GMI PPM Gasurveyor 500 Instruction Manual

PPM Gasurveyor 500
User Handbook

Issue 6
28/07/04
Part Number: 42142
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i
COPYRIGHT
This User Handbook is copyright of Gas Measurement Instruments Ltd (GMI) and
the information contained within is for use only with the PPM Gasurveyor 500
instruments. Reproduction, in whole or in part, including utilisation in machines
capable of reproduction or retrieval without written permission of Gas Measurement
Instruments Ltd is prohibited. Reverse engineering is not permitted.
LIABILITY
Every care has been taken in the preparation of this document, but GMI Ltd do not
accept any responsibility for errors or omissions and their consequences. Information
in this document is subject to change without notice. This document does not constitute
a specification or basis for a contract. Your statutory rights under law are not affected.
MODIFICATION NOTICES
GMI aim to notify customers of relevant changes in the product operation and maintain
this manual up to date. In view of the policy of continuous product improvement
there may be operational differences between the latest product and this manual.
This Handbook is an important part of the PPM Gasurveyor 500 product. Please
note the following points:
• It should be kept with the instrument for the life of the product.
• Amendments should be attached.
• This Handbook should be passed on to any subsequent owner/user of the
instrument.
• Although every care is taken in the preparation of this Handbook it does not
constitute a specification for the instrument.
SOFTWARE
Software supplied on EPROM or similar device for use in a particular product, may
only be used in that product and may not be copied without the written permission of
Gas Measurement Instruments Ltd. Reproduction or disassembly of such embodied
programmes or algorithms is prohibited. Ownership of such software is not
transferable and GMI Ltd does not warrant that the operation of the software will be
error free or that the software will meet the customer’s requirements.
DISPOSAL ADVICE
When no longer in use, dispose of the instrument carefully and with respect for the
environment. GMI will dispose of the instrument without charge if returned to the
factory.

PPM GASURVEYOR 500 USER HANDBOOK
ii
SAFETY
• The instrument must be regularly serviced and calibrated by fully trained
personnel in a safe area.
•Batteries: Alkaline batteries or *Rechargeable battery pack must be
exchanged (*and recharged) in a safe area and fitted correctly before use.
Never use damaged batteries or expose to extreme heat.
See Section 4 : OPERATOR MAINTENANCE.
• Only GMI replacement parts should be used.
• If the instrument detects gas, follow your own organisation’s procedures and
operational guidelines.
• The combustion chamber is a flameproof assembly and must not be opened
in the presence of a flammable atmosphere.
• PPM Gasurveyor 500 instruments are certified as EEx iad IIC T4
(-20oC<Tamb <50oC). BAS01ATEX2292 II 2 G.
UL Class 1 Groups A, B, C and D.
• This equipment is designed and manufactured to protect against other
hazards as defined in paragraph 1.2.7 of Annex II of the ATEX Directive
94/9/EC
Any right of claim relating to product liability or consequential damage to any third
party against GMI is removed if the warnings are not observed.
AREAS OF USE
Exposure to certain chemicals can result in a loss of sensitivity of the flammable
sensor. Where such environments are known or suspected it is recommended that
more frequent response checks are carried out. The chemical compounds that can
cause loss of sensitivity include Silicones, Lead, Halogens and Sulphur. Do not
use instrument in potentially hazardous atmospheres containing greater than 21%
Oxygen. The enclosure material is polypropylene and must not be exposed to
environments which are liable to result in mechanical or thermal degradation or to
damage caused by contact with aggressive substances. Additional protection may
be required in environments where the instrument enclosure is liable to damage.
STORAGE, HANDLING AND TRANSIT
The batteries in the rechargeable pack contain considerable energy and care should
be taken in their handling and disposal. Battery packs should be removed if the
instrument is stored for longer than 3 months. The instrument is designed to handle
harsh environments. The sensing elements are sealed to IP54 and the rest of the
instrument to IP64. If not subject to misuse or malicious damage, the instrument
will provide many years of reliable service. The instrument contains electrochemical
sensors with a life of 2 years. Under conditions of prolonged storage the sensors
should be removed. The sensor contains potentially corrosive liquid and care should
be taken when handling or disposing of the sensor, particularly when a leak is
suspected.

