Gemini 501-B User Manual

SMOKE DETECTORS SENSITIVITY ANALYZER

Model 501-B

USER’S GUIDE

GEMINI SCIENTIFIC CORP.

1122-B ASTER AVENUE, SUNNYVALE, CA 94086

Phone: 408.554.0310 Fax: 408.554.7143

E-mail: Gemini@geminiscientific.com

Web: http://www.geminiscientific.com

Version 3 - May 2004

ANALYZER FOR SMOKE DETECTORS

Model 501-B Aerosol Generator

USER’S GUIDE

GEMINI SCIENTIFIC CORP., 1122-B ASTER AVENUE, SUNNYVALE, CA 94086

Version 3 – May 2004

Serial No.:

Date Calibrated:

Inspected by:

Sold To:

For technical assistance, please dial 800.582.8882

Warranty....................................................................................................................................................... 1

Warning ........................................................................................................................................................ 1

1.0 Introduction............................................................................................................................................ 2

2.0 Specifications ........................................................................................................................................ 2

3.0 Principles of Operation.......................................................................................................................... 3

3.1 General..................................................................................................................... 3

3.2 Main Elements of the Instrument ............................................................................. 3

3.2.1. Compressor and Vacuum Pumps ......................................................................... 3

3.2.2. Nebulizer and Oil Reservoir .................................................................................. 3

3.2.3. Manifold.................................................................................................................5

3.2.4. Impactor ................................................................................................................ 5

3.2.5. Drain Reservoir ..................................................................................................... 5

3.2.6. Filters..................................................................................................................... 5

3.2.7. Controls, Switches, Dilution Adjust, Pressure Adjust, Concentration Adjust ........ 5

3.2.8. Blower. Hose, Wands, Wall-mounted adaptor, diffuser and Shroud .................... 6

3.2.9. Temperature.......................................................................................................... 6

3.2.10 Exposure Time ..................................................................................................... 6

3.2.11 Operation ............................................................................................................. 7

4.0 Operating Instructions ........................................................................................................................... 9

4.1 Initial Operation ......................................................................................................... 9

4.2 Oil Temperature ........................................................................................................ 10

4.3 Test Completion ........................................................................................................ 10

4.4 Storage of Instrument................................................................................................ 10

5.0 Inspection Protocol and Test Procedures ............................................................................................. 11

5.1 General Objective ..................................................................................................... 11

5.2 Legal and Technical Authorities ................................................................................ 11

5.3 Sensitivity Ranges..................................................................................................... 12

5.4 Test Procedures........................................................................................................ 12

5.5 Calibration and Accuracy ..........................................................................................14

5.6 Operational Precautions............................................................................................ 14

6.0 Servicing................................................................................................................................................. 15

6.1 General...................................................................................................................... 15

6.2 Calibration and Working Standards .......................................................................... 15

6.3 Routine Maintenance ................................................................................................16

6.4 Problem Diagnostics ................................................................................................. 16

7.0 Replacement Parts................................................................................................................................. 17

7.1 Table of Parts ............................................................................................................ 17

7.2 Replacement of Battery............................................................................................. 17

FIGURE 1 Front View of Model 501-A Tester............................................................................................ 4

FIGURE 2 Example of Test Decision Tree & Statement of Results ..........................................................13

TABLE 1 Problem Diagnostics.................................................................................................................. 16

TABLE 2 Replacement Parts .................................................................................................................... 17

TABLE 3 Accessories ............................................................................................................................... 17

APPENDIX A Calibration of the Gemini 501-B ........................................................................................... 18

APPENDIX B Nebulizer Assembly & Maintenance..................................................................................... 19

APPENDIX C Sample Smoke Detector Test Report .................................................................................. 20

APPENDIX D Instructions on How to Change the Vacuum Filter Element ................................................ 21

APPENDIX E Material Safety Data Sheet - RUDOL OIL............................................................................ 22

APPENDIX F Pictorial Illustrations............................................................................................................... 24

APPENDIX G Duct Detector Testing ........................................................................................................... 25

Warranty

Gemini Scientific Corp. warrants the instrument described herein to be free from defects in material and factory workmanship for a period of one year, and agree to repair such instruments, which under normal use and service disclose the defect to be the fault of Gemini Scientific Corp.

Gemini Scientific Corp.’s obligation under this Warranty relates to the original purchaser and is limited to a return of the purchase price or at the Gemini Scientific Corp.'s sole discretion, to the repair or replacement of the instrument or any of its parts, which prove to be defective. For this Warranty to be in effect, any material or part alleged to be defective is to be returned to Gemini Scientific Corp. with our prior written approval, fully insured and transportation prepaid by the purchaser, within 12 months from date of delivery.

