kit does not include gas. 54-17-A0303 Calibrati on adapt or f or sensors i nst al led in standard housings 54-17-A0304 Calibrati on adapt or for sensors installed in explosion-proof housi ngs 54-9031 Methane 50% LEL in air, 103 liters 54-9032E Propane 50% LEL equivalent in air, 103 liters 54-9033 Carbon monoxide (CO), 50 ppm in air, 103 l iters 54-9034 Hydrogen sulfide (H2S), 25 ppm i n ni trogen, 58 liters 54-9037 Sulfur dioxide (SO2), 10 ppm i n nitrogen, 58 liters 54-9052 Chlorine (Cl2), 5 ppm i n nitrogen, 58 liters 54-9055 Nitric oxide (NO), 30 ppm in nit r ogen, 58 l i t ers 54-9056 Nitrogen dioxide (NO2), 5 ppm i n nitrogen, 58 liters 54-9065 Phosphine (PH3), 5 ppm i n nitrogen, 58 liters 54-9039 Zero Air, 20.9% oxygen in nitrogen, 103 liters

Appendix B ZoneGuard fixed gas detection system technical specifications

ZoneGuard VAC Outputs Warning (Low) and Danger (high) alarm, DPDT relay - contacts rated 5 Amp at 250 VAC, non-

inductive load ZoneGuard VDC Outputs Warning (Low) and Danger (high) alarm +12 VDC at 0.5 Amp ZoneGuard Display 8 character 14-segment backlit LCD for gas r eadings and other messages ZoneGuard Indicators

(LED) Audible alarm Built-i n audi ble alarm (85 dB at 3 feet) Power Requirements 110 VAC - 50/60 Hz Temperature Range

Humidit y Range 0 to 100% RH Classification for use in

hazardous locations Weather Protection Contr oller housing: NEMA 4X enclosure (IP rating of 654)

Dimensions ZoneGuard controller: 10” (25 cm) x 7.5” ( 19 cm) x 5.25” (13 cm ) Wi r i ng: For oxygen remote detectors use (minimum) 22 gauge AWG, 6 conductor twisted-pair shielded

Power on: green; low alarm: amber; high alarm: red

System components designed to function over range of -40° F to 110° F (-40° C to 43° C)

(Type of sensor installed may modify range.)

Sensors installed in explosion-proof rem ot e housings: Submitted for Classi fication by ULCas

Explosion-Proof for Class 1, Di vision 1, Groups A, B, C, D, E, F, anf G hazardous locations.

with drain. For t oxic use (minim um) 22 gauge AWG, 4 conductor twisted-pair shielded with

drain. For combustible use 18 gauge AWG, 4 conduct or t wi sted-pair shielded with drain.

Page 21

Page 23

Appendix C ZoneGuard default alarm settings

Gas Warning Level Danger Level

Combustible gas 10% LEL 20% LEL Oxygen Low: 19.5%

High:22.0% Carbon monox ide 35 PPM 100 PPM Hydrogen sulfide 10 PPM 20 PPM Sulf ur dioxi de 2.0 PPM 5.0 PPM Nitrogen di oxide 1.0 PPM 5.0 PPM Chlorine 0.5 PP M 1.0 PPM Chlorine dioxide 0.3 PPM 1.0 PPM Phosphine 0.3 PPM 1.0 PPM

Appendix D ZoneGuard sensor ranges

Gas Range

Combustible gas 0-100% LE L Oxygen 0-25% Carbon monox ide 0-1000 PPM Hydrogen sulfide 0-200 PPM Sulf ur dioxi de 0-100 PPM Nitrogen di oxide 0-20 PPM Chlorine 0-20 PPM Chlorine dioxide 0-10 PPM Phosphine 0-10 PPM

Low: 18.0% High:23.5%

Appendix E ZoneGuard toxic sensor cross sensitivity data

The table below lists the cross sensitivity of electrochemical t oxic sensors used in Biosystems por t abl e gas detectors to gases other than their target gas. Depending on the nature of the reaction each gas has with the sensor, the effect can either decrease the signal (negative cross sensitivit y) or i ncr ease the signal; (posit i ve cross sensitiv i t y) . Each figure represents the reaction of the sensor to 100 ppm of gas, t hus pr oviding a percentage sensitivity to that gas relat i ve to its target gas.