iii
REVISION RECORD
Date Pages Description Of Change
Issue 1 All New Handbook
03.06.99
Issue 2 All Handbook revised to
18.05.01 reflect updated
instrument options and
features.
Issue 3 All Handbook revised to
22.03.02 incorporate effect of
CR 2272 and CR 2288.
Issue 4 All Handbook revised to
01.05.02 incorporate effect of
CR 2305
Issue 5 All Handbook revised to
17.07.03 incorporate effect of
CR 2291
Issue 6 All Handbook revised to
28/07/04 include Appendix C
(translations)

PPM GASURVEYOR 500 USER HANDBOOK
iv

v
CONTENTS
COPYRIGHT ................................................................. i
LIABILITY ...................................................................... i
MODIFICATION NOTICES ........................................... i
SOFTWARE .................................................................. i
DISPOSAL ADVICE ...................................................... i
SAFETY ........................................................................ ii
AREAS OF USE ........................................................... ii
STORAGE, HANDLING AND TRANSIT ...................... ii
REVISION RECORD ..................................... iii
INTRODUCTION ........................................... 1
GENERAL INFORMATION ........................... 3
Ranges of Operation .................................................... 3
LEL, 0 to 100% .......................................................... 3
Volume Gas, 0 to 100 % ............................................ 4
PPM Flammable 0 – 1000 ppm ................................. 5
Threshold Display Options ......................................... 6
Search Mode .............................................................. 7
Geiger Indication ........................................................ 8

PPM GASURVEYOR 500 USER HANDBOOK
vi
Construction .................................................................. 8
Batteries ........................................................................ 9
Disposable Alkaline (LR20) Dry Cell Batteries .......... 9
Rechargeable Battery Pack ....................................... 9
Filters .......................................................................... 10
Liquid Crystal Display (LCD) ...................................... 10
Before Use Checks ..................................................... 11
OPERATING INSTRUCTIONS.................... 13
Modes of Operation .................................................... 13
Mode 1 ..................................................................... 14
Mode 2 ..................................................................... 14
Calibration Date Features ........................................ 15
Switching Off the Instrument Pump ......................... 15
Switching Off ............................................................ 16
Changing Range ...................................................... 16
Activate the Audible Geiger Indication (PPM or
Search Range) ......................................................... 16
Zeroing the ppm or Search Range .......................... 17
Summary of Button Operation ................................. 18
Operator Messages / Fault Flags ............................... 18
OPERATOR MAINTENANCE ..................... 21
Rechargeable Battery Pack ........................................ 21
Standard Charger ..................................................... 21

vii
CONTENTS
Flatbed Charger ....................................................... 22
Smart Charger .......................................................... 22
Replacing the Battery Pack ..................................... 23
Recharging the Battery Pack ................................... 24
Replacing Alkaline (LR20) Dry Cell Batteries ............ 24
Filter Replacement ..................................................... 26
Probe Handle Assembly - Part No. 13561 .............. 27
In-line Dust Filter (Accessory) ................................. 28
In-line Water Filter (Accessory) ............................... 29
CALIBRATION ............................................ 31
Calibration Validity ...................................................... 32
ACCESSORIES........................................... 33
ADDITIONAL INFORMATION ..................... 37
Training ....................................................................... 37
World Wide Web ......................................................... 37
TYPICAL OPERATING PARAMETERS .....A-1
Size ........................................................................ A-2
Weight .................................................................... A-2
Operating Temperature .......................................... A-2
Humidity ................................................................. A-2

PPM GASURVEYOR 500 USER HANDBOOK
viii
Construction ........................................................... A-2
Display .................................................................... A-2
Sampling System ................................................... A-2
Power Source ......................................................... A-3
FIELD CALIBRATION ................................ B-1
Selectable Ranges in FCM ....................................... B-3
Entering FCM ............................................................ B-3
Zeroing the Instrument ............................................. B-4
Field Calibration Procedure ...................................... B-5
Quitting FCM ............................................................. B-9
Quit And Save Changes ........................................ B-9
Quit Without Saving Changes ................................ B-9
OPERATING INSTRUCTIONS.................. C-1
English ..................................................................... C-2
Deutsch (German) ................................................... C-6
Svensk (Swedish) .................................................. C-10
Dansk (Danish) ...................................................... C-14
Nederlands (Dutch) ............................................... C-18
INDEX ............................................................ I