This Warranty shall not apply to an instrument which has been (l) subjected to misuse, negligence, or accident; (2) connected, installed, operated or adjusted other than in accordance with instructions furnished by the Gemini Scientific Corp.; (3) repaired, modified or serviced by someone not authorized by the Gemini Scientific Corp., so that in our judgment on the performance or reliability of the instrument has been impaired.

We reserve the right to make replacement with equivalent merchandise and to make changes at any time in the specification, design, or construction of the instrument without incurring obligation to make any commensurate changes in units previously delivered.

Gemini Scientific Corp. assumes no liability for consequential or contingent damages for a defective instrument covered by this Warranty, failure of delivery in whole or part, or for any other cause. This Warranty and the writing to which it is attached constitute the understanding of the buyer and seller so that no terms, conditions, or agreement purporting to modify the terms hereof shall be binding unless made in writing and signed by an authorized agent of the home office of the Gemini Scientific Corp.

WARNING

THE AEROSOL FROM THIS INSTRUMENT MAY BE HARMFUL TO THE HEALTH OF THE OPERATOR IF PRECAUTIONS ARE NOT TAKEN.

The Model 501-B Aerosol Generator/Smoke detector Analyzer generates an aerosol consisting of a refined NF-Grade white

mineral oil in air. Aerosol concentration at the discharge point of the hose is adjustable from 0 to 45 mg/m3 (0 to 6 mg/min). Room air would dilute the discharge quickly. The aerosol smoke is odorless and not visible. Proper precautions to avoid over exposure such as good ventilation and limited discharge time are recommended. Do not hold end of hose close to face during aerosol discharge.

The maximum allowable limit under OSHA (Occupational Safety and Health Administration) regulation in an eight-hour

weighted average for oil-based aerosol is 5 mg/m3. The RUDOLTM White Mineral Oil is approved by the FDA (Food and Drug Administration) for use on skin and incidental food contact.

To reach the OSHA allowable limit, for example, you need to discharge at the maximum concentration rate (6 mg/min) into a non-ventilated 14x12x10 feet room for a period of about 50 minutes. However, in typical testing, very little aerosol is introduced into the room. The normal time per test is only about 30 seconds at 1/4 of the maximum concentration, far below the OSHA safety limit. However, precaution is necessary to avoid situations where exposure can reach above the OSHA limit.

THIS INSTRUMENT SHOULD NOT BE USED IN OR NEAR CONCENTRATED OXYGEN ENVIRONMENTS SUCH AS OXYGEN TENTS OR OPERATING ROOMS IN A HOSPITAL.

THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TO OPERATING PERSONNEL.

The Model 501-B Aerosol Generator-Analyzer for Smoke Detectors operates on a rechargeable 12V Ni-Metal Hydride battery. This voltage appears at the serial number label and various other points on the chassis. The power of the instrument should be completely turned off before opening the front panel for filter change or repair. Only qualified personnel, who are familiar with the location of the voltage and the hazards involved, may open the cabinet with power circuit energized. When connecting a new battery, make sure to observe correct polarity. Connect the red positive (+) line to the red positive (+) battery terminal and connect the black negative (-) line to the black negative (-) battery terminal.

1.0 Introduction

The Gemini 501-B Smoke Detector Analyzer/Aerosol Generator is an instrument ideally suited to measure the sensitivity response of installed smoke detectors. The Generator produces an aerosol with particles size

characteristics resembling fire smoke. The range of concentration, between 0 and 45 mg/m3 or from 0 to 4 %/ft obscuration (UL-268), is sufficient to trigger the alarm thresholds of all UL-approved ionization and photoelectric smoke detectors.

The calibration reading for each instrument represents both the UL-268 obscuration standard in (%/ft) and to aerosol mass concentration in (mg/m3). The calibration reading on the LCD allows the operator to determine the

sensitivity of the detector and compare it to the range specified by the manufacturer as printed on the back of each detector.

The instrument can save a considerable amount of time for inspection personnel who must remove detectors from ceiling positions for periodic cleaning or testing. Using the hose, wands, and shroud, test smoke is delivered to the detector without removing it from the ceiling. From the test results, inspectors can decide whether to remove the detector for cleaning or sensitivity adjustment.

The current NFPA 72 Fire Alarm Code (1996) recommends sensitivity inspection of installed detectors within one year after installation and every alternate year thereafter.

2.0 Specifications

Aerosol Characteristics Particle size

Number median diameter......................... 0.2 micrometer (um)

Mass median diameter ............................. 0.45 um

Repeatability............................................. ± 5 %

Generation Characteristics

Test stream flow rate ................................ 60 L/min.

Aerosol flow rate....................................... 0 - 4.2 L/min.

