Crowcon Q-Test User manual
H2S
CO
CH4
M070001/ENG
Issue 3 Jan 2015
Q-Test
User & Operator Manual
Q-Test
Quick and simple in-field gas test
and calibration solution
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Contents
3
CONTENTS
Prologue..............................................5
Safety Information......................................6
Unpacking ............................................7
1. Set-up .............................................8
1.1 Mounting ................................................8
1.2 Prior to use..............................................10
1.2.1 Opening the Q-Test ...................................10
1.2.2 Inspection ..........................................10
1.3 Inlet/exhaust connections .................................11
1.3.1 Inlet Connections ....................................11
1.3.2 Regulators ..........................................11
2. Operation .........................................12
2.1 Inserting the Gas-Pro .....................................12
2.2 Gas-Pro control ..........................................12
2.3 Bump test ...............................................13
2.3.1 Bump Test Functionality...............................14
2.3.2 Speedy bump........................................15
2.3.3 Smart bump .........................................15
2.3.4 Calibration after bump fail .............................16
2.4 New sensor calibration/service .............................17
2.5 Gas Test Screen Flow .....................................17
2.6 Q-Test Gas Suitability .....................................18
2.7 Gas Testing Requirements/Recommendations ................18
2.8 Test Gas Requirements....................................19
2.8.1 Speedy Bump Recommended Gas Levels ................19
2.8.2 Smart Bump Recommended Gas Levels .................20
2.8.3 Calibration after bump fail Recommended Gas Levels ......22
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3. Service and maintenance ............................24
3.1 General .................................................24
3.2 Periodic checks ..........................................24
4. Specication .......................................25
5. Accessories .......................................26
6. Troubleshooting ....................................27
Warranty .............................................28
Crowcon contacts .....................................30
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5
Prologue
General
Thank you for purchasing the Q-Test. At Crowcon we recognise the need for quick and simple gas
test solutions which are suitable for the challenges of on-site and off-site use.
Q-Test provides a quick and simple in-eld gas test and calibration solution. Providing off-site testing
for remote locations where power is not always available or practical. Simple to use and easy to
repeat, Q-Test reduces set-up, training requirements and space needed.
Flexibility
Q-Test manages speedy and smart bumps as well as calibration. Q-Test can also be easily mounted
via din rail mounts on a wall or inside a vehicle to give a gas test solution for any application.
The charging option also gives a permanent home to detectors mounted in vehicles and is easily
powered via a standard in-vehicle power socket or multiregional power supply.
Remote Workers
When in the eld, Q-Test provides conned space workers with repeatable gas testing solutions that
maintain detector integrity and safety. When working in conjunction with +ve Safety™ eet managers
can quickly and easily tell when site requirements have not been adhered to.
Economic
Repeatable test solutions that, through recommended gas use instructions, can offer over 200
speedy bumps from a 34l cylinder and over 330 speedy bumps from a 56l cylinder.
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Safety Information
• 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 or it is not working properly, do not use, read the
troubleshooting guide (see page 27) and/or contact your local Crowcon ofce or agent for
repair/replacement.
• 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 Gas-Pro screen display and alarm warnings prior to use (see Gas-Pro User &
Operator Manual).
• Ensure maintenance, service and calibration is carried out in accordance with the procedures in
the manual and only by trained personnel.
• Gas-Pro is a hazardous area certied gas detector and as such must be operated and
maintained in strict accordance with its instructions, warnings and label information included in
the Gas-Pro manual.
• Use only Crowcon supplied Gas-Pro mulitregion plug or vehicle charging adaptor. Not suitable
for use with other mulitregion plugs as these may cause damage to the unit.
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Unpacking
Remove the Q-Test from the packaging. The standard accessories are under the supporting trays.
The following items will be included as standard:
Box contents
• Q-Test
• CD Manual
Optional items in the box
• Regulators
• Gas-Pro Mulitregion plug
• Vehicle charging adaptor
The box label details the contents.
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1. Set-up
1.1 Mounting
i The gas inlet pipe Àand gas exhaust pipe Áare long enough to allow placement to the left
or the right of the Q-Test Â, powered Q-Test Ãor powered Q-Test with cylinder holder Ä
but should be located prior to mounting.
Figure 1: Inlet/outlet location
Á
Â
Ã
Ä
À
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The Q-Test can be mounted on a standard DIN rail type EN 50022 À or screwed to a suitable at
surface through the 3 holes Áin the module’s main body (see below).
The recommended length of DIN rail if a Q-Test is to be mounted on its own, is 150mm.
If the Q-Test is to be used in conjunction with a cylinder holder, the recommend length of DIN rail
required is 250mm.
The recommended length of DIN rail if a Powered Q-Test is to be mounted on its own, is 275mm
(this is supplied with the powered Q-Test).
