RKI Instruments GX-2003 User Manual

Model GX-2003
Operator’s Manual
Part Number: 71-0089RK
Revision: F
Released: 2/2/11
www.rkiinstruments.com
Read and understand this instruction manual before operating instrument. Improper use of the gas monitor could result in bodily harm or death.
Periodic calibration and maintenance of the gas monitor is essential for proper operation and cor­rect readings. Please calibrate and maintain this instrument regularly! Frequency of calibration depends upon the type of use you have and the sensor types. Typical calibration frequencies for most applications are between 1 and 3 months, but can be required more often or less often based on your usage.
GX-2003 Operator’s Manual
Warranty
RKI Instruments, Inc. warrants the Model GX-2003 sold by us to be free from defects in materials, workmanship, and performance for a period of two years from the date of shipment from RKI Instruments, Inc. This includes the instrument and the original sensors. Replacement parts are warranted for 1 year from the date of their shipment from RKI Instruments, Inc. Any parts found defective within their warranty period will be repaired or replaced, at our option, free of charge. This warranty does not apply to those items which by their nature are subject to deterioration or consumption in normal service, and which must be cleaned, repaired, or r eplaced on a routine basis. Examples of such items are:
Absorbent cartridges Filter elements, disks, or sheets Pump diaphragms and valves
Warranty is voided by abuse including mechanical damage, alteration, rough handling, or repair procedures not in accordance with the instruction manual. This warranty indicates the full extent of our liability, and we are not responsible for removal or replacement costs, local repair costs, transportation costs, or contingent expenses incurred without our prior approval.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES
AND REPRESENTATIONS, EXPRESSED OR IMPLIED, AND ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF RKI INSTRUMENTS, INC. INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL RKI INSTRUMENTS, INC. BE LIABLE FOR INDIRECT, INCIDENTAL, OR CONSEQUENTIAL LOSS OR DAMAGE OF ANY KIND CONNECTED WITH THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
This warranty covers instruments and parts sold to users only by authorized distributors, dealers, and representatives as appointed by RKI Instruments, Inc.
We do not assume indemnification for any accident or damage caused by the operation of this gas monitor and our warranty is limited to replacement of parts or our complete goods.
GX-2003 Operator’s Manual Warranty
Table of Contents
Chapter 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
About the GX-2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2: Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Instrument Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Control Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Alarm LED Arrays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Infrared Communications Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Buzzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Flow Chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inlet Filter Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Tapered Rubber Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Protective Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sample Hose & 10 Inch Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bar Hole Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 3: Using the GX-203 in Normal Mode . . . . . . . . . . . . . . 14
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start Up, Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Turning On the GX-2003, Normal Mode Only . . . . . . . . . . . . . . . . 14
Turning On the GX-2003 in Normal With All Modes Active . . . . . 17
Performing a Demand Zero, Normal Mode . . . . . . . . . . . . . . . . . . . 18
Turning Off the GX-2003, Normal Mode. . . . . . . . . . . . . . . . . . . . . 19
Ta b l e o f C o n t e n t s GX-2003 Operator’s Manual
Measuring Mode, Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Monitoring an Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Combustible Gas Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Measuring Mode, Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Resetting and Silencing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Responding to Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Display Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HC Range Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
ID Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Peak Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Elapsed Time Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TWA/STEL Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Date/Time/Battery Charge Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clear Data Logger Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remaining Log Time Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Datalogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Data Cal 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Calibration Supplies and Equipment . . . . . . . . . . . . . . . . . . . . . . . . 32
Preparing for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Calibrating the GX-2003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjusting the LCD Contrast. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Chapter 4: Using the GX-2003 in Bar Hole Mode . . . . . . . . . . . . 39
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Start Up, Bar Hole Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Turning On the GX-2003, Bar Hole Mode . . . . . . . . . . . . . . . . . . . . 39
Performing a Demand Zero, Bar Hole Mode . . . . . . . . . . . . . . . . . . 42
Bar Hole Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Performing a Bar Hole Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Turning Off the GX-2003, Bar Hole Mode . . . . . . . . . . . . . . . . . . . . 45
Chapter 5: Using the GX-2003 in Leak Check Mode . . . . . . . . . 46
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Start Up, Leak Check Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Turning On the GX-2003, Leak Check Mode . . . . . . . . . . . . . . . . . . 46
