Crowcon I-Test Mounting instructions

H2S
CO
CH4
M070002
Issue 5 Aug 2015
I-Test
User & Operator Manual
I-Test
Quick and simple in-field gas test
and calibration solution
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Contents
Contents

3
CONTENTS
Safety Information......................................7
Unpacking ............................................7
I-Test Overview ........................................8
Suitability .............................................8
I-Test Functional Overview ...............................8
1. Physical Set-up/Installation of I-Test ...................11
1.1 Mounting ...............................................11
1.2 Inlet/exhaust connections .................................12
1.3 Electrical connections & controls ...........................12
1.4 Prior to use..............................................13
1.4.1 Inspection ..........................................13
1.5 Charging................................................14
2. Operating I-Test ....................................15
2.1 Gas Monitor Testing Overview ..............................15
2.2 Loading a monitor into an I-Test ............................16
2.3 Test Progress Status Indication.............................17
2.4 Test Result Status Indication ...............................18
2.5 Main menu status icons ...................................19
2.6 Replacing an empty gas cylinder............................19
2.7 I-Test Safe Shutdown .....................................19
3. I-Test Manager Software .............................20
3.1 Introduction .............................................20
3.2 I-Test Manager system requirements ........................20
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3.3 I-Test Manager installation & setup ..........................21
3.4 I-Test Manager Functional Overview .........................23
3.4.1 Manage Cylinders ....................................23
3.4.2 Inlet Conguration ...................................23
3.4.3 Actions .............................................23
3.4.4 Field Conguration ..................................23
3.4.5 Reporting/Data Management ...........................23
3.4.6 I-Test Display Settings ................................24
3.4.7 I-Test Conguration Upload/Download Options............24
3.5 Starting the software......................................24
3.6 Language selection .......................................25
3.7 Initial Conguration of I-Test ...............................25
3.7.1 Manage cylinders ....................................25
3.7.2 Create a new conguration ............................29
3.7.3 I-Test settings .......................................31
3.7.4 Inlet Conguration ...................................40
3.7.5 Field conguration ...................................41
3.8 I-Test save conguration options ...........................47
3.8.1 Save to I-Test ........................................48
3.8.2 Save to Database.....................................50
3.8.3 Save to USB Memory Stick.............................52
3.9 I-Test Manager Conguration Upload Options .................54
3.9.1 Upload Conguration from I-Test .......................55
3.9.2 Upload Conguration from Database ....................57
3.9.3 Upload Conguration from USB Memory stick ............59
3.10 Data management .......................................61
3.10.1 Import logs from USB memory stick ....................62
3.10.2 View gas monitor log les ............................63
3.10.3 View gas monitor event logs ..........................67
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3.11 Create Reports ..........................................70
3.11.1 Create Calibration Report .............................70
3.11.2 Create Bump Test Report .............................76
3.12 Exception Reporting .....................................81
3.12.1 Creating an Exception Report .........................81
3.12.2 Exception Report Settings ............................82
3.12.3 Create Exception Report .............................85
3.13 Information and Settings .................................88
3.13.1 About .............................................88
3.13.2 Settings ...........................................89
3.13.3 Support............................................89
4. Conguring I-Test via Front Panel Keypad ..............90
4.1 Front panel layout ........................................90
4.1.1 Home screen ........................................91
4.1.2 I-Test Safe Shutdown .................................91
4.1.3 Control buttons ......................................92
4.1.4 I-Test charging indicator...............................92
4.1.5 Test Status indicator ..................................92
4.2 Accessing the I-Test Main menu ............................93
4.3 Inlet setup...............................................94
4.3.1 Select cylinder prole .................................95
4.3.2 Setting Cylinder Gas Concentrations ....................96
4.3.3 Setting Cylinder Lot Number ...........................97
4.3.4 Setting Cylinder expiry date ...........................98
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4.4 Conguring I-Test Test Sequence ...........................99
4.4.1 Speedy bump.......................................100
4.4.2 Smart bump ........................................101
4.4.3 Calibration .........................................102
4.4.4 Gas Monitor Log File Transfer to I-Test..................104
4.4.5 Selection of I-Test Banner ............................105
4.5 USB Memory Stick Functionality ...........................106
4.5.1 Plugging in the memory stick .........................106
4.5.2 Upload I-Test conguration from USB Memory Stick to I-Test ..107
4.5.3 Download I-Test activity log from I-Test to USB Memory stick ..108
4.5.4 Download gas monitor logs from I-Test to USB memory stick . 109
5. I-Test Specication.................................110
6. Service and maintenance ...........................111
7. Accessories ......................................112
8. Standard Target Gas Cylinders.......................113
9. Cross Calibration Cylinders .........................114
10.Troubleshooting ...................................115
Appendix A: Allowable Cylinder Proles .................117
Appendix B: Graph Function Explained ..................118
Appendix C: I-Test Icons...............................120
Warranty ............................................123
Crowcon contacts ....................................125
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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, contact your
local Crowcon ofce 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 monitor’s screen display and alarm warnings prior to use (see the relevant
user & operator manual).