If the Powered Q-Test is to be used in conjunction with a cylinder holder, the recommend length of
DIN rail required is 350mm.
Mount the DIN rail to the wall (at side against the wall), allowing space on at least one side to slide
the Q-Test on.
The cylinder holder is available to mount on the DIN rail or direct to the wall.
i Ensure that when the Q-Test is mounted, the Gas-Pro screen and operator button will be
accessible (see Figure 7 on page 12).
Figure 2: Mounting the Q-Test
À
Á
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1.2 Prior to use
1.2.1 Opening the Q-Test
Press the release button Àand lower the door Áas shown below:
Figure 3: Opening the Q-Test
There are two open levels, if left to fall the door will open to 45º. The door can be fully opened by
pulling the door down gently.
1.2.2 Inspection
Before use, the Q-Test should always be checked for any signs of physical damage, paying special
attention to the ow gasket À, the gas inlet pipe Áand gas exhaust pipe Â. Ensure there is no
damage to the gasket; this could result in poor gas ow.
Figure 4: Inspection prior to use
À
Á
Â
À
Á
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1.3 Inlet/exhaust connections
The gas cylinder is connected to the gas inlet pipe Àand the gas exhaust pipe Áshould be
connected to a suitable length of pipe that vents to outside air. These pipes are long enough to allow
placement to the left or the right of Q-Test.
1.3.1 Inlet Connections
For non reactive gases Crowcon recommend the use of Tygothane or Tygon 3603 pipe. If this pipe is
used, the maximum recommended tube length from the regulator to Q test inlet is 30m.
For use with reactive gases Crowcon recommends the use of Tygothane pipe (AC0301). If this pipe
is used the maximum recommended tube length form the regulator to Q test inlet is 1m.
When using reactive gases, for correct operation, all pipe work and regulators should be purged with
the respective reactive gas.
Figure 5: Inlet/exhaust connections
1.3.2 Regulators
Q-Test can be used with 0.5 litres per min or 1 litre per min regulators. Fixed ow or trigger
regulators are required as the user is responsible for opening the gas ow at the correct time (when
prompted by the Gas-Pro). See accessories section for details.
Á
À
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2. Operation
2.1 Inserting the Gas-Pro
Turn the Gas-Pro on, wait for it to nish the start up process and then insert the Gas-Pro into the
Q-test as shown below:
Figure 6: Inserting the Gas-Pro
2.2 Gas-Pro control
When the Gas-Pro is inserted into the Q-Test, you will need to see the display screen Àand have
access to the operator button Á(see below).
Figure 7: Gas-Pro controls
À
Á
ÂÃ
À
Á
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2.3 Bump test
If the Gas-Pro is congured for Bump/Pump functionality, then by placing the Gas-Pro in a Q-Test
module, the Bump/Pump screen will be displayed (see Figure 8 below).
i IftheGas-Proisanonpumpedunitandnotconguredforbumptestthe‘sensors
blockedbyowplate’warningiconwillbeshownwheninsertedintotheQ-Test.TheGas-
ProwillneedtobeconguredforbumptooperatecorrectlyintheQ-Test.
i IftheGas-Proisapumpedunitandnotconguredforbumptestthepumpwill
immediatelystart.TheGas-Prowillneedtobeconguredforbumptooperatecorrectlyin
the Q-Test.
Figure 8: Bump/Pump screen
Click the operator button to highlight for Bump testing and then double click it to select the Bump test.
According to the Gas-Pro conguration, the user may be asked to choose which group of gases to
bump and either a Speedy bump or Smart bump test will be performed (see page 15).
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2.3.1 Bump Test Functionality
As part of the bump testing functionality Gas-Pro offers the ability to allocate gas sensors tted to the
Gas-Pro into different ‘bump test groups’. These groups apply to both the speedy and smart bump
functionality.
The groups available are ‘Daily’ and ‘Intermittent’, these can be congured via Portables-Pro.
This allows a different gas test regime to be applied for different sensors inline with site/company
procedures. The information below explains this in greater detail:
If the sensors are grouped into the ‘Intermittent’ group with, for example, a 90 day interval (this
interval is congurable in Portables-Pro), Gas-Pro will inform the user a bump test is due on the 90th
day of use. This is indicated by a gas test due warning on the Gas-Pro screen during start up.
Figure 9: Gas test due screen
Gas-Pro will not inform the user of a need for a gas test until the interval period from the last
successful bump has expired. However on applying a magnetised ow plate, or placing Gas-Pro
into the Q-Test, the user will be given the option to complete a gas test (or proceed to pumped
operation).
If the sensors are grouped into the ‘Daily’ group, the Gas-Pro will inform the user a bump test is due
at the start of each working day (actually every 24 hours). This is indicated by a gas test due warning
on the Gas-Pro screen during start up.