Performing a Demand Zero, Leak Check Mode. . . . . . . . . . . . . . . . . 49
GX-2003 Operator’s Manual Table of Contents
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Locating a Leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Turning the Buzzer On and Off in Leak Check Mode. . . . . . . . . . . . 50
Turning Off the GX-2003, Leak Check Mode . . . . . . . . . . . . . . . . . . 51
Chapter 6: Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Tips for Using Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Using Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Updating the Alarm Point Settings . . . . . . . . . . . . . . . . . . . . . . . . . 54
Updating the Lunch Break Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Updating the Alarm Latching Setting . . . . . . . . . . . . . . . . . . . . . . . 56
Updating the Alarm Silence Setting . . . . . . . . . . . . . . . . . . . . . . . . . 56
Updating the Confirmation Beep Setting . . . . . . . . . . . . . . . . . . . . . 57
Updating the Interval Time Setting . . . . . . . . . . . . . . . . . . . . . . . . . 57
Updating the Log Data Over Write Setting . . . . . . . . . . . . . . . . . . . 57
Updating the Date and Time Settings . . . . . . . . . . . . . . . . . . . . . . . 58
Updating the Calibration Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Updating the Calibration Time Remaining Setting . . . . . . . . . . . . . 59
Updating the Calibration Expired Action Setting . . . . . . . . . . . . . . 59
Updating the LCD Contrast Setting. . . . . . . . . . . . . . . . . . . . . . . . . 60
Updating the GX-2003’s Serial Number. . . . . . . . . . . . . . . . . . . . . . 60
Turning the User ID Function On or Off. . . . . . . . . . . . . . . . . . . . . 61
Calibrating Using Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 61
Calibrating Using Single Calibration . . . . . . . . . . . . . . . . . . . . . . . . 63
Updating the LCD Backlight Time Setting. . . . . . . . . . . . . . . . . . . . 65
Turning the Password Function On or Off. . . . . . . . . . . . . . . . . . . . 65
Turning LB Mode Display On or Off . . . . . . . . . . . . . . . . . . . . . . . . 66
Setting the Bar Hole Measurement Time . . . . . . . . . . . . . . . . . . . . . 66
Exiting Setup Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Chapter 7: Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Replacing or Recharging the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacing Alkaline Batteries or Ni-MH Battery Pack . . . . . . . . . . . 70
Recharging the Battery Pack in the Instrument . . . . . . . . . . . . . . . . 71
Recharging the Battery Pack Out of the Instrument. . . . . . . . . . . . . 72
Ta b l e o f C o n t e n t s GX-2003 Operator’s Manual
Replacing the HC and CO Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Replacing a Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Replacing the Hydrophobic Disk Filter, Cotton Filter,
and Wire Mesh Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Appendix A: Calibrating with a Sample Bag . . . . . . . . . . . . . . . 80
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Calibration Supplies & Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Preparing for Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Calibrating the GX-2003. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Calibrating with the Auto Calibration Method. . . . . . . . . . . . . . . . . 83
Calibrating with the Single Calibration method . . . . . . . . . . . . . . . . 85
Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
WARNING: Understand manual before operating. Substitution of
components may impair intrinsic safety. To prevent ignition of a hazardous atmosphere, batteries must only be changed or charged in an area known to be nonhazardous. Not tested in oxygen enriched atmospheres (above 21%).
GX-2003 Operator’s Manual Table of Contents
Chapter 1: Introduction
Overview
This chapter briefly describes the GX-2003. This chapter also describes the GX-2003 Operator’s Manual (this document). Table 1 at the end of this chapter lists the specifications for the GX-2003.
About the GX-2003
Using an advanced detection system consisting of up to five gas sensors, the GX-2003 sample draw gas monitor detects the presence of combustible gas, oxygen (O
sulfide (H to-use design makes it ideally suited for a wide range of applications,
including sewage treatment plants, utility manholes, tunnels, hazardous waste sites, power stations, petrochemical refineries, mines, paper mills, drilling rigs, and fire fighting stations. The GX-2003 offers a full range of features, including:
S) simultaneously. The GX-2003’s compact size and easy-
2
), carbon monoxide (CO), and hydrogen
2
• Simultaneous four-gas monitoring of combustible gases, O and H
S (in Normal Mode)
2
, CO,
2
• Choice of three operating modes: Normal Mode for typical confined space or area monitoring; Bar Hole Mode for checking of bar holes when searching for underground gas leaks; and Leak Check Mode for locating leaks in valves and piping.
• Sample-drawing pump with up to 40-foot range
• Liquid crystal display (LCD) for complete and understandable information at a glance
• Distinctive audible/vibrating alarms for dangerous gas conditions and audible alarms for unit malfunction
• Microprocessor control for reliability, ease of use, and advanced capabilities
• Alarm trend data (when used in Normal Mode)
• Data logging functions (when used in Normal Mode)
• STEL/TWA (when used in Normal Mode) and over range alarm display
1 • O v e r v i e w GX-2003 Operator’s Manual
• Peak hold and average readouts (when used in Normal Mode)
• Built-in time function
• RF shielded high impact plastic case
• CSA classified for Class I, Division I, Groups A, B, C, and D hazardous atmospheres
WARNING: The Model GX-2003 detects oxygen deficiency, elevated
levels of oxygen, combustible gases, carbon monoxide, and hydrogen sulfide, all of which can be dangerous or life threatening. When using the Model GX-2003, you must follow the instructions and warnings in this manual to assure proper and safe operation of the unit and to minimize the risk of personal injury. Be sure to maintain and periodically calibrate the GX-2003 as described in this manual.
NOTE: ONL Y THE COMBUSTIBLE GAS DETECTION PORTION OF
THIS INSTRUMENT HAS BEEN ASSESSED FOR PERFORMANCE.