• Ensure maintenance, service and calibration is carried out in accordance with the procedures in
the manual and only by trained personnel.
• Any gas monitor that is hazardous area certied must be operated and maintained in strict
accordance with its instructions, warnings and label information included in the relevant user &
maintenance manual.
Unpacking
Remove the I-Test from the packaging. The standard accessories are under the supporting trays.
The following items will be included as standard:
Box contents
• I-Test
• Power Supply
• Pipe Fittings x 2
• Inlet Tubing 1m
• Exhaust Tube 3m
• USB Flash Memory Stick
• CD containing:
User & Operator Manual
I-Test Manager PC Application
• Packing check List
• Declaration of Conformity
Optional items in the box
• Demand ow regulators
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8
I-Test Overview
I-Test is suitable for small and large eet users alike and offers simple gas monitor bump testing and
calibration, including full data management.
I-Test versions are available for both Gas-Pro and T4.
I-Test can quickly and simply undertake testing and store data either locally to the I-Test or allow
download to a PC or USB memory stick, including download and storage of gas monitor log les.
I-Test provides data management allowing easy reporting of bump test and calibration results across
the eet.
I-Test can also offer simple updating of gas monitor details such as alarm levels with updates being
managed within the eet during regular bump tests.
Using minimal gas and managing sequencing the I-Test ensures sensors are gassed correctly every time.
Suitability
I-Test is suitable for testing and calibrating Gas-Pro and T4 units tted with one or more of the following
sensors: Oxygen, Carbon Monoxide, Hydrogen Sulphide, Carbon Dioxide IR or Methane Pellistor.
I-Test will be functional with Gas-Pro units congured with rmware versions 1V09 & 2V06 onwards. The
rmware version of Gas-Pro can be seen as part of the start up screens when the monitor is powered up.
I-Test is functional with rmware versions of T4 from 1V01 upwards.
I-Test Functional Overview
I-Test offers the following main functions and features for the testing, calibration and management of
gas monitors.
Speedy bump
A speedy bump will test the monitor sensors to the rst alarm level.
Gas is presented across/over the sensors for a designated time (dependent on sensor gas type)
during which alarm level one should be activated. This will be deemed a pass if the monitor goes into
alarm or a failure if the monitor does not go into alarm.
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9
Smart bump
A smart bump will test that the gas monitor responds correctly to a specied 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 monitor is within pre-specied tolerance limits
within this time window.
Calibration
I-Test can be congured to undertake the routine service calibration of a gas monitor. In this instance
a calibration would be completed without a bump test being required.
I-Test is suitable for routine service calibration of monitors.
If a new sensor has been tted to the monitor then Portables-Pro should be used to calibrate the
monitor not I-Test, otherwise incorrect calibration may occur.
Calibration after bump fail
If any sensor fails a speedy bump or smart bump, I-Test can be congured to perform a ‘calibration
after bump fail, immediately after the bump test failure.
Gas Monitor Field Conguration
During normal operation, whilst performing gas testing, I-Test can be congured to change aspects
of the inserted gas monitor conguration, such as sensor alarm levels as well as other aspects of
conguration.
Gas Monitor Log Download
During normal operation I-Test can be congured to download either event logs and/or data logs
from the monitor under test. These log les are stored locally and can be extracted either via PC or
USB ash drive.
Data Management & Reporting
I-Test in conjunction with its PC Application, I-Test Manager, can be utilised for full data management
of the bump test and calibration data.
I-Test Manager allows the user to specify exception reports to quickly identify instruments, for
example, that have not been bump tested or failed bump test. I-Test Manager will also allow a user
to upload and view monitor log les from the I-Test. Bump test and calibration reports can also be
created, printed and stored.
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10
Gas Inlets/Exhaust
I-Test is available with 2 inlet ports and 1 exhaust port. One inlet is reserved for purge gas (fresh air),
and the other inlet is the test gas inlet.
USB Input/Outputs
I-Test offers the ability to upload its conguration settings either via USB connection to a PC or via a
USB Flash Drive inserted into a connector on the side of the I-Test.
DC Input/Battery Backup
I-test is capable of operating from a DC power supply but also able to operate for a short period of
time on an internal backup batter pack should the DC supply fail.
Keypad interface
I-Test offers keypad interfaces that will allow a user to change many of the conguration settings
without the need to connect a PC or insert a USB Flash Drive.
