Heath Consultants Gasurveyor 500 User Manual

Heath Gasurveyor 3-500

User’s Manual

Issue 4 20/07/04 Part Number: 42129

GMI welcomes comments on all our publications. Your comments can be of great value in helping us to improve our customer publications. Please send any comments that you have to our Sales Department at GMI. Contact details are provided inside the back cover of this handbook.

Instrument Service / Repair contact details are also provided inside the back cover of this handbook.

COPYRIGHT

This User Handbook is copyright of Gas Measurement Instruments Ltd (GMI) and the information contained within, is for use only with the Gasurveyor 3-500 instrument. Reproduction, in whole or in part, including utilisation in machines capable of reproduction or retrieval without written permission of Gas Measurement Instruments Ltd is prohibited. Reverse engineering is not permitted.

LIABILITY

Every care has been taken in the preparation of this document, but GMI Ltd do not accept any responsibility for errors or omissions and their consequences. Information in this document is subject to change without notice. This document does not constitute a specification or basis for a contract. Your statutory rights under law are not affected.

MODIFICATION NOTICES

GMI aim to notify customers of relevant changes in the product operation and maintain this manual up to date. In view of the policy of continuous product improvement there may be operational differences between the latest product and this manual.

This Handbook is an important part of the Gasurveyor 3-500 product. Please note the following points:

• It should be kept with the instrument for the life of the product.

• Amendments should be attached.

• This Handbook should be passed on to any subsequent owner/user of the instrument.

• Although every care is taken in the preparation of this Handbook it does not constitute a specification for the instrument.

SOFTWARE

Software supplied on EPROM or similar device for use in a particular product, may only be used in that product and may not be copied without the written permission of Gas Measurement Instruments Ltd. Reproduction or disassembly of such embodied programmes or algorithms is prohibited. Ownership of such software is not transferable and GMI Ltd does not warrant that the operation of the software will be error free or that the software will meet the customer’s requirements.

DISPOSAL ADVICE

When no longer in use, dispose of the instrument carefully and with respect for the environment. GMI will dispose of the instrument without charge if returned to the factory.

GASURVEYOR 3-500 USER HANDBOOK

SAFETY

• The instrument must be regularly serviced and calibrated by fully trained personnel in a safe area.

• Batteries: Alkaline batteries or *Rechargeable battery pack must be exchanged (*and recharged) in a safe area and fitted correctly before use. Never use damaged batteries or expose to extreme heat. See Section 4 : OPERATOR MAINTENANCE.

• Only GMI replacement parts should be used.

• If the instrument detects gas, follow your own organisation’s procedures and operational guidelines.

• The combustion chamber is a flameproof assembly and must not be opened in the presence of a flammable atmosphere.

• Gasurveyor 3-500 instruments are certified as EEx iad IIC T4

(-20oC< Tamb < 50oC). BAS01ATEX2292 II 2 G.

UL Class 1 Groups A, B, C and D.

• This equipment is designed and manufactured to protect against other hazards as defined in paragraph 1.2.7 of Annex II of the ATEX Directive 94/9/EC

Any right of claim relating to product liability or consequential damage to any third party against GMI is removed if the warnings are not observed.

AREAS OF USE

Exposure to certain chemicals can result in a loss of sensitivity of the flammable sensor. Where such environments are known or suspected it is recommended that more frequent response checks are carried out. The chemical compounds that can cause loss of sensitivity include Silicones, Lead, Halogens and Sulphur. Do not use instrument in potentially hazardous atmospheres containing greater than 21% Oxygen. The enclosure material is polypropylene and must not be exposed to environments which are liable to result in mechanical or thermal degradation or to damage caused by contact with aggressive substances. Additional protection may be required in environments where the instrument enclosure is liable to damage.

STORAGE, HANDLING AND TRANSIT

The batteries in the rechargeable pack contain considerable energy and care should be taken in their handling and disposal. Battery packs should be removed if the instrument is stored for longer than 3 months. The instrument is designed to handle harsh environments. The sensing elements are sealed to IP54 and the rest of the instrument to IP64. If not subject to misuse or malicious damage, the instrument will provide many years of reliable service. The instrument contains electrochemical sensors with a life of 2 years. Under conditions of prolonged storage the sensors should be removed. The sensor contains potentially corrosive liquid and care should be taken when handling or disposing of the sensor, particularly when a leak is suspected.

