Crowcon Gas-Pro User manual

H2S
CO
CH4
Gas-Pro
User & Operator Manual
Gas-Pro
Multi-gas confined space monitor
M07995
Issue 3 Mar 2012
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3
CONTENTS
PROLOGUE .............................................6
Gas-Pro Overview ...............................................6
Safety Information........................................7
Unpacking .............................................10
1. Set-up ..............................................11
1.1 Prior to use.................................................11
1.2 Gas-Pro orientation ..........................................11
1.3 Charging...................................................12
1.4 Fitting a ow plate ...........................................13
1.5 Quick view .................................................14
2. Operation ...........................................15
2.1 General ....................................................15
2.2 Turn on ....................................................15
2.3 Pump test ..................................................19
2.4 Detecting gas ...............................................20
2.4.1 Diffusion monitoring .....................................20
2.4.2 Pumped mode ..........................................21
2.4.3 Manual sampling ........................................21
2.4.3.1 Using the Hand Aspirator.............................21
2.5 Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
2.5.1 Low battery alarm .......................................22
2.5.2 Instantaneous alarm .....................................22
2.5.3 Time weighted average alarm (TWA)........................22
2.5.4 Accepting and clearing alarms ............................23
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2.5.5 Sensor types ...........................................23
2.5.5.1 Oxygen sensors ....................................23
2.5.5.2 Electro-chemical sensors.............................23
2.5.5.3 Infra red sensors ...................................23
2.5.5.4 Pellistor sensors....................................24
2.5.5.5 Pellistor saver mode .............................24
2.6 Gas-Pro functions ...........................................25
2.6.1 Accessing the user menus ................................25
2.6.2 Home screen ........................................25
2.6.3 Manual zero .........................................25
2.6.4 Time weighted average ................................25
2.6.5 Pre-entry check (PEC) .................................26
2.6.5.1 Starting a Pre-entry check ............................26
2.6.5.2 Carrying out a Pre-entry check ........................27
2.6.6 Peak review .........................................28
2.6.7 Settings ............................................28
2.6.7.1 User setting ....................................28
2.6.7.2 Pump setting ...................................28
2.6.7.3 Sounder volume .................................28
2.7 Shut down .................................................29
2.8 Additional Features ..........................................29
2.8.1 +ve Safety™ ............................................29
2.8.1.1 +ve Safety™ indicator meanings .......................29
2.8.2 Data and event logging...................................30
2.8.3 Bump/Pump functionality.................................30
3. Gas testing and calibration .............................31
3.1 Introduction ................................................31
3.1.1 Speedy bump...........................................32
3.1.1.1 Procedure ........................................32
3.1.2 Smart bump ............................................32
3.1.2.1 Procedure ........................................32
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3.1.3 Calibration .............................................33
3.1.3.1 Procedure ........................................33
3.1.4 New sensor calibration ...................................33
3.2 Functionality ...............................................33
4. Service and maintenance ..............................34
4.1 General ....................................................34
4.2 ESD warning ...............................................34
4.3 Sensor replacement .........................................34
5. PC interface and Portables-Pro .........................36
5.1 General ....................................................36
5.2 PC interface cable ...........................................36
6. Accessories .........................................37
7. Specication .........................................38
8. Troubleshooting ......................................39
8.1 Pump test failure ............................................39
8.2 Fault screens ...............................................39
8.2.1 Fault Descriptions .......................................40
8.2.2 Fault codes ............................................41
9. Appendices ..........................................42
9.1 Sensors ...................................................42
9.1.1 Toxic ..................................................42
9.1.2 Flammable Sensors .....................................43
9.1.3 Oxygen ................................................43
9.1.4 IR.....................................................43
9.2 Sensor Limitations ..........................................44
9.3 Charging and run times ......................................44
9.4 Crowcon contacts ...........................................45
Warranty ...............................................46
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PROLOGUE
Gas-Pro Overview
Thank you for purchasing the new Gas-Pro. At Crowcon we recognise the need for reliable and
robust personal monitors which are sized to be worn and simple to use.
Gas-Pro is a portable Conned Space Entry (CSE) monitor capable of detecting up to 5 gases in
a compact and wearable design featuring an optional internal pump. Focused on users and eet
managers alike, Gas-Pro offers application focused solutions giving greater operating time and
reduced set up time.
Gas-Pro is classied for use in hazardous areas and gives loud and bright audible and visual alarm
indications as well as a vibrate alert. The top mount display is backlit for ease of use, and the simple
single button solution makes using and training quick and easy.