SENSOR TYPE Carbon

monoxide (CO)

CO H2S SO2 NO NO2 Cl2 H2 HCN HCl NH3 Ethylene

100 < 10 0 0 0 0 < 10 100 0 < 10 ~ 20 100 < 30 < 0 0 0 0 0 < 15 ~ - 20 ~ - 120 100 120 40 < 10 ~ - 20 < 5 90 100 ~ 33 < 60 < 5 0 0 0 0 < 15 0 < 50 < 1 0 0

< 3 0 0 0 0 0

0 0 0 0 0 0

~ 50 0 0 0 0 0

Hydrogen sulfide (H2S)

Sulfur dioxide (SO2)

Nitrogen dioxide (NO2)

Chlorine (Cl2)

Chlorine dioxide (ClO2)

~ − 20 ~ − 20 ~ − 7

< − 0.5

0 0

Phosphine (PH3)

Page 22

Page 24

Appendix F ZoneGuard dimensional drawings, electrical schematics, and wiring

diagrams

Dimensional drawing of ZoneGuard controller

Page 23

Page 25

Dimensional drawing of ZoneGuard explosion-proof remote detector assembly

Page 24

Page 26

Dimensional drawing of ZoneGuard standard (non-explosion-proof) remote detector assembly

Page 25

Page 27

Appendix G Calibration

Frequency

One of the most common questions that we are asked at Biosystems is:

“How often sh ould I calibr ate my g as detector?”

Sensor Reliability and Accuracy

Today’s sensors are designed to provide years of reliable service. In fact, m any sensors are designed so that with normal use they will only lose 5% of their sensitivit y per year or 10% over a two-year period. Given this, it should be possible to use a sensor for up to two full years without any significant loss of sensitivity.

A lot of sensors indeed do last that long with only minimal loss of sensitivity. However, there are a number of reasons why a sensor may unexpectedly lose additional sensiti v i t y or even fail to respond to gas. Such reasons include desiccation, poisoning, physical restriction of airfl ow, overexposure, leakage, and mechanical damage due to dropping or immersion.

Verification of Accuracy

Wi t h so many reasons why a sensor can lose sensitivity and given the fact that dependable sensors can be key to survival in a hazardous environment, frequent verification of sensor performance is paramount.

There is only one sure way to verify that a sensor can respond to the gas for which it is designed. That i s t o expose it to a known concentration of tar get gas and compare the reading with the concentration of the gas. This is referred to as a “bump” test. This test is very simple and takes only a few seconds to accomplish. The saf est

course of action is to do a “bump” test prior t o each day’s use. It is not

necessary to make a calibration adjustment i f t he readings are between 90% and 120% of the expected value. As an example, if a CO sensor is checked using a gas concentration of 50 PPM it is not necessary to perform a calibrati on unl ess the readings are either below 45 PPM or above 60 PPM.

Lengthening the Intervals

between Verification of

Accuracy

We are often asked whether there are any circumst ances in which the period between accuracy checks may be lengthened.

Biosystems is not t he only manufactur er to be asked this question! One of the professional organizations to which Biosyst em s belongs is the Industrial Saf ety Equipm ent As s oc iation ( ISEA). The “Instrument Products” group of this organization has been very active in developing a protocol to clari fy the mini mum conditions under which the interval between accuracy checks may be lengthened.

A number of leading gas detection equipment manufact ur ers have participat ed in the development of the ISEA guidelines concerning c alibrat ion frequency. Biosystems procedures cl osel y fo llow t hese guideli nes.

If your operating procedures do not permit daily checking of the sensors, Biosystems recommends the following procedure to establish a safe and prudent accuracy check schedule for your Biosystems instr uments:

1. During a period of initial use of at least 10 days in the intended atmosphere, check the sensor response daily to be sure there is nothing in the atmosphere that is poisoning the sensor(s). The period of initi al use must be of sufficient durat i on t o ensure that the sensors are exposed to all conditions that might have an adverse effect on the sensors.

2. If t hese tests demonstrate that it is not necessary to make adjustments, the time between checks may be lengthened. The interval between accuracy checking should not exceed 30 days.

3. When the interval has been extended the toxic and combustible gas sensors should be replaced immediately upon warranty expiration. This will minimize the risk of failur e during the interval between sensor checks.

4. The history of t he inst r ument response between verifications should be kept. Any conditions, incidents, experiences, or exposure to contami nants that might have an adverse effect on the calibration state of the sensors should trigger immediate re-verification of accuracy before further use.

5. Any changes in the environment in which the instrum ent is being used, or changes in the work that is being performed, should t r i gger a resumption of dai ly checking.

6. If t here is any doubt at any t ime as to the accuracy of the sensors, verify the accuracy of the sensors by exposing them to known concentration test gas before further use.