GX-2003 Operator’s Manual About the GX-2003 • 2
Specifications
Table 1: GX-2003 Specifications
Target Gas %LEL
Combustible
Gas
(Methane
Calibration
Standard)
Range
(Increment)
Auxiliary
Range
(Increment)
0-100% LEL
(1% LEL)
0-5,000 ppm
(100 ppm)
In Leak Check
Mode Only
Sampling
Method
Response
Time
Accuracy ± 5% of reading
or ± 2% LEL
(whichever is
greater)
% Volume
Combustible
Gas
Oxygen (O
) Hydrogen
2
Sulfide
(H
S)
2
(Methane
Calibration
Standard)
0 - 100% vol
(1% vol)
0-40.0% vol
(0.1 vol%)
0-100 ppm
(0.5 ppm)
n/a n/a n/a n/a
Sample Draw
T90 Within 30 Seconds
± 5% of
reading or ±
2% full scale
(whichever
is greater)
± 0.5% O
2
± 5% of
reading or ±
2 ppm H
S
2
(whichever
is greater)
Carbon
Monoxide
(CO)
0-500 ppm
(1 ppm)
± 5% of
reading or
± 5 ppm
CO
(whichever
is greater)
Display Dot Matrix LCD Display
Gas Alarms
(Factory
Settings)
Alarm 1
10% LEL
None Alarm 1
19.5 vol% (Decreasing)
Alarm 2
50% LEL
Alarm 2
23.5 vol% (Increasing)
Operating
-20°C to 50
°
C/Below 85% RH (Without Condensation)
Temperature
& Humidity
Alarm 1
10 ppm
Alarm 2
30 ppm
TWA
10 ppm
STEL
15 ppm
Alarm 1
25 ppm
Alarm 2
50 ppm
TWA
25 ppm
STEL
200 ppm
3 • S p e c i f i c a t i o n s GX-2003 Operator’s Manual
Safety/
Regulatory
C US
186718
CSA classified, “C/US”, as Intrinsically Safe. Exia. Class I, Groups A, B, C, &
D. Temperature Code T3C.
Power
Supply
Continuous
Operating
Hours
@ 25 °C
Case High-impact Plastic, RF Shielded, Dust and Weather Proof
Standard
Accessories
Optional
Accessories
• Three AA size alkaline batteries standard
• Ni-MH Battery Pack (3.6 VDC Nominal) optional, Direct Charging
• Alkaline Batteries: 14 Hours (Non Alarm Operation, Fu lly Charged)
• Ni-MH Battery Pack: 16 Hours (Non alarm Operation, Fully Charged)
• 10 foot hose
• 10 inch probe
• Flexible 4 inch tapered rubber nozzle
• Protective rubber boot
115 VAC Ch arging Station
12 VDC Charging St ation
Data Logging Software
IrDA/Serial or IrDA/USB Cable for Downloading Data to a Computer With Data Logging Software (not needed if computer has an infrared port)
Communication Software (Windows
Automatic Calibration Station & Software
Bar Hole Probe
®
98, 2000, & XP)
Dimensions and Weight
Approximately 171(H) x 65(W) x 39(D) mm (5.6”H x 2.5”W x 1.5”D)
About this Manual
The GX-2003 Operator’s Manual uses the following conventions for notes, cautions, and warnings.
NOTE: Describes additional or critical information.
CAUTION:Describes potential damage to equipment. WARNING: Describes potential danger that can result in injury or
death.
Approximately 310 g (11 oz.)
GX-2003 Operator’s Manual About this Manual • 4
Chapter 2: Description
A
r
r
er
r
Overview
This chapter describes the GX-2003 instrument and accessories.
Instrument Description
The instrument includes the case, sensors, LCD, control buttons, printed circuit boards, alarm LED’s, infrared communication port, buzzers, vibrator, batteries, pump, flow chamber, and inlet filter holder.
Inlet Filter
Holder
larm LED
Array
Tapered Rubber Nozzle
Inlet Fitting
Exhaust
HC Filte Retaine
AIR
DISPLAY
(ADJ)
(SHIFT)
RESET
SILENCE
Flow
Chamber
LCD
Control Buttons
CO Filt Retaine
Battery Cover
Buzzer Openings
Figure 1: Components of the GX-2003, Front & Back
5 • O v e r v i e w GX-2003 Operator’s Manual
R
LED Array (near & far side)
IR Communitcations Port
Battery Charging
Battery Cover
Release Knob
Contacts
ight Side View Bottom View
Figure 2: Components of the GX-2003, Side & Bottom
Case
The Model GX-2003’s sturdy, high-impact plastic case is radio frequency (RF) resistant and is suitable for use in many environmental conditions, indoors and out. The case is dust proof and weather resistant. Rubber gripping surfaces are located on the right and left side of the case to aid in holding the unit in your hand.
A clear plastic window through which the LCD can be viewed is located on the front of the case. Three brass charging contacts that are used when the GX-2003 is placed in the charging station are on the bottom of the case. The battery cover release knob is also on the bottom. The battery cover and flow chamber are located on the back of the GX-2003. The inlet filter holder is located on the top of the GX-2003 case.
GX-2003 Operator’s Manual Instrument Description • 6
Sensors
The GX-2003 uses up to five sensors to monitor combustible gas, oxygen (O2), carbon monoxide (CO), and hydrogen sulfide (H
simultaneously. The sensors are located inside the GX-2003 and are held in their sockets by the flow chamber. The sensors use different detection principles, as described below.