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7
Safety Information
• Gas-Pro is a hazardous area certied gas detector and as such must be operated and
maintained in strict accordance with the instructions, warnings and label information included in
this manual. Gas-Pro must be operated within the limitations stated.
• Read and understand all instructions in the operation section of this manual prior to use.
• Before use ensure that the equipment is in good condition, the enclosure is intact has not been
damaged in any way.
• If there is any damage to the equipment do not use, contact your local Crowcon ofce or agent
for repair/replacement.
• Do not disassemble or substitute components as this may impair intrinsic safety and invalidate
safety certication.
• Only genuine Crowcon replacement parts must be used; substitute components may
invalidate certication and warranty of the Gas-Pro and accessories, reference “Service and
Maintenance” section for details.
• No live maintenance is permissible.
• Observe all warnings and instructions marked on the unit and within this manual.
• Observe site health and safety procedures for gases being monitored and evacuation procedures.
• Understand the screen display and alarm warnings prior to use.
• If this product is not working properly, read the troubleshooting guide and/or contact your local
Crowcon ofce or agent, for details reference the ‘Crowcon Contacts’ section of the manual.
• Ensure maintenance, service and calibration is carried out in accordance with the procedures in
the manual and only by trained personnel.
• The Gas-Pro re-chargeable battery must only be charged in non-hazardous (safe) areas.
• Only connect to Gas-Pro in a safe area for charging or communications.
• Gas-Pro must not be charged or have communication to the device, at ambient temperatures
greater than +40°C.
• Charging cable assemblies, whilst nominally providing a voltage of 6.5V, must not exceed a
voltage of 9.1V and a current of 850mA as this may impair intrinsic safety and invalidate safety
certication (Um=9.1V, Ii=850mA).
• Communication cable assemblies, whilst nominally operating at a voltage of 3.0V TTL, must
not exceed a voltage of 9.1V and a current of 850mA as this may impair intrinsic safety and
invalidate safety certication (Um=9.1V, Ii=850mA).
• The devices are intended for use in normal atmospheric conditions of temperature –20 °C to
+55 °C; pressure 80 kPa (0,8 bar) to 110 kPa (1,1 bar); and air with normal oxygen content,
typically 21 % v/v (volume/volume).
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• Gas-Pro may be used in Zones 1 and 2, for Group llA, llB and llC gases and vapours and for
Temperature Classes T1, T2, T3 and T4. (see Certication labels below).
• Certication labels
The certication marking is as follows:
• Gas-Pro is certied for use in ambient temperatures in the range -20°C to +55°C (-4 to 131°F).
• Applicable Standards
Refer to equipment marking for conrmation of applicable certication before use.
IECEx
IEC 60079-0:2004 4th Edition
IEC 60079-0:2007-10 5th Edition
Electrical apparatus for explosive gas atmospheres Part 0: General requirements
IEC 60079-11:2006 5th Edition
Explosive atmospheres - Part 11: Equipment protection by intrinsic safety “i”
IEC 60079-1 2007-04 6th Edition
Explosive atmospheres - Part 1: Equipment protection by ameproof enclosures “d”
Ex d ia IIC T4 Gb Tamb -20°C to +55°C
IECEx ULD 11.0004X
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ATEX:
EN 60079-0:2006
EN 60079-0:2009
Electrical apparatus for explosive gas atmospheres Part 0: General requirements
EN 60079-11:2007
Explosive atmospheres - Part 11: Equipment protection by intrinsic safety “i”
EN60079-1:2007
II 2 G Ex d ia IIC T4 Gb Tamb -20°C to +55°C
DEMKO 11 ATEX 1031772X
UL
Gas detector use in hazardous locations Class 1 Division 1, Groups A, B, C and D only as to
intrinsic safety.
UL 913 7th Edition
UL 60079-0:2005 4th Edition
UL 60079-11:2002 1st Edition
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10
Unpacking
Remove the Gas-Pro from the packaging. The standard accessories are under the supporting trays.
The following items will be included as standard:
Box contents
• Gas-Pro
• Quick Start Guide
• CD Manual
• Packing check List
• Calibration Certicate
• Declaration of Conformity
The following items are optional:
Optional items
• Charger cradle
• Charger lead (see Power & Communication Cables Technical Data)
• Flow plate (standard for pumped units)
i If you have ordered a charger and/or cradle this will also be included in the box.