Concentration Range

Adjustable.................................................0 - 40 mg/m3 (0 - 4 %/ft obscuration)

Reset, concentration ................................ ±4%

Type of aerosol......................................... RudolTM Oil *

Operating temperature .............................24 ±3°C (75 ±5°F)

Mechanical Characteristics

Dimensions, overall .................................. 9.5 x 6.5 x 7 in. (24.1x 16.5 x 17.8 cm)

Weight, approximately.............................. 11 lb. (5.0 kg), with battery

Hose length .............................................. 5 ft. (1.5 m)

Oil Reservoir Volume .....................................approx. 30 ml

Power Requirement ....................................... 12 V DC, 6.5 Amp-Hr Ni-MH Battery

-------------------

RUDOL oil, a NF-grade white mineral oil, aromatics-free, saturated aliphatic hydrocarbons. Viscosity = 29 centistokes @40 C. Specific

gravity = 0.87 @25 °C. RUDOL is a registered trademark of Witco Chemical Corp. It conforms to the FDA-CFR 172.878, which allows for direct skin & food contacts and stabilized with Vitamin E for long shelf life.

3.0 Principles of Operation

3.1 General

The Gemini 501-B Aerosol Generator/Smoke Detector Analyzer operates on the principle of nebulization of a liquid to produce a poly-dispersed micro-sized spray with a relatively large mass median diameter. An impactor reduces the median diameter by selectively removing the larger diameter particles. The remaining aerosol is diluted by a large volume of room air at a constant rate from the blower. Hose and wands carry the aerosol up to a shroud, which covers the test detector at the ceiling.

A dual-head compressor/vacuum diaphragm pump is used in the system. The compressor line provides the air pressure necessary for the operation of the nebulizer. Aerosol output and particle size distribution from the nebulizer is kept constant by maintaining a constant pressure from the compressor. The vacuum line provides suction to vary the aerosol concentration of the test stream by diverting part of the aerosol from the generator. The amount of diversion is controlled by an adjustable valve and measured by a flow meter.

3.2 Main Elements of the Instrument

Figure 1 shows the locations of some of the elements (pages4).

3.2.1. Compressor / Vacuum Pump

The compressor line generates the air pressure necessary to operate the nebulizer. The vacuum line removes a specified quantity of aerosol using a control valve that varies the final concentration of the aerosol in the test stream. This flow is monitored by a flow meter.

3.2.2. Nebulizer and Nebulizer Reservoir (Figure 1 (9))

The nebulizer produces the aerosol from the Rudol liquid using the pressurized air. Calibration of each instrument is based on the particular nebulizer supplied. Therefore, nebulizer is not interchangeable with other testers with different serial numbers.

WARNING: Oil for the nebulizer is stored in the 30-ml transparent acrylic nebulizer reservoir.

Before storage, oil has to be emptied from the nebulizer reservoir to prevent oil from flowing back into the system, which may damage the electronic components of the tester.

10 11

12. Filter Element

Figure 1, Front View of Model 501-B

1. Function Switch (On / Off / Battery Recharge)

2. Compressor/Pump Switch (On / Off)

3. Concentration Adjust Knob

4. Pressure Adjust Knob

5. Pressure LED Indicator

6. Dilution LED Indicator

7. Timer Reset Button

8. Pressure Line Jet

9. Nebulizer Reservoir

10. Drain Reservoir

11. Dilution Adjust Knob

8 9

3 4

3.2.3. Manifold

The manifold is a central flow-switching chamber, which connects the nebulizer, impactor, vacuum line, drain outlet, and drain reservoir. It is from this chamber that adjustable portions of the aerosol are discarded through the drain and vacuum system while the remainder goes to the final test stream.

3.2.4. Impactor

The impactor, located inside the manifold, consists of a metal disc with 3 small holes. The function of the impactor is to select the aerosol particulate with proper size distributions (smoke sized particles). Do not modify (enlarge or close) any holes on the impactor.

3.2.5. Drain Reservoir (Figure 1 (10))

In order to control the concentration of aerosol in the test stream, varying amounts of aerosol from the nebulizer are pulled by the vacuum into the filter, or by gravity into the drain reservoir. The drain reservoir should be attached to the drain outlet before any testing. In order for the system to work, the drain reservoir should not contain any leakage. The drain reservoir should be emptied when it is about 3/4 full or before storage.

3.2.6. Filters

The disposable filter (blue) on the front panel absorbs all of the excess smoke from the vacuum stream before it enters the vacuum pump. It protects the mass monitor and the vacuum pump.

The filter SHOULD be replaced when the filter element turns red, which is after about 100-150 tests.

3.2.7. Controls

Function Switch (ON/OFF/Battery recharge) The switch should be set at the “OFF” position during

storage or between tests. When the switch is set at the “ON” position, the blower will be turned on and the system will be ready. To charge the internal battery, connect the NiMH charger provided and turn the switch to the “Battery recharge” position.