1
INTRODUCTION
The PPM Gasurveyor 500 is a two button instrument
designed to measure Parts Per Million, Lower Explosive
Level and Volume flammable gas. The instrument is
designed to the latest standards and is certified for use in
Hazardous Areas.
The PPM Gasurveyor 500 contains the following ranges:
$LEL, 0 to 100%
$Volume gas, 0 to 100%
$PPM Flammable
$Search mode (enhanced ppm flammable range)
1

PPM GASURVEYOR 500 USER HANDBOOK
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$As the PPM Gasurveyor 500 has a wide variety of
available user selected options, it is not possible
to provide an operator handbook specific to each
possible variation, therefore, what we have pro-
vided in the following pages is the standard de-
fault of how the instrument would generally be
configured, with the possible options detailed in
italic text.
GMI recommend that you take the time to study your
instrument and, where practical and with advice from your
company’s Purchasing / Management departments,
highlight your particular instrument configuration.
The main features of the instrument are:
$Rugged polypropylene case, sealed to IP54 rating
and suitable for outdoor use.
$Two button operation allowing the user access to
all features.
$LCD with backlighting which displays the current
gas readings (in both digital and analogue forms)
together with operational and status information.
$Audible and Visual Geiger indication, configured
in PPM Flammable and Search ranges, provides
indication of gas concentration increase via the in-
creased rate of sounder and LED pulse.
$Directly interfaces with the GMI Auto Test Cali-
bration Systems.

3
2
GENERAL INFORMATION
Ranges of Operation
LEL, 0 to 100%
The LEL range indicates the explosibility of the flammable
gas in the sample. This is displayed as a percentage of the
lower explosive limit (LEL) of the gas.
The instrument range is displayed in the top right corner
of the display as % LEL. From 0 to 10% LEL the digital
display resolves to 0.1% LEL. From 10 to 100% LEL the
digital display resolves to 1% LEL. The analogue bar
graph follows in 4% steps. An example of the LEL display
is shown in Figure 2.1. Autoranging will automatically
switch the range to Volume Gas when 100% LEL is
reached.
The detection principle for this range is a catalytic reaction.
Figure 2.1 LEL Range

PPM GASURVEYOR 500 USER HANDBOOK
4
Volume Gas, 0 to 100 %
This range displays the total volume of a specific
flammable gas with respect to air. The calibration gas is
shown on the service label and for the purpose of this
handbook is assumed to be methane. Instruments
calibrated for methane in air should only be used for
measuring such mixtures. To change the calibration gas,
e.g. from methane to propane, the instrument must be
recalibrated by suitably trained personnel.
On the Volume Gas range the instrument range is
displayed in the top right corner of the LCD as GAS. The
digital display resolves the signal to 1% GAS with the
analogue bar graph following in steps of 4%. Figure 2.2
shows the Volume Gas display. The detection principle
for the Volume Gas range is thermal conductivity.
Figure 2.2 Volume Gas Range

5
GENERAL INFORMATION
PPM Flammable 0 – 1000 ppm
This range is used to measure very low levels of gas and
indicates the parts per million concentration of the gas in
air (1000 ppm is equivalent to 0.1% Volume Gas).
The digital display reading resolves to 5 ppm with the
analogue bargraph following in steps of 40 ppm. The ppm
range is more sensitive than LEL and Volume ranges and
takes longer to stabilise. The detection principle is a
catalytic reaction with the sensitivity of the sensors greatly
enhanced compared to the LEL range. Digital signal
correction techniques are used to minimise drift. The ppm
range includes a manual zeroing procedure.
The ppm range has the option of using a ‘threshold’. By
this, we mean that we can display either a blank screen
or simply a zero (0) on the display, up to a pre-set level.
This allows small readings, which may not be due to the
gas we wish to find or very small amounts of gas, to be
ignored if they fall below any pre-set action levels. This
allows the operator to react only to significant levels.
The ppm range has no threshold set by default. If your
instrument has a threshold, write the level here:
.......................................................................................
The ppm range, by default, has the audible and visual
Geiger indication configured which provides indication
of gas concentration increase via the increased rate of
sounder and LED pulse.
When the instrument is switched on, the visual Geiger
indication is enabled and the audible Geiger indication is

PPM GASURVEYOR 500 USER HANDBOOK
6
disabled. To enable audible Geiger indication, press and
hold Button Two .
The display changes between PPM and Aud (if enabled)
as shown in Figure 2.3.
Figure 2.3 PPM Range
Threshold Display Options
The ppm range will by default, if a threshold is
selected, display below the threshold as zero (0) on the
screen.
The option is to display a blank screen for levels below
the threshold, as shown in Figure 2.4.
Figure 2.4 Threshold Display Option