Combustible Gas Sensors
% LEL Sensor (NC-6264AT)
The % LEL sensor detects combustible gas in the % LEL range. It uses a catalytic element for detection. The reaction of gas with oxygen on the catalyst causes a change in the resistance of the element which affects the current flowing through it. The current is amplified by the GX-2003’s circuitry, converted to a measurement of combustible gas concentration, and displayed on the LCD.
NOTE: The % LEL sensor can not be used in instruments that utilize
Bar Hole Mode or Leak Check Mode.
2
S)
LEL/PPM Sensor (NC-6264ALB)
The LEL/ppm combustible sensor is a specialized version of the % LEL sensor. It is used instead of the % LEL sensor in instruments that are intended for use in Bar Hole Mode or Leak Check Mode. The LEL/ppm sensor can also be used for detection in Normal Mode.
%Volume Sensor
The % volume sensor detects combustible gas in the % volume range. It uses a thermal conductivity (TC) element for detection. The presence of combustib le gas cool s the element causing a change in the resistance of the element which affects the current flowing through it. The current is amplified by the GX-2003’s circuitry, converted to a measurement of combustible gas concentration, and displayed on the LCD.
Oxygen Sensor
The O2 sensor is a galvanic type of sensor. A membrane covers the cell and allows gas to diffuse into the cell at a rate proportional to the
partial pressure of o xygen. T he oxygen reacts in the cell and produces a voltage proportional to the concentration of oxygen. The voltage is measured by the Model GX-2003’s circuitry, converted to a measurement of gas concentration, and displayed on the LCD.
7 • I n s t r u m e n t D e s c r i pt i o n GX-2003 Operator’s Manual
CO and H2S Sensors
The CO and H2S sensors are electrochemical cells that consist of two precious metal electrodes in a dilute acid electrolyte. A gas permeable
membrane covers the sensor face and allows gas to diffuse into the electrolyte. The gas reacts in the sensor and produces a current proportional to the concentration of the target gas. The current is amplified by the Model GX-2003’s circuitry, converted to a measurement of gas concentration, and displayed on the LCD.
LCD
A digital LCD (liquid crystal display) is visible through a clear plastic window on the front of the case. The LCD display simultaneously shows the gas reading for all installed sensors. The display also s hows information for each of the GX-2003’s program modes.
Control Buttons
Five control buttons are located below the LCD. They are arranged in a circular pattern around a central button, the POWER ENTER button. The DISPLAY (ADJ) button is on the left, the RESET SILENCE button on the right, the AIR button on the top, and the (SHIFT)▼ is on the bottom.
Table 2: GX-2003 Control Button Functions
Button Function(s)
POWER ENTER • turns the GX-2003 on and off.
• used during setup and calibration.
RESET SILENCE si lences and reset s audible alar m if the GX-2003 is pr ogrammed
for latching alarms and the alarm silence option is on
DISPLAY (ADJ) • activates Display Mode
• enters instructions into the GX-2003’s microprocessor
AIR • activates the demand-zero function (au tomatically adjusts the
GX-2003 in fresh-air conditions)
• scrolls through the display and settings modes
(SHIFT) • scrolls through the display and settings modes
• enters instructions into the GX-2003’s microprocessor
1 The GX-2003’s alarms are user-adjustable. See “Chapter 6: Setup Mode” on page 52.
1
Printed Circuit Boards
The GX-2003 printed circuit boards analyze, record, control, store, and display the information collected. The circuit boards are located inside the case. They are not user serviceable.
GX-2003 Operator’s Manual Instrument Description • 8
Alarm LED Arrays
Four red alarm LED (light emitting diode) arrays are visible through frosted plastic lenses in the case. One is on the front, one on the left side, one on the right side, and one on the top of the case. The alarm LED arrays alert you to gas, low battery, and failure alarms.
Infrared Communications Port
An infrared (IR) communications port is located on the lower right side of the GX-2003. The data transmitted through the port is in standard IrDA pr otocol. A compu ter’s infrared port or an IrDA /serial or IrDA/USB cable connected to a computer’s serial port can be used to download data saved by the GX-2003 to a computer using the GX­2003 Downloading Software. See the downloading software operator’s manual for data logging and downloading instructions.
Buzzers
Two solid-state electronic buzzers are located inside the case. Two holes on the bottom front of the case allow the sound to exit the case. The buzzers sound for gas alarms, malfunctions, low battery voltage, and as an indicator during use of the GX-2003’s many display and adjustment options.
Vibrator
A vibrating motor inside the GX-2003 case vibrates for gas alarms, unit malfunctions, low battery voltage, and as an indicator during normal use of the various modes of the GX-2003.
Batteries
Three AA-size alkaline batteries (standard) or an optional rechargeable Ni-MH battery pack (3.6 VDC) power the GX-2003. Instrument run time is dependent upon battery type. At 25°C the alkaline batteries last up to 14 hours and the Ni-MH battery pack lasts up to 16 hours. The battery icon in the lower right of the LCD shows remaining battery life. If a Ni-MH battery pack is installed in the GX­2003, an “N” appears to the right of the battery icon.