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1. Physical Set-up/Installation of I-Test
1.1 Mounting
The I-Test can be used ‘standalone’ or (as recommended) mounted on a standard DIN rail type EN
50022 À(see below).
Figure 1: Mounting the I-Test
The recommended length of DIN rail if an I-Test is to be mounted on its own, is 140mm.
If the I-Test is to be used in conjunction with a cylinder holder, the DIN rail should be 250mm
minimum.
À
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1.2 Inlet/exhaust connections
I-Test has three gas ports: the test gas is connected to inlet À, the purge inlet Áshould be
connected to fresh air, and the gas exhaust outlet Âshould be connected to a suitable length of pipe
that vents to outside air.
! Gas cylinders must be used with demand ow regulators.
i To ensure accurate bump testing and calibration the purge inlet must be connected to
fresh air.
Figure 2: Inlet/exhaust connections
ÀTest gas inlet
Á Purge inlet
ÂExhaust outlet
1.3 Electrical connections & controls
Figure 3: Electrical connections & controls
ÀMemory stick connector
ÁUSB interface connector
 On/off pushbutton
ÃPower input socket
Â
Á
À
Â
Á
À
Ã
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1.4 Prior to use
1.4.1 Inspection
Before use, the I-Test should always be checked for any signs of physical damage. Press the
release button À, lower the module’s front ap Á and check the ow gasket Â. Also check the gas
inlet pipe Ãand gas exhaust pipe Ä.
It is recommended that the ow gasket is replaced at regular intervals dependent upon regularity of use.
i A damaged or incorrectly tting seal may cause I-Test to incorrectly test/calibrate a
gas monitor.
Figure 4: Inspection prior to use À
Á
Ã
Ä
Â
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1.5 Charging
Before using the I-test it should be charged for 7 hours as follows:
XConnect the power adapter to a suitable mains outlet and connect its DC connector to the power
input socket on the I-Test (see Figure 3).
XTurn the I-Test on by pressing the on/off pushbutton (see Figure 3). The charging indicator will be
displayed (see below).
i When connected to the power adaptor I-Test will be charged even if powered off.
Figure 5: Charging indications
ÀBattery low
Á Battery discharging
 Battery charging
à Battery charged
ÄBattery fault
i I-Test must be charged between 0°C and 40°C for correct charging operation.
Â
À
Á
Ã
Ä
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2. Operating I-Test
This section details how to operate I-Test to perform the desired testing after I-Test has been fully
congured via I-Test Manager (see page 25) or via I-Test Front panel Keypad (see page 90).
Ensure I-Test is installed correctly and that the test gas cylinder is attached as detailed on page 12.
i Before operating the I-Test it must be congured via I-Test Manager PC Application and
must then be disconnected from the PC USB connection. If I-Test is not disconnected
from the PC it will not operate.
i Before a test can be undertaken ensure the I-Test display screen is showing the home
screen. If the home screen is not shown the congured test will not be initiated.
i Ensure the test gas cylinder connected to the inlet, has the same gas mix and
concentration as congured in the I-Test (see page 40 or page 94).
i When manufactured I-Test is congured with a default gas cylinder and a default expiry
date. This expiry date must be changed to that of the actual cylinder to be attached or
I-Test will not function correctly as it will report that the cylinder has expired.
i To ensure accurate bump testing and calibration the purge inlet MUST be connected to
fresh air.
i When I-Test is initially powered it will perform a purge cycle for approximately 30
seconds, before I-Test can be used.
2.1 Gas Monitor Testing Overview
Once I-Test has been congured to carry out a test or a sequence of tests, proceed as follows:
XEnsure the I-Test is either fully charged and/or connected to a suitable power source (see page 14).
XEnsure the I-Test is NOT connected to the PC via the USB socket.
XConnect the required gas cylinder to the appropriate inlets (see page 12).
XEnsure the purge inlet is connected to fresh air.
XEnsure a suitable length of pipe that vents to outside air is connected to the exhaust outlet.
XTurn the gas monitor on and wait for it to nish its start up routine.
XTurn on I-Test and wait for the start up purge sequence to complete
XInsert the gas monitor into I-Test (see page 16).
XThe congured test or test sequence will automatically be performed and I-Test will indicate the
success or failure of the test (see page 18).
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2.2 Loading a monitor into an I-Test
i Before inserting the gas monitor ensure it is not in fault mode.
Turn the gas monitor on, wait for it to nish the start up process and then press the release button
À, lower the module’s front ap Á, place the gas monitor into it’s holder  and close the front ap
Ã(see below):
Figure 6: Opening the I-Test
i Once I-Test has been congured to carry out a test or sequence of test (e.g. bump test or
calibration) this will start as soon as the door is closed.