REVISION RECORD

Date Pages Description Of Change

Issue 1 All New Handbook

21.09.00

Issue 2 All Handbook revised to

25.05.01 reflect updated

Issue 3 All Handbook revised to

17.07.03 include effect of CR 2291

Issue 4 All To include Appendix C 20/07/04 (translations)

instrument options and features

iii

GASURVEYOR 3-500 USER HANDBOOK

LIABILITY ...................................................................... i

MODIFICATION NOTICES ........................................... i

SOFTWARE .................................................................. i

DISPOSAL ADVICE ...................................................... i

SAFETY ........................................................................ ii

AREAS OF USE ........................................................... ii

STORAGE, HANDLING AND TRANSIT ...................... ii

REVISION RECORD ..................................... iii

INTRODUCTION ........................................... 1

GENERAL INFORMATION ........................... 3

Ranges of Operation .................................................... 3

LEL, 0 to 100% .......................................................... 3

Volume Gas, 0 to 100 % ............................................ 4

LEL Displayed as % Volume Equivalent ................... 5

Alarms ........................................................................... 5

Alarm Functions ......................................................... 6

Construction .................................................................. 7

GASURVEYOR 3-500 USER HANDBOOK

Batteries ........................................................................ 7

Disposable Alkaline (LR20) Dry Cell Batteries .......... 7

Rechargeable (NiCd) Battery Pack ........................... 8

Filters ............................................................................ 8

Liquid Crystal Display (LCD) ........................................ 9

Before Use Checks ....................................................... 9

OPERATING INSTRUCTIONS.................... 11

Modes of Operation .................................................... 11

Switching On ............................................................ 12

Calibration Date Features ........................................ 13

Switching Off the Instrument Pump ......................... 13

Switching On in Purge Mode ................................... 14

Switching Off ............................................................ 14

Summary of Button Operation .................................... 15

Operator Messages / Fault Flags ............................... 15

OPERATOR MAINTENANCE ..................... 19

Rechargeable Battery Pack ........................................ 19

Standard Charger ..................................................... 19

Flatbed Charger ....................................................... 20

Smart Charger .......................................................... 20

Replacing the Battery Pack ..................................... 21

Recharging the Battery Pack ................................... 22

CONTENTS

Replacing Alkaline (LR20) Dry Cell Batteries ............ 22

Filter Replacement ..................................................... 24

CALIBRATION ............................................ 27

Calibration Validity ...................................................... 28

ACCESSORIES........................................... 29

ADDITIONAL INFORMATION ..................... 33

Training ....................................................................... 33

World Wide Web ......................................................... 33

TYPICAL OPERATING PARAMETERS .....A-1

Size ........................................................................ A-2

Weight .................................................................... A-2

Operating Temperature .......................................... A-2

Humidity ................................................................. A-2

Construction ........................................................... A-2

Display .................................................................... A-2

Sampling System ................................................... A-2

Power Source ......................................................... A-3

vii

GASURVEYOR 3-500 USER HANDBOOK

FIELD CALIBRATION ................................ B-1

Selectable Ranges in FCM ....................................... B-3

Entering FCM ............................................................ B-3

Zeroing the Instrument ............................................. B-4

Field Calibration Procedure ...................................... B-5

Quitting FCM ............................................................. B-9

Quit And Save Changes ........................................ B-9

Quit Without Saving Changes ................................ B-9

OPERATING INSTRUCTIONS.................. C-1

English ..................................................................... C-2

Français (French) .................................................... C-6

Deutsch (German) ................................................. C-10

Svensk (Swedish) .................................................. C-14

Dansk (Danish) ...................................................... C-18

Nederlands (Dutch) ............................................... C-22

INDEX ............................................................ I

viii

INTRODUCTION

The Gasurveyor 3-500 is a two button flammable gas leak location and purge instrument, designed to measure Lower Explosive Level (LEL) and Volume flammable gas. The instrument is designed to the latest standards and is certified for use in Hazardous Areas.