When the GX-2003 detects low battery voltage, a low battery warning is activated. When battery voltage is too low for normal operation, the GX-2003 sounds a dead battery alarm.
The alkaline batteries or Ni-MH pack can be r eplaced by removing the battery cover on the back of the case. Turn the battery cover release knob counterclockwise to release the cover.
The Ni-MH battery pack can be recharged by placing the GX-2003 in
9 • I n s t r u m e n t D e s c r i pt i o n GX-2003 Operator’s Manual
its optional battery charging station or by placing the battery pack in the charging station.
NOTE: Use of batteries or battery chargers not specified by RKI
Instruments, Inc. will void the CSA classification and may void the warranty. See “Replacing or Recharging the Batteries” on page 70.
WARNING: To prevent igniti on of a hazard ous atmosph er e, batt eries
must only be changed or charged in an area known to be nonhazardous.
Pump
A diaphragm pump inside the GX-2003 draws the sample to the sensors. It can draw sample from as far as 40 feet from the GX-2003. The pump is not user serviceable.
CAUTION:Sample hose lengths of more than 40 feet are not recommended
for the GX-2003 because of flow rate reduction.
Flow Chamber
The flow chamber is on the back of the GX-2003 and is held in place by three phillips screws. The flow chamber seals on the face of the sensors inside the GX-2003 and routes flow from the pump to the sensors to the exhaust port (also a part of the flow chamber). The flow chamber includes filter ports for the HC filter and the CO filter.
HC Filter
The HC filter is located in the flow chamber directly over the % LEL sensor. It is a yellow and black plastic ring which contains two H
removal filter disks and a thin white plastic sheet with a hole in the middle on each side to support the H
S removal filter disks. The
2
yellow side of the HC filter snaps into a thr eaded plastic filter r etainer which screws into the flow chamber over the % LEL sensor.
The H
S removal filter disks ar e white when new. They scrub H2S out
2
of the gas sampled to increase the life of the combustible sensor. They darken as they absorb H
S and the HC filter must be changed when
2
the filter disks turn a dark brown color. The recommended replacement frequency will depend on how often the unit is exposed to H
S and the concentration. Check the condition of the H2S removal
2
filter disks through the holes in the white plastic support sheets quarterly.
S
2
GX-2003 Operator’s Manual Instrument Description • 1 0
CO Filter
The CO filter is located in the flow chamber directly over the CO sensor. It is a red and black plastic ring which contains two charcoal filter disks, two H
S removal filter disks, and a thin white plastic sheet
2
with a hole in the middle on each side to support the filter disks. The charcoal filter disks are black, have a woven texture, and are impregnated with an H
S absorbing material. The red side of the CO
2
filter snaps into a threaded plastic filter retainer which scr ews into the flow chamber over the CO sensor.
The CO sensor will respond if exposed to H
S and certain
2
hydrocarbon gases. The charcoal filter disks scrub these gases out of the sample to avoid false CO readings. The H
extend the H
S absorbing life of the char coal disks . If false or elevated
2
CO readings are noticed, especially in the presence of H
S filter disks are used to
2
S, change the
2
CO filter.
Inlet Filter Holder
The filter holder is a clear plastic dome shaped piece on the top of the case. A male quick connect fitting is located on the inlet filter holder. This is the GX-2003’s inlet fitting. A cotton dust filter is inside the filter holder. The filter holder may be removed by turning it counterclockwise and pulling it away from the case. Two flat membrane disk hydrophobic filters, a wire mesh disk, and a rubber filter retaining gasket are held in place by the filter holder and are located in the bottom of the case chamber where the filter holder is installed.
11 • I n s t r u m e n t D e scr i p t i o n GX-2003 Operator’s Manual
Standard Accessories
The standard accessories include the tapered r ubber nozzle, protective rubber boot, sample hose, and 10 inch probe. An optional bar hole probe is also available and is described at the end of this section.
Tapered Rubber Nozzle
A cone shaped 4 inch long rubber nozzle is included with the GX-2003 as standard. It can be installed on the inlet fitting by pushing the larger end over it. The smaller end can be inserted through a hole in a wall or some other access to an enclosed area to sample the environment.
Protective Rubber Boot
A protective rubber boot is provided as standard with the GX-2003. It has an integral belt clip on the back. The boot can be installed onto the GX-2003 for additional protection and to wear the GX-2003 on a belt.
Belt Clip
Figure 3: Protective Rubber Boot
GX-2003 Operator’s Manual Standard Accessories • 12
Sample Hose & 10 Inch Probe
A 10 foot sample hose and a 10 inch probe are included as standard with the GX-2003. When desired, the rubber nozzle may be removed and the sample hose and 10 inch probe may be connected to the inlet fitting. Sample hose lengths are available from 10 feet to 40 feet (see “Parts List” on page 78). The quick connect end of the sample hose connects to the inlet fitting of the GX-2003 and the probe screws onto the end of the hose with the threaded fitting.
CAUTION:Sample hose lengths of more than 40 feet are not recommended
for the GX-2003 because of flow rate reduction.