Further accessories are available but will not be contained in the box (see Section 6).
i Gas-Pro in the off state can be left on charge indenitely
i Should the unit be deep discharged charging indication will not be shown until the unit
has been charging for 1 hour and the operator button has been pressed.
i When on and charging a warning will advise the user to turn the Gas-Pro off after 12
hours or remove from charge
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11
1. Set-up
1.1 Prior to use
Before use, the Gas-Pro should always be checked for any signs of physical damage.
Gas-Pro uses a Lithium Ion (Li-ion) battery pack and should arrive with sufcient charge to be used
straight out the box. However, if this is the rst time of use, you may need to charge the battery to
attain the full operating time (see Charging on page 12).
For battery run times, see the table on page 44.
i The actual operating time will depend on the types of sensor installed.
1.2 Gas-Pro orientation
Figure 1: Gas-Pro
ÀD-ring à Sounder ÆSensor apertures É Charging cable
ÁAlarm bars Ä Operator button ÇDual colour LCD display Certication label
 +ve Safety™ indicator Å Pump inlet/outlet* È Alligator clip
* Blanked for non-pumped unit.
À
Ç
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É
È
Ä
Â
Å
Æ
Á
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1.3 Charging
Charging should only take place in non-hazardous (safe) areas. To charge, simply plug the cable Àinto
the charging socket Áon the Gas-Pro and turn on the mains supply (see Figure 2 below). If a charging
cradle or vehicle cradle is being used, ensure the Gas-Pro ts rmly on to the power connector.
i The charger must be able to supply 6.5V@ 450mA with an output voltage that does not
exceed 9.1V (Um).
Figure 2: Charger connection
To show the Gas-Pro is charging, both LEDs within the alarm bars will ash red and will change to green
once fully charged. This state will continue until the trickle charge is complete. Charging will then terminate
showing no indication. The screen will also show the battery icon lling in the middle of the screen when
the Gas-Pro is off, and in the bottom left-hand corner when it is on. The battery icon contains a maximum
of six segments to indicate the battery’s state of charge. For example, with three segments shown and a
fourth ashing, the battery is 50% charged À, and when all six are shown, the battery is fully charged Á
(see Figure 3 below).
Figure 3: Charging indications
À
Á
À Á
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1.4 Fitting a ow plate
A ow plate can be used for a number of applications requiring pumped operation or during a manual gas
test/calibration. Attach a ow plate before turning the Gas-Pro on if the Gas-Pro includes a pump and a
pump test is required as part of the start up process (see Pump test on page 19).
There are two types of ow plate: one for a Gas-Pro with internal pump and one for a Gas-Pro with
no pump. Although there is no difference to the attachment procedure, they are not interchangeable
(see Figure 4 for the visible differences between the two). The pumped ow plate has the symbol
in the top left corner to aid recognition.
Figure 4: Pumped and non pumped ow plates
À Pumped ow plate
Á Non pumped ow plate
Check the ow plate’s gasket is free from dirt and has not been damaged prior to tting. To t a ow
plate, locate it over the Gas-Pro sensors as shown in Figure 5 and tighten the securing screw À.
Figure 5: Fitting a ow plate
The ow plate includes a quick connect tting for attaching sample tubes and probes.
À Á
À
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1.5 Quick view
Even when the detector is off, users can display details about the conguration of the Gas-Pro by
momentarily pressing the operator button for one audible blip. The LED to the left of the display will
ash red once and the Quick view screen shown in Figure 6 below will be displayed for 10 seconds.
Figure 6: Quick view display
ÀGas type and unit detected
ÁBattery status
ÂQuickview icon
à ID or serial number
i The +ve Safety™ LED status is also shown (see Figure 1).
Ã
Á
À
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15
2. Operation
2.1 General
!Before turning the Gas-Pro on, ensure it is in ‘clean air’ (i.e. outside, in normal air, away
from any plant process or suspected gas location). This will allow the Gas-Pro to be
zeroed using clean air as the base point. If the Gas-Pro is zeroed in contaminated air a
false gas reading can result, or the zero could fail.
2.2 Turn on
In ‘clean air’, turn on the Gas-Pro by holding down the operator button for 3 audible blips. The Gas-
Pro will warm up, going through a series of automatic processes as follows:
Firstly a test screen pattern will be generated. Watch this to ensure there are no missing pixels on
your display screen.
Whilst the Gas-Pro is warming up, two screens will be displayed.