The Gasurveyor 3-500 contains the following ranges:

$ LEL, 0 to 100%

$ Volume gas, 0 to 100%

As the Gasurveyor 3-500 has a wide variety of available user selected options, it is not possible to provide an operator handbook specific to each possible variation, therefore, what we have provided in the following pages is the standard default of how the instrument would

GASURVEYOR 3-500 USER HANDBOOK

generally be configured, with the possible options detailed in italic text.

GMI recommend that you take the time to study your instrument and, where practical and with advice from your company’s Purchasing / Management departments, highlight your particular instrument configuration.

The main default features of the instrument are:

$ Rugged carbon loaded polypropylene case, sealed

to IP54 rating and suitable for outdoor use.

$ Two button operation allowing the user access to

all features.

$ LCD with backlighting which displays the current

gas readings (in both digital and analogue forms) together with operational and status information.

$ Audible and Visual alarm options, if selected, are

pre-set to specific gas concentration levels.

$ Directly interfaces with the GMI Auto Test Cali-

bration Units.

GENERAL INFORMATION

Ranges of Operation

LEL, 0 to 100%

The LEL range indicates the explosibility of the flammable gas in the sample. This is displayed as a percentage of the lower explosive limit (LEL) of the gas. For methane 100% LEL corresponds to 5% Volume methane in Air.

The instrument range is displayed in the top right corner of the display as % LEL. From 0 to 10% LEL the digital display resolves to 0.1% LEL. From 10 to 100% LEL the digital display resolves to 1% LEL. The analogue bar graph follows in 4% steps. An example of the LEL display is shown in Figure 2.1. Autoranging will automatically switch the range to Volume Gas when 100% LEL is reached.

The detection principle for this range is a catalytic reaction.

Figure 2.1 LEL Range

GASURVEYOR 3-500 USER HANDBOOK

Volume Gas, 0 to 100 %

This range displays the total volume of a specific flammable gas with respect to air. The calibration gas is shown on the service label and for the purpose of this handbook is assumed to be methane. Instruments calibrated for methane in air should only be used for measuring such mixtures. To change the calibration gas, e.g. from methane to propane, the instrument must be recalibrated by suitably trained personnel.

On the Volume Gas range the instrument range is displayed in the top right corner of the LCD as GAS. The digital display resolves the signal to 1% GAS with the analogue bar graph following in steps of 4%. Figure 2.2 shows the Volume Gas display. The detection principle for the Volume Gas range is thermal conductivity.

When using PURGE mode to measure flammable gas in air or Nitrogen, or a combination of both background gases, the Gasurveyor 3-500 will use the thermal conductivity Volume gas range only.

The digital display will resolve the signal to 1% Gas, with the analogue bar graph following in steps of 4%.

Figure 2.2 Volume Gas Range

GENERAL INFORMATION

LEL Displayed as % Volume Equivalent

The LEL Displayed as a % Volume Equivalent is available for methane in air calibrated instruments only.

In this mode, the range is displayed in the top right hand corner of the display, as % Gas. From 0 to 100% LEL Equivalent, the digital display resolves to 0.1% Gas.

Note: If you are using the Gasurveyor 3-500 instrument for purge operations using the Volume Gas range, ensure that LEL Displayed as a % Volume Equivalent range option, is not selected as a user option.

Alarms

The Gasurveyor 3-500, by default, has both audible and visual alarms off when operating.

The audible alarm is rated up to 85 dB(A). The visual alarm is a red LED indicator which protrudes from the instrument top plate, allowing viewing from any angle above the top plate.

The instrument, where selected, can have alarm levels for the Flammable LEL pre-set.

The Gasurveyor 3-500 has the facility to have two (2) instantaneous alarm levels for the flammable LEL range in the instrument. These are described as LOW and HIGH, although generally only the high alarm would be active.

When both instantaneous alarms are set, the LOW audible and visual alarm cycle will be activated for 0.5 seconds on and 0.5 seconds off. The HIGH audible and visual alarm cycle will be activated for 0.25 seconds on and

0.25 seconds off.

GASURVEYOR 3-500 USER HANDBOOK

The option is to have the instantaneous alarms activated.