DISPLAY
(SHIFT)
(ADJ)
SILENCE
RESET
AIR
Sample
Hose
Probe
Figure 4: Sample Hose and Probe
Bar Hole Probe (Optional)
An optional bar hole probe is available for the GX-2003. It is designed to be used when the GX-2003 is operated in Bar Hole Mode to check bar holes when tracking down underground gas pipe leaks (see “Chapter 4: Using the GX-2003 in Bar Hole Mode” on page 39). The bar hole probe has the same handle as the standar d probe, but has a 30 inch fiberglass tube instead of the standard tube. Four holes are drilled through the 30 inch tube’s wall near the end and the end is plugged so that debris from the barhole cannot be drawn into the tube. The sample is drawn through the drilled holes in the tube wall.
End Plugged
Figure 5: Bar Hole Probe
13 • S t a n d a r d A c c e s s o ri e s GX-2003 Operator’s Manual
Chapter 3: Using the GX-2003 in Normal Mode
Overview
This chapter explains how to operate the GX-2003 in Normal Mode. Normal Mode is used to perform confined space entry monitoring or general area monitoring. While in Normal Mode, Display Mode and Calibration Mode are accessible.
If a standard version of the GX-2003 is ordered, it is shipped with Bar Hole Mode and Leak Check Mode disabled so that the instrument only runs in Normal Mode when turned on.
Start Up, Normal Mode
This section explains how to start up the GX-2003 in Normal Mode, get it ready for operation, and turn it off
NOTE: The screens illustrated in this section are for a 4-gas unit that
has the % LEL range for the CH displayed by your GX-2003 may be slightly different.
channel. The screens
4
Turning On the GX-2003, Normal Mode Only
The following description of the GX-2003 start up sequence assumes that the following menu items in Setup Mode are turned on: LUNCH BREAK, USER/ST ATION ID, and CAL. TIME REMAINING. If any of these items is turned off, then the corresponding screen will not appear. This description also assumes that the LB Mode item in Setup Mode is turned off so that Bar Hole Mode and Leak Check Mode are not active.
1. Connect the tapered rubber nozzle or the sample hose to the GX­2003’s quick connect inlet fitting.
2. If a sample hose is used, screw the probe onto the sample hose’s threaded fitting.
3. Press and briefly hold down the POWER/ENTER button. Release the button when you hear a beep.
GX-2003 Operator’s Manual Overview • 1 4
4. If LUNCH BREAK is turned on (see page 55), the Resume Datalog Screen displays.
RESUME DATALOG ? 4 YES: AIR NO: DISPLAY 21:09
Press and release the AIR button to continue accumulating
time-weighted average (TWA), PEAK readings, and time in operation from the last time the GX-2003 was used. The short­term exposure limit [STEL] reading is reset each time the GX­2003 is turned on.
Press and release the DISPLAY(ADJ) button to reset the
accumulation of these measurements.
If you do not press the AIR or DISPLAY(ADJ) button within 5 seconds, the GX-2003 automatically resumes accumulating the TWA, PEAK readings, and time in operation.
5. If USER/STATION ID is turned on (see page 61), the ID Screen displays for a few seconds.
USER ID
*********
STATION ID
*********
6. After the ID Screen, if CAL. TIME REMAINING is turned on, the screen that appears next depends on how CAL.EXPIRED ACTION is set in the Setup Mode Menu (page 59).
If the unit is due for calibration and CAL. EXPIRED ACTION
is set to CONFIRM TO USE, then the following screen displays.
CAL. DATE PAST
CAL. IS REQUIRED
The alarm LED’s and buzzer will pulse several times and the vibrator will activate for a second. After this, press the RESET SILENCE button until you hear a beep to continue.
15 • S t a r t U p , N o r m a l M od e GX-2003 Operator’s Manual
If the unit is due for calibration and CAL. EXPIRED ACTION
is set to CANNOT USE, then the following screen displays.
CAL. DATE PAST
NOT OPERATED
The GX-2003 cannot be used until a calibration has been performed either by selecting AUTO CALIBRATION or SINGLE CALIBRATION in the Setup Mode menu. See “Calibrating Using Auto Calibration” on page 61 or “Calibrating Using Single Calibration” on page 63 for calibration instructions.
If calibration is not due or CAL EXPIRED ACTION is set to NO
EFFECT, then the following screen appears for a few seconds indicating when the next calibration is due.
NEXT CAL. DATE
Dec/18/’03
TIME TO CAL. 45 DAYS
7. The Date/Time/Battery Level Screen appears for a few seconds.
Sept/23/’03
20:34
BATTERY:
This screen displays the current date, time, and an indication of how much battery charge remains. If the battery icon is fully filled in black, then the batteries are at full charge.
8. If the GX-2003 experiences a sensor failure during start up, a screen indicating which sensor failed displays. In the example below, the H
S sensor has failed.
2
FAIL
SENSOR
< > < >
< > <H2S> < >
21:09
If you wish to continue, press and release the RESET SILENCE button to acknowledge the failure. The gas reading for the failed sensor will be replaced by “XXX”. Replace the failed sensor as
GX-2003 Operator’s Manual Start Up, Normal Mode • 16
soon as possible.
9. The GX-2003 is now operating in Normal Mode and monitoring for gas in Measuring Mode. The Normal Operation Screen appears.