If Gas-Pro is turned off and on again within 24 hours of the gas test, the Gas-Pro will not inform
the user of a need for a bump test. However on applying a magnetised ow plate, or placing Gas-
Pro into the Q-Test the user will be given the option to complete a gas test (or proceed to pumped
operation).
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2.3.2 Speedy bump
A speedy bump tests the Gas-Pro to rst alarm level.
Gas is presented across/over the sensor for a designated time (dependent on sensor gas type)
during which alarm level one should be activated.
This is deemed a pass if the detector goes into alarm and the detector is functioning (sounder, LED’s
and vibrator, veried by the user).
It is a fail if the detector does not go into alarm.
2.3.2.1 Procedure
XPlace the Gas-Pro in the Q-Test module.
XClick the operator button to highlight for Bump testing and then double click it to select the
Bump test.
XThe screen will show ‘Gas on’.
XAttach the gas bottle to the inlet pipe and turn it on.
XAfter a time (depicted by a time bar at the base of the display), the display will show if the gas(es)
being tested have passed or failed . Gases not being tested will display [*]. The test will
end before the preset time if all gases being tested pass.
2.3.3 Smart bump
A smart bump tests that the Gas-Pro responds correctly to a specied level of test gas.
Gas is passed over/across the sensors and a predicted response is expected within a time window
dependant on the sensor response time.
The test is passed if the gas level indicated by the detector is within pre-specied limits within this
time window (the parameters of this test are congurable via Portables-Pro).
2.3.3.1 Procedure
XPlace the Gas-Pro in the Q-Test module.
XClick the operator button to highlight for Bump testing and then double click it to select the
Bump test.
XThe screen will show ‘Gas on’.
XAttach the gas bottle and turn it on.
XAfter a time (depicted by a time bar at the base of the display), the display will show if the gas(es)
being tested have passed or failed . Gases not being tested will display [*].
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2.3.4 Calibration after bump fail
If any channel fails speedy bump or smart bump then Gas-Pro can be congured (via Portables-Pro)
to perform a ‘calibration after bump fail’ immediately after the test failure.
As this test immediately follows a speedy or smart bump, if ‘calibration after bump fail’ is congured
the speedy or smart bump test will need to undertaken with calibration quality gas.
i EnsurethegasappliedmatchesthecongurationsettingsintheGas-Proorthetestwill
fail. This can be done via Portables-Pro.
i Shouldaammablesensorbetted,checkthelabelfortheoriginalcalibrationtargetgas.
2.3.4.1 Procedure
i Calibration should only be performed with appropriately accurate gas.
• If calibration is intended the instrument should have been zeroed manually within 15 minutes
prior to the calibration attempt.
• Following a bump test failure, leave the instrument in the Q-test module and the gas on.
• Wait for the calibration result screen indicated by the or .
Figure 10: Gas test due screen
• The Gas-Pro then returns to normal operation.
During this process the new calibration values are stored to the instrument memory and the
calibration dates are advanced by the congured interval – commonly 1 month as the Gas-Pro has
not been through a formal service/calibration routine (dependant upon region/setting).
If the gas test calibration fails this may be indicative of a more serious sensor issue, including the
need to replace sensors. The instrument should then be serviced.
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2.4 New sensor calibration/service
Servicing or the tment of a new sensor can only be undertaken by a suitably trained technician
using the PC software and the appropriate gases.
In addition calibration should be performed as required by local or organisational regulations. In
the absence of suitable evidence, such as a eld assessment by a competent person, Crowcon
recommend regular service and calibration every 6 months.
2.5 Gas Test Screen Flow
The following sequence of screen shots should be viewed with reference to the sections on ‘Speedy
Bump’, ‘Smart Bump’ & ‘Calibration after bump fail‘.
The screen shots show the general ow of the gas test functionality dependant upon the actual test
and the decisions made.
Figure 11: Gas test screen ow
Gas Groups Gas On
Gas Off
Bump/Pump
Pass
Pass
Fail
Fail
One gas fail
One gas fail
Calibration after bump fail
If enabled & manual zero <15mins prior
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2.6 Q-Test Gas Suitability
The following gases are suitable for use with the Q-Test:
• Oxygen
• Carbon Monoxide
• Hydrogen Sulphide
• Carbon Dioxide
• Sulphur Dioxide (Reactive gas)
• Methane
• Butane
• Propane
• Pentane
• Acetylene
• Ethylene
• Ammonia (Reactive gas)
• Nitrogen Dioxide
• Nitric Oxide
• Ozone (Reactive gas)
• Chlorine (Reactive gas)
• Chlorine Dioxide (Reactive gas)
2.7 Gas Testing Requirements/Recommendations
When using reactive gases all pipe work and regulators should be purged with the respective
reactive gas.