It is the responsibility of the user to ensure that the alarm levels, where set in the instrument, are appropriate for the safe operation and legal requirements for the country / industry in which the unit is being used.

Alarm Functions

The Gasurveyor 3-500, by default, has the alarm function on the flammable range disabled.

Where the alarm function is enabled, the instrument has the facility to have either latching or non-latching alarms.

Latching means that when the alarm level is exceeded, the LED will flash (visual) and the sounder will pulse rapidly (audible). Latching alarms are cleared manually,

by a double press of Button Two , after the detected

gas level has fallen below the alarm limit.

Each alarm has to be acknowledged individually, e.g. If both LOW (10%) and HIGH (20%) instantaneous alarms have been set, then both would have to be acknowledged individually if LEL is greater than 20%. If the audible and/or visual indicators are set to off then the display alarm function would need to be acknowledged in the same way. Alarm display example is shown in Figure 2.3.

Figure 2.3 LEL Alarm Display Example

GENERAL INFORMATION

Non-Latching means that the alarms clear automatically when the gas level falls below the alarm limit.

For both latching and non-latching alarms, it is possible for both audible and visual indicators to be either On or OFF independent of each other.

Construction

The instrument is housed in a tough, impact resistant, moulded case made of carbon loaded polypropylene.

The top panel is protected by a stainless steel top plate covering a toughened glass LCD cover.

The battery pack is sealed and attached to the main instrument body by means of 2 stainless steel hexagonal screws.

The instrument is sealed against dust and water to IP54 standard. The sensors are protected from dust and water by membrane and cotton filters.

Batteries

Disposable Alkaline (LR20) Dry Cell Batteries

Alkaline batteries provide approximately 15 hours operational life at ambient temperature of 20 When the batteries are low or exhausted it is necessary to fit 4 new batteries. Do not mix old and new batteries.

An indication of the battery condition is displayed after power on and during warm-up, with status shown as either OK or LO. If LO condition is displayed, a maximum battery operational life of 120 minutes remains. During

C (68oF).

GASURVEYOR 3-500 USER HANDBOOK

operation the ‘BAT’ alarm flag is displayed when approximately 60 minutes of operating time remains at normal temperature. The instrument may continue to be used until it switches off automatically.

Rechargeable (NiCd) Battery Pack

The GMI rechargeable battery pack provides approximately nine hours operational life, from fully charged, at ambient temperature of 20

C (68oF). An indication of the battery condition is displayed after power on and during warm-up, with status shown as either OK or LO. If LO condition is displayed, a maximum battery operational life of 90 minutes remains. During operation the ‘BAT’ flag is displayed when approximately 30 minutes operating time is left at normal temperatures. The instrument will then turn off.

There are three GMI Battery Chargers: a Standard Charger, a Flatbed Charger and a Smart Charger. The Smart Charger has both slow and fast charge options as well as a serial link for communications with the instrument. See Rechargeable Battery Pack in Section 4

OPERATOR MAINTENANCE.

Filters

A number of different filter types are available from GMI. The minimum requirement is a cotton particulate filter and a hydrophobic filter which are incorporated in the probe handle assembly, supplied with the instrument. Filters must be checked at frequent intervals and where appropriate changed to ensure a clean sample path. If water

GENERAL INFORMATION

is drawn into the instrument any filter which has been contaminated must be cleaned or replaced. See Filter

Replacement in Section 4 OPERATOR MAINTENANCE.

Liquid Crystal Display (LCD)

The LCD shows the current gas readings in both analogue and digital form together with operational and status information. The display is protected by a toughened glass cover. Backlighting is provided to enable the display to be seen under low ambient light conditions.

Before Use Checks

The following checks should be carried out before using the instrument on site:

$ The instrument is clean and in good condition.

$ The batteries have sufficient power left in them

for the intended use of the instrument.

$ The filters are clean and in good condition.

$ The sample line and any accessories are in good

condition and leak free.

$ All gas ranges are operational and zeroed correctly.

$ The calibration is still valid.

GASURVEYOR 3-500 USER HANDBOOK

OPERATING INSTRUCTIONS

Modes of Operation

The instrument has two modes of operation which are accessed by switching the instrument ON with either

Button One or Button Two . See Figure 3.1

below.