CH4 0%LEL OXY 20.9VOL%
H2S 0.0ppm
CO 0ppm
21:09
N
The concentrations of the target gases are displayed along with the time and battery charge level. If an “N” appears next to the battery icon as illustrated above, the GX-2003 is being powered by Ni-MH battery pack. If no “N” appears, then alkaline batteries are powering the unit.
Turning On the GX-2003 in Normal Mode With All Modes Active
If the LB Mode item in Setup Mode is set to ON (see “Turning LB Mode Display On or Off” on page 66), then the user must select Normal Mode during the start up sequence to operate in Normal Mode. See “Chapter 4: Using the GX-2003 in Bar Hole Mode” on page 39 for a description of Bar Hole Mode and “Chapter 5: Using the GX-2003 in Leak Check Mode” on page 46 for a description of Leak Check Mode.
The following description of the GX-2003 start up sequence assumes that the following menu items in Setup Mode are turned on: LUNCH BREAK, USER/ST ATION ID, and CAL. TIME REMAINING. If any of these items is turned off, then the corresponding screen will not appear.
NOTE: In order for BAR HOLE MODE to appear as a selection in the
Mode Select Screen in Step 3 below, the GX-2003 must have both a % volume combustible sensor and an LEL/PPM sensor installed. If a GX-2003 has only the LEL/PPM sensor installed, then BAR HOLE MODE will not appear as a choice as shown in Step 3 below and NORMAL MODE and LEAK CHECK MODE will be the only choices displayed.
1. Connect the tapered rubber nozzle or the sample hose to the GX­2003’s quick connect inlet fitting.
2. If a sample hose is used, screw the probe onto the sample hose’s threaded fitting.
17 • S t a r t U p , N o r m a l M od e GX-2003 Operator’s Manual
3. Press and briefly hold down the POWER/ENTER button. The Mode Select Screen displays.
>NORMAL MODE BAR HOLE MODE LEAK CHECK MODE
21:09
NOTE: If a “N” appears to the right of the battery icon, this indicates
that a Ni-MH battery pack is being used instead of alkaline batteries.
4. The cursor will begin in front of Normal Mode and Normal Mode will flash dark and light indicating it is selected.
5. With Normal Mode selected, continue with the startup sequence as described in the previous section, “Turning On the GX-2003, Normal Mode Only”, from step 4 on page 15 on.
NOTE: If no button is pressed for 20 seconds, the unit will proceed
into whichever mode has the cursor in front of it.
6. To exit Normal Mode and return to the Mode Select Screen, press and hold the (SHIFT)▼ button for 5 seconds while in the Normal Operation Screen.
Performing a Demand Zero, Normal Mode
Before using the GX-2003, it is recommended to set the fresh air readings for the target gases by performing a demand zero. This will set the CH
20.9%.
1. Find a fresh-air environment. This is an environment free of toxic or combustible gases and of normal oxygen content (20.9%).
2. Turn on the unit as described above in “Turning On the GX-2003, Normal Mode Only” or “Turning On the GX-2003 in Normal Mode With All Modes Active”.
3. Press and hold the AIR button. The display prompts you to hold the AIR button.
4. Continue to hold the AIR button until the display prompts you to release the AIR button. The GX-2003 will set the fresh air reading for all channels. Start up is complete and the unit is now ready for monitoring.
, CO, and H2S channels to zero and the OXY channel to
4
GX-2003 Operator’s Manual Start Up, Normal Mode • 18
Turning Off the GX-2003, Normal Mode
1. Press and hold the POWER ENTER button.
2. The buzzer will sound and the LCD back light will flash for about five seconds.
3. Release the button when GOODBYE appears on the display. When GOODBYE disappears and the backlight turns off, the unit is off.
Measuring Mode, Normal Operation
The GX-2003 has three operating modes within Normal Mode: Measuring Mode, Display Mode, and Calibration Mode. This section describes using the GX-2003 in Measuring Mode during normal operation.
In Measuring Mode the GX-2003 continuously monitors the sampled atmosphere and displays the gas concentrations present for its target gases. In a low-light environment, press and release any button to turn on the display backlight. See “Updating the LCD Back Light Time Setting” on page 65 to program backlight duration. If CONFIRMATION BEEP is turned on in the Setup Mode menu, the GX-2003 beeps once every 15 minutes to confirm that it’s operating.
Monitoring an Area
1. Start up the GX-2003 as described above in “Start Up, Normal Mode” on page 14 or “Turning On the GX-2003 in Normal Mode With All Modes Active”. It is now in Measuring Mode
2. Take the GX-2003 to the monitoring area. If the tapered rubber nozzle is used, put the nozzle tip in the area
to be monitored. If the hose and probe is used, put the probe tip in the area to be
monitored.
3. Wait 10 - 15 seconds and observe the display for gas readings. If a reading is observed, allow the reading to stabilize to determine the gas concentrations present.
NOTE: Response time increases with the length of the sample hose.
Long sample hoses will require mor e time to show a r esponse at the GX-2003. The maximum sample hose length recommended for the GX-2003 is 40 feet. Consult RKI
19 • M e a s u r i n g M o d e , N o r m a l O p e r a t i o n GX-2003 Operator’s Manual
Instruments, Inc. for longer sample hose lengths.