Do not remove the gas monitor from I-Test until the test sequence has completely nished.
The gas monitor audible alarm will be muted for the duration of the test, at the end of the
test the audible alarm will be reinstated.
Once a test has completed allow the monitor sensors to recover to ambient levels before
a retest. Failure to do so may cause the monitor be tested/calibrated incorrectly.
The rst gas test after a prolonged period of inactivity may not be successful as I-Test will
need to be primed with the test gas, the test should be repeated.
! Gas cylinders must be used with demand ow regulators.
À
Á
Â
Ã
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2.3 Test Progress Status Indication
I-Test displays a set of progress indications whilst a test is being performed, an example of which
can be seen in Figure 7.
Figure 7: Progress indications
The rst status bar indicated by the icon , indicates the progress through the full test sequence
The second status bar status bar indicates the current test being performed, in this example a
speedy bump test. .
The third status bar shows further detail of the current test, in this example that inlet 1 is being
operated. .
See page 120 for details of all icons.
13 May 2013 11:16:37
I-Test
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2.4 Test Result Status Indication
During the process of the test the LED will ash amber. If the test is passed I-Test will display the
following icon and the LED Àon the I-Test gas monitor pod will be illuminated green. If the test
is failed I-Test will display the following icon and the LED on the I-Test gas monitor pod will be
illuminated red (see below).
Figure 8: Result indications
I-Test will also display the icon if I-Test was unable to perform the congured test.
This may occur for example if a monitor is inserted with an unsupported sensor/gas tment or if the
attached cylinder does not contain a suitable test gas for a specic sensor type in the monitor.
If the monitor is not correctly inserted in the gas monitor pod it may not be recognised by I-Test.
This will be indicated by the I-Test gas monitor pod LED red and the icon ashing for a period of
approximately 30 seconds. The monitor must be removed from the I-Test and reinserted.
Note:
If a monitor is inserted into I-Test with a specic sensor due bump test (not all sensors may be due a
bump test on the same date) and the attached cylinder does not contain the required gas, I-Test will
display the icon and not perform a bump test on any sensors.
If a monitor is inserted into I-Test with a specic sensor(s) not due a bump test and the attached
cylinder does not contain that required gas(s) but the cylinder does contain the gas for remaining
sensors due a bump test. I-Test will continue to bump test the sensors due and will not bump test the
sensor(s) not due.
13 May 2013 11:18:42
I-Test
13 May 2013 11:18:42
I-Test
À
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2.5 Main menu status icons
At certain times (e.g. after bump tests) a status icon Àis displayed on the Main menu as shown in
Figure 9 below.
Figure 9: Status Icon
These status icons have the following meanings:
• Action successful
• Action failed
2.6 Replacing an empty gas cylinder
If a cylinder connected to the inlet is completely exhausted I-Test will recognised this and the icon
will be displayed on the screen.
It will be necessary to physically replace the cylinder and enter the new gas concentrations, Cylinder
Lot Number, and Cylinder Expiry Date via either I-Test front panel (see page 97 and page 98) or
via I-Test Manager (see page 40 and page 40).
i If the cylinder was exhausted during a calibration the monitor may indicate a service fault
which must be cleared. Remove the monitor from I-Test and cancel all fault indications. Once
the cylinder has been replaced the monitor can then be reinserted and test can be repeated.
i If I-Test detects an exhausted cylinder and the cylinder is physically changed, a new
Cylinder Lot number and Cylinder Expiry Date must be entered. If this process is not
followed, I-Test will not allow gas testing to continue and will indicate this on the screen.
2.7 I-Test Safe Shutdown
If it is required to remove power from I-Test either by removing the power lead or switching off via the
on/off push button then the safe shutdown process must be followed.
Please refer to Section 4.1.2 on page 91 for full details.
2012 21 Aug 10:25:00
À
• Gas monitor needs calibration
• Gas monitor unidentied/Sensor unidentied
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3. I-Test Manager Software
3.1 Introduction
Before I-Test can be used for the rst time it must be congured using the I-Test Manager PC
software supplied. This allows I-Test to be fully congured to perform bump test or calibration as per
user requirements.
I-Test Manager should now be installed.
3.2 I-Test Manager system requirements
The following are the minimum system requirements that will enable the I-Test Manager software to
run efciently:
• Processor Pentium 4 or equivalent
• Processor speed 2.2 GHz
• Bus Speed 400 mHz
• Memory size 1Gb
• Hard Drive 40 Gb
• CD Rom 48x (CD)
• Monitor 15 inch
• Resolution 800 x 600 minimum
• Operating system Windows XP or later
• USB port 2
• Mouse & Keyboard Yes
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