Figure 7: Initial screens at turn on
After a successful test cycle the LCD screen will remain green, the sounder and LEDs will indicate
the Gas-Pro is healthy.
i A Gas-Pro tted with a pump is congured as standard to start the pump automatically
when switched on, provided that a ow plate is tted. Such a Gas-Pro tests the pump
automatically at this point (for more details on this, see Pump test on page 19).
i If the battery level is low, an alarm will sound, and the battery icon on the screen will be partial.
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If the Gas-Pro is congured for regular Gas Testing (Bump Test), the date of the last Gas Test will
also be shown (for more information on Gas Testing, see Gas testing and calibration on page 31).
Figure 8: Gas test due screen
The next screen indicates when the Gas-Pro was last calibrated. It also indicates when the next calibration
is due with a warning symbol next to the number of days left. If the calibration due date has expired,
the number of days gure is not displayed and the warning symbol ashes.
Figure 9: Calibration due screen
If the calibration due lockout feature has been enabled the lockout icon will be displayed.
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The next screen (Figure 10) will display the current detector settings (for more information on these
settings, see Gas-Pro functions on page 25).
Figure 10: Current settings screen
The Autozero Conrm screen will be displayed next.
Figure 11: Autozero conrm screen
Press the operator button to enter the Autozero mode, otherwise the countdown will progress and
will not perform a zero. An Autozero should not be performed unless the Gas-Pro is in clean air.
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When the autozero has nished or been skipped, the next screen is the home screen (Figure 12)
and displays the gas levels.
i Figure 12 shown below is for 5 gases in clean air.
Figure 12: Home screen
ÀGas type
ÁUnit
ÂLevel
ÃHome Screen icon
ÄBattery level
ÅPump present
(rotating when on)
In ‘clean air’, CO2and Oxygen levels are typically 0.04% and 20.9% respectively. In zero mode,
these gases will actually run an ‘offset’ zero.
!From the 1st November 2010, EN60079-29 part 1 has been harmonised under the ATEX
directive 94/9/EC. Therefore to comply with the ATEX directive, portable apparatus sensing
ammable gases should have a functional check with ammable gas before each day of
use (see Gas testing and calibration on page 31). Other testing regimes may be employed
depending on local circumstances.
The Gas-Pro is now ready for use.
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19
2.3 Pump test
In the default conguration, a pumped Gas-Pro with a ow plate attached (see Fitting a ow plate on
page 11) will run a pump test during the start up process. A pump test will also be run whenever a
ow plate is attached during normal operation.
i If the Gas-Pro is congured for Bump functionality, the Bump/Pump prompt will be
displayed if a ow plate is attached or the Gas-Pro is placed in a Q-Test module during
normal use (see Bump/Pump functionality on page 30).
i Prior to tting, the ow plate’s gasket should be checked for any damage.
The pump test ensures accurate sealing as well as monitoring pump performance.
The user will need to cover the pump inlet À(see Figure 13 below) when prompted to do so by the
symbol on the screen.
Figure 13: Pump inlet
When the test has nished, the pump will either pass or fail .
If the pump test takes place during start-up and the Gas-Pro passes, the pump will remain on and
the start-up process will continue as normal. If the test is passed during normal use, the Gas-Pro will
remain in the pumped mode until the ow plate is removed.
On failing the pump test the fail screen will persist with an audible alert until the button is pressed
and the test repeats OR the ow plate is removed and the Gas-Pro returns to unpumped operation.
For further detail on failing a pump test see Pump test failure on page 39.
À
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2.4 Detecting gas
When being used in wet/dirty environments the use of the ‘dust cover’ is recommended for both
pumped and un pumped units.
2.4.1 Diffusion monitoring
If you wish to monitor gases in ambient air for dangerous levels, the Gas-Pro can be worn by either
clipping the strong alligator clip to clothing/overalls in the breathing zone or through the use of a
chest harness.
In the default, non-alarm state, Gas-Pro’s sounder À will emit a beep every 10 secs, its condence
LEDs Á will ash green, the +ve Safety™ indicator Âwill show the current status, and the LCD display
à will indicate it is running by ashing the icon.
Figure 14: Gas-Pro indicators
In the alarm state, Gas-Pro will vibrate, its sounder Àwill emit a rapid tone, the alarm LEDs Á will ash
red and blue, the +ve Safety™ indicator Âwill be off in alarm, the LCD display Ãwill also be red and
highlight the gas in alarm.
À
Á
Â
Ã
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