Compressor/Pump Switch (ON/OFF) When the system is ready (Function Switch set at the “ON”

position), set the Compressor Switch at the “ON” position will turn on the compressor. Concentration of the aerosol can then be adjusted using the Concentration Adjust knob.

Dilution Adjust. The dilution LED lights (Red, Green, Yellow) indicates the dilution airflow rate. The

correct rate is shown by the green light. Red and yellow mean "high" and "low" respectively. To maintain the correct airflow rate, adjust the dilution knob on the right of the top panel until the green light is on. If normal adjustment is not enough, one or a few of the 6 openings in the diffuser located inside the shroud (the clear plastic bowl) may have to be enlarged or covered. (See Table 1, Problem Diagnostics, P. 15).

Pressure Adjust The pressure LED lights (Red, Green, Yellow) indicates the compressed air

pressure. The correct rate is shown by the green light. Red and yellow mean "high" and "low" respectively. To maintain the correct pressure, turn the pressure adjust knob on the top panel until the green light is on.

Concentration Adjust. Use the concentration adjust valve to adjust the sensitivity reading on your

LCD. Turning clockwise will lower the sensitivity readout (smaller amount of smoke output) whereas turning counter-clockwise will increase the sensitivity readout (larger amount of smoke output).

Internal Battery / External Power Source Switch (for newer Models May 2004 or later only) on the left

panel. When set at the “INT BAT” internal battery position, the tester will be powered by the

internal NiMH battery. When set at the “EXT Power” position, the tester will be powered by an external power source, either through the provided AC Adapter (12VDC output) or any other 12V DC battery. The AC Adapter or an external 12VDC battery must be connected to the “AC Adapter/Ext Battery” jack next to the “INT BAT/EXT Power” switch.

3.2.8. Blower, Hose, Wands, Diffuser, and Shroud

Blower. The blower provides air to dilute the aerosol from the nebulizer. The dilution-air adjust knob

controls the flow rate of the dilution air (See 3.2.7).

Hose and wand. Insert the plastic end of the 5-ft., 1-1/2 inch diameter flexible hose to the output

port (right side) of the analyzer and connect the other end to the wand and the shroud. An operator using a single-length wand can reach a normal ceiling height of about 8 feet. Additional wands may be coupled to reach ceilings as high as 20 feet. For a 30-feet application, an optional high-reach kit is also available. It is a retractable pole that allows you to reach up to 30-feet ceiling.

Wall-mounted detectors testing adaptor Connect one end of the adaptor to the wand and the other

end to the diffuser and the shroud. The adaptor can be bent at any arbitrary angle up to 90 degree. This facilitates the testing of wall-mounted smoke detectors.

Shroud. The purpose of the shroud (the clear plastic bowl) is to cover the detector so that the

aerosol of known concentration is not affected by room air. For good results the edge of the shroud should touch most of the wall surface around the detector.

However, since the test stream is flowing out at a high rate of about 2.1 ft

/min (60 L/min), room air would not be able to dilute the smoke stream even though the shroud is as much as 1/2 inch away from the wall. For some older models of smoke detectors and duct detectors, a different size of shroud may be needed. Please contact Gemini Scientific for more info.

Diffuser. The diffuser inside the shroud has six holes, which limits the flow rate and distribute the

smoke evenly to the detector. It also serves as a connection between the wands and the shroud. Holes on the diffuser may need to be closed or enlarged to attain correct flow rate.

(See 3.2.7)

Duct detector testing adaptor This optional testing adaptor allows you to test duct detectors.

3.2.9 Temperature

To monitor the aerosol temperature, the temperature probe should be inserted into the small aluminum well on top of the nebulizer. Temperature reading is shown at the lower left corner of the LCD. The sensitivity reading on the LCD is corrected for fluctuations in temperature. However, operating temperature should not be below 70

F when smoke output is greatly reduced due to the low temperature. Temperature above 90 degree during testing would be fine since the sensitivity is adjusted accordingly.

3.2.10 Exposure Time

The purpose of the timer is to help the inspector control the smoke exposure time. If the detector does not respond within 30 to 45 seconds after exposure, stop the test. Reset to a higher concentration level for the next test. However, for some brands of detectors (with a longer sampling time), or in borderline cases, 45 to 55 seconds or more of exposure time may be required to find the maximum sensitivity.

How fast the detector responds should not

be used to determine the sensitivity of the detector. To avoid nuisance alarm, some detectors are designed to alarm only after exposure to smoke for at least 24 seconds at the proper designated level of concentration. Please refer to the smoke detector manufacturer’s specifications and manual for more details.

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