OFF

INST.

ON OFF

PUMP

PURGE

ALARM ACK.

GASURVEYOR 3-500

Figure 3.1 Instrument Front Plate

Mode 1. Switching ON with Button One provides

two gas ranges:

a) LEL autoranging to Volume Gas.

GASURVEYOR 3-500 USER HANDBOOK

Audible/visual alarms can operate in this mode.

Mode 2. Switching ON with Button Two

provides access to only 0-100% Vol Gas range for purge applications. No audible/visual alarms are available in this mode.

Switching On

Press and hold Button One

to turn the instrument on.

This initiates the instruments warm up cycle and switches on the pump. Figure 3.2 displays the warm up cycle for the Gasurveyor 3-500.

Note: Battery status is displayed as either OK or LO at start-up.

Figure 3.2 Warm Up

OPERATION

Calibration Date Features

At the end of warm-up and before the Gasurveyor 3-500 instrument is ready for measuring, the instrument will indicate on the display when the next calibration is due. This will be displayed as month and year, as shown in Figure 3.3:

Calibration Due

February 2002

(Alternate flash)

Figure 3.3 Calibration Date

The re-calibration interval pre-set for all Gasurveyor 3-500 instruments is twelve (12) months.

This period can be altered as an option, however, you should ensure that the instrument is always within its calibration period prior to use.

An option which ensures that an ‘out of calibration instrument’ is not used, is the automatic switch-off when overdue.

Switching Off the Instrument Pump

A single press of Button One

, when the pump is

running, turns the pump off and stops sampling. Pressing button one again turns the pump back on.

GASURVEYOR 3-500 USER HANDBOOK

Switching On in Purge Mode

To switch on in Purge mode, press and hold Button Two

. The Gasurveyor 3-500 will initiate the warm-up

sequence as explained previously. This mode uses the thermal conductivity Volume gas range only since inert Nitrogen atmospheres are likely to be present. When in purge mode, the PURGE flag is activated on the display, as shown in Figure 3.4.

(Alternate flash)

Figure 3.4 Purge Mode

Switching Off

A double press of Button One

turns the instrument

off.

Summary of Button Operation

OPERATION

ffOsehctiwS

tnemurtsnI

in Purge mode

Press and

Hold

OnsehctiwS

tnemurtsnI

OnsehctiwS

Instrument

Measure

Mode

Button 1

Button 2

Single Press

Toggles Pump

On / Off

(during operation)

Double

Press

Acknowledge

Alarm

Operator Messages / Fault Flags

Various messages can appear on the LCD screen to indicate instrument status.

‘SAMPLE’

This indicates that the pump is running and the instrument is sampling.

‘OFF’

This indicates that the instrument is about to switch off. This command can be cancelled by a single press of any button.

GASURVEYOR 3-500 USER HANDBOOK

‘SAMPLE FAULT’

This indicates a problem with the instrument’s flow due to the sample path being blocked, water ingress, a blocked filter or pump failure.

In Measure and Purge mode, the pump stops automatically. The sample line, filters etc. should be checked for water ingress or blockage and Button One

should then be pressed to restart the pump.

‘CHECK ZERO’

This indicates that there may have been a zero shift due to the presence of gas. Switch off the instrument and switch on again in fresh air.

‘ZERO FAULT’

This indicates that the zero is outwith its calibration limits. Switch the instrument off and then on again in fresh air. If the fault does not clear, return the instrument for servicing.

‘BAT’

This indicates that the batteries will soon require replacement. At this point there will be approximately 60 minutes operation left in a set of alkaline batteries, although this figure will vary depending on battery manufacturer, temperature conditions, usage etc. With rechargeable batteries the ‘BAT’ flag indicates approximately 30 minutes operation left.

As the battery power continues to fall, the LCD flashes a ‘BAT FAULT’ message. Subsequently the LCD displays

OPERATION

‘OFF’ and the instrument automatically switches off. The batteries should be replaced immediately.

‘BAT FAULT’

This indicates that the batteries require replacing.

‘1’

This message which can also appear after power on, indicates that a calibration data error has been detected. The instrument should be returned for servicing.

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