7
Search Mode
Search mode is an enhanced variant of the ppm flammable
range with increased resolution and faster response. Search
mode can be used for detecting leaks which can then be
classified using the more accurate ppm, LEL and Volume
Gas ranges.
The Search range provides an indication of gas only, and
it should not be used to carry out any assessment of gas
levels.
The pump speed in this range is higher, which is apparent
from the increased sound from the pump.
The Search range, by default, has the audible and visual
Geiger indication configured which provides indication
of gas concentration increase via the increased rate of
sounder and LED pulse.
When the instrument is switched on, the visual Geiger
indication is enabled and the audible Geiger indication is
disabled. To enable audible Geiger indication, press and
hold Button Two .
The display changes between search symbol and Aud (if
enabled) as shown in Figure 2.5.
Figure 2.5 Search Mode
GENERAL INFORMATION

PPM GASURVEYOR 500 USER HANDBOOK
8
Geiger Indication
The Geiger provides indication that as the gas
concentration increases, the sounder (if activated) and the
LED, pulse at an increasing rate. When the PPM
Gasurveyor 500 has PPM Flammable or Search range
selected, or is switched on in full autorange mode then,
by default, the visual Geiger indication is enabled and
the audible Geiger indication is disabled.
To enable the audible Geiger indication, press and hold
Button Two .
A further press and hold of Button Two will increase
the audible level. A further press and hold of Button Two
will return to visual only Geiger indication.
Note: When Search mode is selected, the pump operates
at an increased speed. If Search mode is selected when
the pump is switched off, the pump then reactivates.
Construction
The instrument is housed in a tough, impact resistant,
moulded case made of polypropylene.
The top panel is protected by a stainless steel top plate
covering a toughened glass LCD cover.
The battery pack is sealed and attached to the main in-
strument body by means of 2 stainless steel hexagonal
screws.
The instrument is sealed against dust and water to IP54
standard. The sensors are protected from dust and water
by membrane and cotton filters.

9
Batteries
Disposable Alkaline (LR20) Dry Cell Batteries
Alkaline batteries provide approximately 15 hours
operational life at ambient temperature of 20oC (68oF).
When the batteries are low or exhausted it is necessary to
fit 4 new batteries to reset the battery indicator to 100%.
Do not mix old and new batteries.
An indication of the battery condition is displayed after
power on and during warm-up, with status shown as either
OK or LO. If LO condition is displayed, a maximum
battery operational life of 120 minutes remains. During
operation the ‘BAT’ alarm flag is displayed when
approximately 60 minutes of operating time remains at
normal temperature. The instrument may continue to be
used until it switches off automatically.
Rechargeable Battery Pack
The GMI rechargeable battery pack provides
approximately nine hours operational life, from fully
charged, at ambient temperature of 20oC (68oF). An
indication of the battery condition is displayed after power
on and during warm-up, with status shown as either OK
or LO. If LO condition is displayed, a maximum battery
operational life of 90 minutes remains. During operation
the ‘BAT’ flag is displayed when approximately 30
minutes operating time is left at normal temperatures. The
instrument will then turn off.
There are three GMI Battery Chargers: a Standard
Charger, a Flatbed Charger and a Smart Charger. The
GENERAL INFORMATION

PPM GASURVEYOR 500 USER HANDBOOK
10
Smart Charger has both slow and fast charge options as
well as a serial link for communications with the
instrument. See Rechargeable Battery Pack in Section 4
OPERATOR MAINTENANCE.
Filters
The PPM Gasurveyor 500 has a cotton particulate filter
located behind the instrument inlet nozzle. The filter
should be checked at frequent intervals or when the
SAMPLE FAULT flag appears in the instrument display,
and where appropriate, changed to ensure a clean sample
path. In the event of the SAMPLE FAULT flag becoming
activated, the pump should be stopped as soon as possible
and the filter replaced. See Filter Replacement in Section
4 OPERATOR MAINTENANCE.
If SAMPLE FAULT still shows, after filter replacement,
the instrument will require to be returned for servicing.
Liquid Crystal Display (LCD)
The LCD shows the current gas readings in both analogue
and digital form together with operational and status
information. The display is protected by a toughened glass
cover. Backlighting is provided to enable the display to
be seen under low ambient light conditions.