Crowcon recommend using a typical ow rate of the test of 0.5 litres per minute.
When using chlorine and chlorine dioxide as the test gas the typical ow rate should be increased to
1 litre per minute.
Chlorine dioxide gas testing (or calibration) must only be carried out using a chlorine dioxide
generator. Crowcon recommend Advanced Calibration Designs, inc. Gas Generator, model:
CAL2000 (P/N: 750-0603-AT), using the Chlorine Dioxide Cell (P/N: 510-2060-00). Refer to
generator instructions for use.
Ozone gas testing (or calibration) must only be carried out using an ozone generator. Crowcon recommend
Analytical Technology, inc. Ozone Generator, Model: A23-14. Refer to generator instructions for use.
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2.8 Test Gas Requirements
For each type of gas test that can be undertaken by Q-Test; speedy bump; smart bump and
calibration after bump fail, Crowcon recommend the following gas levels.
Care should be taken to ensure Gas-Pro is congured correctly such that the gas levels applied are
suitable for the test to be undertaken, the conguration can be veried via Portables Pro. If Gas-Pro
is not congured correctly for the gas to be applied, then the test will not be successful.
2.8.1 Speedy Bump Recommended Gas Levels
Table 1 shows the recommended minimum and maximum concentration of gas suitable for a Gas-
Pro congured to undertake a speedy bump test when inserted into a Q-Test.
Table 1
Gas Gas Name Recommended Minimum
Concentration
Recommended
Maximum
Concentration
(see note)
O2Oxygen ≥ congured alarm level 1 threshold ≤ 22% VOL
CO Carbon Monoxide ≥ congured alarm level 1 threshold ≤ 400ppm
H2S Hydrogen Sulphide ≥ congured alarm level 1 threshold ≤ 85ppm
CO2Carbon Dioxide ≥ congured alarm level 1 threshold ≤ 2% VOL
SO2Sulphur Dioxide ≥ congured alarm level 1 threshold ≤ 16ppm
CH4Methane ≥ congured alarm level 1 threshold [ATEX] 2.2% VOL
[UL] 2.5% VOL
C4H10 Butane ≥ congured alarm level 1 threshold [ATEX] 0.7% VOL
[UL] 0.6 % VOL
C3H8Propane ≥ congured alarm level 1 threshold [ATEX] 0.85% VOL
[UL] 1.05% VOL
C2H2Acetylene ≥ congured alarm level 1 threshold [ATEX] 0.55% VOL
[UL] 0.75% VOL
C5H12 Pentane ≥ congured alarm level 1 threshold [ATEX] 1.15% VOL
[UL] 1.2% VOL
C2H4Ethylene ≥ congured alarm level 1 threshold [ATEX] 1.15% VOL
[UL] 1.35% VOL
NH3Ammonia ≥ congured alarm level 1 threshold ≤ 85ppm
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Gas Gas Name Recommended Minimum
Concentration
Recommended
Maximum
Concentration
(see note)
N02Nitrogen Dioxide ≥ congured alarm level 1 threshold ≤ 17ppm
NO Nitric Oxide ≥ congured alarm level 1 threshold ≤ 85ppm
O3Ozone ≥ congured alarm level 1 threshold
≤ 0.7ppm
(concentration from
recommended
generator)
CL2Chlorine ≥ congured alarm level 1 threshold ≤ 3ppm
CLO2Chlorine Dioxide ≥ congured alarm level 1 threshold ≤ 0.8ppm
i Ensure the accuracy of the gas cylinder used does not allow the nominal gas
concentration of the gas applied, to exceed the recommended maximum value.
2.8.2 Smart Bump Recommended Gas Levels
Table 2 shows the recommended minimum and maximum concentration of gas suitable for a Gas-
Pro congured to undertake a smart bump test when inserted into a Q-Test.
Table 2
Gas Gas Name Recommended Minimum
Concentration
Recommended Maximum
Concentration
(see note)
O2Oxygen ≥ congured alarm level 1 threshold ≤ 22% VOL
CO Carbon Monoxide ≥ congured alarm level 1 threshold ≤ 400ppm
H2S Hydrogen Sulphide ≥ congured alarm level 1 threshold ≤ 85ppm
CO2Carbon Dioxide ≥ congured alarm level 1 threshold ≤ 2% VOL
SO2Sulphur Dioxide ≥ congured alarm level 1 threshold ≤ 16ppm
CH4Methane ≥ congured alarm level 1 threshold [ATEX] 2.2% VOL
[UL] 2.5% VOL
C4H10 Butane ≥ congured alarm level 1 threshold [ATEX] 0.7% VOL
[UL] 0.6% VOL
C3H8Propane ≥ congured alarm level 1 threshold [ATEX] 0.85% VOL
[UL] 1.05% VOL
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