H2Scan HY-ALERTA 1600 User manual

HY-ALERTATM 1600
Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
27215 Turnberry Lane, Unit A
Valencia, CA. 91355, USA
Tel: [phone] / Fax: [phone]
E-mail: [e-mail]
Website: http://www.h2scan.com

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Our Mission
Deliver unsurpassed value and optimize green initiatives with our one of a kind
continuous hydrogen-specific sensing technology worldwide.
Our Value Propositions
Enable end-user customers to efficiently and effectively optimize:
Electric utility power transformer fleet and other oil-filled assets (Grid)
Petroleum refinery and other industrial process control
Facility and equipment safety to minimize downtime
...at a much lower total costs of ownership than the competition.
Our Strategic Objectives
H2scan's technology accepted as the new gold standard in hydrogen sensors.
H2scan's business recognized for innovation and ingenuity, high quality
products and systems, application -specific solutions, and exceptional customer
service and satisfaction.
H2scan's success results from teamwork, strategic partnerships and market
leadership leading to sales growth and improved profitability.

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CONTENTS
1DESCRIPTION........................................................................................................................................5
2SPECIFICATIONS...................................................................................................................................5
3ATEX RATING.........................................................................................................................................6
4INSTALLATION.......................................................................................................................................7
4.1 Associated Equipment ..................................................................................................................7
4.2 Mounting .......................................................................................................................................8
4.3 Connections ..................................................................................................................................8
4.4 Settings .........................................................................................................................................9
5STARTUP................................................................................................................................................9
5.1 Settings .........................................................................................................................................9
6OPTIMUM UNIT PERFORMANCE.......................................................................................................10
7OPERATION .........................................................................................................................................10
7.1 Analog Output .............................................................................................................................10
7.2 Display ........................................................................................................................................10
7.3 Keypad........................................................................................................................................11
7.4 Configuration Menu.....................................................................................................................11
8SERIAL COMMUNICATION .................................................................................................................12
8.1 Software......................................................................................................................................12
8.2 Connection..................................................................................................................................12
8.3 Format and Settings....................................................................................................................12
8.4 Command Levels........................................................................................................................12
8.5 Command Summary...................................................................................................................13
9MAINTENANCE ....................................................................................................................................17
9.1 Cleaning......................................................................................................................................17
10 CALIBRATION.....................................................................................................................................17
10.1 Factory Calibration –...............................................................................................................17
10.2 Field Calibration......................................................................................................................17
11 FIELD CALIBRATION..........................................................................................................................17
11.1 Calibration Interval..................................................................................................................17
11.2 Gases......................................................................................................................................17
11.3 Gas Connection......................................................................................................................17
11.4 Procedure ...............................................................................................................................17
11.5 Calibration Using the Serial Interface.....................................................................................18
11.6 Calibration Using the Keypad.................................................................................................20
12 CLEAR FIELD CAL..............................................................................................................................20
12.1 Clear Field Cal Using the Serial Interface ..............................................................................20
12.2 Clear Field Cal Using the Keypad ..........................................................................................20
13 MESSAGES.........................................................................................................................................20
13.1 Warmup_XXX.........................................................................................................................20
13.2 Settle.......................................................................................................................................20
13.3 Wait_XXX ...............................................................................................................................20
13.4 htroff........................................................................................................................................20
13.5 Error_XXX...............................................................................................................................21
14 APPENDIX 1 FOXTERM SETUP........................................................................................................22
14.1 Foxterm Installation ................................................................................................................22
14.2 Foxterm setup.........................................................................................................................22
15 APPENDIX 2 - MENUS .......................................................................................................................23
16 APPENDIX 3........................................................................................................................................28
16.1 Control Drawing......................................................................................................................28
16.2 Serial Barrier Switch Settings for RS232 connection to PC...................................................31