Gas detectors used for the detection of oxygen deficiencies, fl ammable gases and vapors, or toxic contaminants m ust be maintained and operated properly to do the job they were designed to do. Always follow the guidelines provided by the manufacturer for any gas detection equipment you use!

If there is any doubt regarding your gas detector's accuracy, do an accuracy check! All it takes is a few mom ents to verify whether or not your instruments are safe to use.

One Button Auto Calibration

Whi l e it is only necessary to do a “bump” test to ensure that the sensors are working properly, all current Biosystems gas detectors offer a one button auto cali br ation feature. This feature allows you to calibr at e a Biosystems gas detector in about the same time as it takes to complete a “bump” t est. The use of autom atic bump test and cali bration stations can further simpl i f y t he tasks, whil e automati c al ly maint ai ni ng records.

Don't take a chance

with your life.

Verify accuracy frequently!

Biosystems Applications Notes are available at the Biosystems website at

http://www.biosystems.com

Page 28

BIOSYSTEMS STANDARD WARRANTY GAS DETECTION PRODUCTS

General

Biosystems LLC (hereafter Biosystems) warrants gas detectors, sensors and accessories manufactured and sold by Biosystems, to be free from defects in materials and workmanship for the periods listed in the tables below.

Damages to any Biosystems products that result from abuse, alteration, power fluctuations including surges and lightning strikes, incorrect voltage settings, incorrect batteries, or repair procedures not made in accordance with the Instrument’s Reference Manual are not covered by the Biosystems standard warranty.

The obligation of Biosystems under this warranty is limited to the repair or replacement of components deemed by the Biosystems Instrument Service Department to hav e been defective under the scope of this standard warranty. To receive considerati on for warranty repair or replacement procedures , products must be returned with transportation and shipping charges prepaid to Biosystems at its manufacturing location in Middletown, Connecticut, or to a Biosystems Authorized Warranty Service Center. It is necessary to obtain a return authorization number from Biosystems prior to shipment.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES AND REPRESEN TATIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. BIOSYSTEMS WILL NOT BE LIABLE FOR LOSS OR DAMAGE OF ANY KIND CONNECTED TO THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION O R OPERATE PROPERLY.

Instrument & Accessory Warranty Periods

Product(s) Warranty Period

PhD5, PhD Lite, PhD Plus, PhD Ultra, Cannonball3, MultiVision, Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra, ToxiVision, Ex Chek

ToxiPro®, MultiPro

ToxiLtd®

Mighty-Tox

Mighty- Tox 2 Prorated credit is given towards repair or purchase of a new unit of

the same type. IQ Systems, Series 3000, Airpanel, T r avel panel, ZoneGuar d,

Gas9Chek1 and Gas9Chek4 Battery pac k s and charger s, sampling pumps and other

components, whic h by their design are consumed or depleted during normal operation, or whic h may requir e per iodic replacement

As long as the instrument is in service 2 years from date of pur c hase

2 years after ac tivation or 2 year s after the “Must Be Activated By” date, whichever comes first

90 days after ac tivation or 90 days after the “Must Be Activated By” date, whichever comes first

0 – 6 months of use 100% c r edit 6 – 12 months of use 75% credit 12 – 18 months of use 50% credit 18 – 24 months of use 25% credit

One year f rom the date of purchase

Sensor Warranty Periods

Instrument(s) Sensor Type(s) Warranty Period

PhD Plus, PhD Ultra, PhD5, PhD Lite, Cannonball3, MultiVision, MultiPro,

ToxiVision, Toxi Pro Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra All O thers All Sensors 1 Year

** Damage to combustible gas sensors by acute or chronic exposure to known sensor poisons such as volat i l e lead (aviation gasol i ne addi tive), hydride gases such as phosphine, and vol atile silicone gases emitted from silicone caulks/sealants, silicone rubber molded product s, laboratory glassware greases, spray lubri cant s, heat transfer fluids, waxes & poli shi ng compounds (neat or spray aerosols) , mold rel ease agent s for plastics injection mol ding operations, water proofing form ul at ions, vinyl & leather preser vat ives, and hand lotions which may contain ingredients l i st ed as cyclomethicone, di methicone and polym et hi cone (at the discretion of Biosystems Inst r ument Service departm ent) void Biosystems’ St andar d Warrant y as it appl i es t o the replacement of combustible gas sensors.

, Ex Chek

O2, LEL**, CO, CO+, H2S & Duo-Tox

2 Years

All O ther Sensors 1 Year CO, CO+, H2S 2 Years All O ther Sensors 1 Year

biosystems ZoneGuard Reference Manual

Specifications and Main Features

Frequently Asked Questions

User Manual