4. If a gas alarm occurs, take appropriate action. See “Responding to Alarms” on page 24.
Combustible Gas Detection
The GX-2003 can support two combustible gas sensors, a TC (thermal conductivity) sensor for detection in the % volume range, and a catalytic sensor for detection in the % LEL range. Either or both sensors maybe installed in your unit.
If both the % volume and % LEL sensors are installed, the CH
4
channel is setup at the factory as % LEL/% volume autoranging. In this case, the CH
channel will display the combustible gas
4
concentration in % LEL up to 100% LEL. If the combustible gas concentration rises above 100% LEL, then the unit automatically begins displaying the concentration in % volume.
CAUTION:If the combustible channel is set for %volume only, then there
are no gas alarms for any detection channel. See “HC Range Screen” on page 26.
There are three issues to keep in mind when monitoring for combustible
gas.
• If your GX-2003 is equipped with both combustible sensors, then
the % LEL sensor will be exposed to combustible gas concentrations above its working range during monitoring and calibration. The GX-2003 provides the % LEL sensor with protection against exposure to high levels of combustible gas. It does this by turning off the % LEL sensor power temporarily when it determines that a %LEL over scale (more than 100% LEL) concentration of combustible gas is present that may damage the sensor. When this happens, “OVER” is displayed to the right of the reading and the display units change to % volume.
• Silicone vapors and chlorine and fluorine compounds, such as
chlorinated hydrocarbons, can damage the %LEL sensor. These compounds should be avoided. If exposure to these compounds is suspected, verify the %LEL response on a known gas sample.
• Although the GX-2003 CH
methane (CH
), the combustible sensors will respond to other
4
channel is setup for and calibrated to
4
combustible gases as well.
GX-2003 Operator’s Manual Measuring Mode, Normal Operation • 20
The table below lists the conversion factors for several hydrocarbon gases for the % LEL combustible sensor if it is calibrated to methane. Conversion factors are not available for the % volume TC sensor. To use this table, multiply the display reading on the CH
4
channel by the factor in the appropriate r ow to obtain the actual gas concentration. For example, if you are detecting pentane and the display reads 10% LEL on the CH
channel, you actually have 10%
4
LEL x 1.35 = 13.5% LEL pentane present.
Table 3: LEL Hydrocarbon Conversions
LEL Conversion
Gas
Acetone 1.92 Iso Butane 1.56 Acetylene 2.00 MEK 1.92 Benzene 2.00 Methane 1.00 Ethane 1.25 Methanol 1.65 Ethanol 1.75 Pentane 1.35 Ethylene 1.20 Propane 1.52 Heptane 1.92 Propylene 1.33 Hexane 1.65 Toluene 2.00 Hydrogen 1.00 Xylene 0.93 IPA 2.50
Factor (Methane
Calibration)
Gas
LEL Conversion Factor (Methane
Calibration)
Measuring Mode, Alarms
This section covers alarm indications in Measuring Mode. It also tells you how to reset the GX-2003 after an alarm has occurred and how to respond to an alarm condition.
NOTE: False alarms may be caused by radio frequency (RF) or
electromagnetic (EMI) interference. Keep the GX-2003 away from RF and EMI sources such as radio transmitters or large motors.
21 • M e a s u r i n g M o d e , A la r m s GX-2003 Operator’s Manual
Alarm Indications
CAUTION: If the combustible channel is set for %volume only, then there
are no gas alarms for any detection channel. See “HC Range Screen” on page 26.
The GX-2003 will sound an alarm, the unit will vibrate, and the LED arrays will flash when one of the target gas concentrations rises above the Alarm 1 level, or in the case of oxygen, falls below the Low Alarm setting for that gas.
The Model GX-2003 also sounds an alarm, vibrates, and flashes the LED arrays when the Alarm 2 level is reached for CH
when the concentration of oxygen rises above the High Alarm level, and when the STEL and TWA alarm points are reached for CO and H
S.
2
When a failure condition occurs, such as a sensor failure, low flow, or dead battery condition, the unit will also sound an alarm, flash the LED arrays, and vibrate.
, CO, and H2S,
4
The table below summarizes the types of alarms produced by the GX-2003.
Table 4: Alarm Types and Indications
Alarm Type Visual Indications Other Indications
Low Alarm
Concentration of gas rises above the low alarm level, or falls below the Low Alarm level for O
.
2
High Alarm
Concentration of gas rises above the Alarm 2 level, or rises above the High Alarm level for O
2
TWA or STEL
Concentration of CO or H
S rises above the
2
TWA or STEL alarm point setting.
ALM1 appears blinking next to gas reading.
Alarm LED arrays flash once per second.
• ALM2 appears
blinking next to gas reading.
• Alarm LED arrays
.
flash twice per second.
• Alarm LED arrays
flash once per second.
• Back light turns on.
• TWA or STEL appears
blinking next to gas reading.
• Pulsing tone once per second
• Unit vibrates once per second
• Pulsing tone twice per second
• Unit vibrates twice per second
• Pulsing tone once per second
• Unit vibrates once per second
GX-2003 Operator’s Manual Measuring Mode, Alarms • 22
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