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IMPORTANT NOTICES
LIMITATION OF LIABILITY
IN THE EVENT OF A DEFECT IN A PRODUCT, H2SCAN SHALL NOT BE RESPONSIBLE FOR ANY
DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING THEREFROM,
INCLUDING, BUT NOT LIMITED TO, LOSS OF REVENUE AND/OR PROFIT.
LIMITED WARRANTY
H2scan Limited Warranty. Each hydrogen instrument (“Product”) will conform, as to all substantial operational features, to the Product
specifications set forth this Manual and will be free of defects which substantially affect such Product’s performance for twelve (12) months
from the ship date for such Product.
Must Provide Notice of Defect. If you believe a Product is defective, you must notify H2scan in writing, within ten (10) days of receipt of such
Product, of your claim regarding any such defect.
Return Product to H2scan for Repair, Replacement or Credit. If the Product is found defective by H2scan, H2scan’s sole obligation under
this warranty is to either (i) repair the Product, (ii) replace the Product, or (iii) issue a credit for the purchase price for such Product, the
particular remedy to be determined [by H2scan] on a case-by-case basis.
Voided Warranty. H2scan’s 12 Month Limited Warranty is void for any of the following:
•The unit is opened and the manufacturing seal is broken
•Unauthorized repair work performed at the customer’s location or carried out by anyone other than H2scan’s factory trained
technicians
•Equipment or parts that have been tampered with, misused, neglected, mishandled, improperly adjusted, or modified in any way
without the written consent of H2scan.
•Equipment or parts that have been damaged due to shipping, misuse, accidents, mishandling, neglect, or problems with electrical
power sources.
•Repair work performed during the warranty period does not prolong the warranty period past the original period.
•System operation in incorrect or inappropriate environments.
•Usage that is not in accordance with system guidelines or an operator’s failure to follow manual instructions.
Limitation of Warranty. THE ABOVE IS A LIMITED WARRANTY AS IT IS THE ONLY WARRANTY MADE BY H2SCAN. H2SCAN MAKES
NO OTHER WARRANTY EXPRESS OR IMPLIED AND EXPRESSLY EXCLUDES ALL WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. YOUR SOLE REMEDY HEREUNDER IS REPAIR OR REPLACEMENT OF THE PRODUCT
OR A CREDIT FOR THE PURCHASE PRICE FOR SUCH PRODUCT, THE PARTICULAR REMEDY TO BE DETERMINED BY H2SCAN
ON A CASE-BY-CASE BASIS. H2SCAN SHALL HAVE NO LIABILITY WITH RESPECT TO ITS OBLIGATIONS UNDER THIS
AGREEMENT FOR CONSEQUENTIAL, EXEMPLARY, OR INCIDENTAL DAMAGES EVEN IF IT HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES. THE STATED EXPRESS WARRANTY IS IN LIEU OF ALL LIABILITIES OR OBLIGATIONS OF
H2SCAN FOR DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE DELIVERY, USE OR PERFORMANCE OF THE
PRODUCTS.
Read and understand this operating manual before installing or using the unit. Only use cables from
H2scan with this unit. If this equipment is used in a manner not specified by H2scan, the protection
provided by this equipment may be impaired.
Hydrogen is flammable at 4% in air. Take indications seriously and be prepared to take action. In the event
of detection of 4% or higher of a hydrogen gas concentration there is a high probability of a hazard to
safety. Inform local emergency response personnel immediately.

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1 DESCRIPTION
The HY-ALERTATM 1600 Intrinsically Safe Area Hydrogen Monitor is designed to detect and/or measure
hydrogen as a component of air. The hydrogen specific solid-state sensing element is housed in a
flameproof enclosure at the tip of the sensor tube, and ATEX certified for Zone 0 hazardous locations. The
electronics assembly housed in a metal housing, which is permanently attached to the sensor tube, is
ATEX certified for Zone 1 hazardous locations. The electronics contains all the circuitry necessary to
operate the sensor and provides calibrated hydrogen readings to a 4-20 mA analog and RS422 digital
outputs. The HY-ALERTATM 1600 has no cross sensitivity to other combustible gases, eliminating false
positive alarms and ensuring safety system reliability.
2 SPECIFICATIONS
Sensitivity Range:
0.4% to 5% hydrogen by volume at 1 ATM,
10% to 125% hydrogen lower flammable limit
Accuracy:
± (0.03 x indication + 0.2) percent hydrogen by volume
Example: accuracy at 1% H2is ±0.23% H2
Response Time:
T90 of 60 sec maximum
Temperature:
Ambient Operating:
Storage:
-20 to +40°C
-40 to +50°C
Sensor Input Voltage:
Range:
Intrinsically Safe:
5 VDC to 28 VDC
10 VDC, 6 W
Power Barrier Input Voltage:
Range:
Nominal:
20 VDC to 28 VDC
24 VDC
Analog Output:
Isolated, Loop Powered 4-20 mA
Serial Communication:
RS-422
Dimensions:
See following figure (dimensions in inches)
Weight:
1 lbs.
Enclosure Rating:
At least IP20, capable of meeting IP64
Dust-tight, protected against water spray from any direction
Approvals and Ratings:
0359
ITS07ATEX25634X
II 1 G, Ex ia II H2, db+db IIB T3 Ga
II 2 G, Ex ib II H2, ib db IIB T3 Gb
Calibration Period:
3 months
Product Life:
10 years

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Figure 1: Dimensions (in inches)
3 ATEX RATING
The HY-ALERTA™ 1600 monitor is certified with a dual zone rating.
Electronics Assembly is Zone 1 (2 G Ex ib)
Probe Tip is Zone 0 (1 G Ex ib+d).

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Figure 2: Hazardous Area and Associated Equipment
Table 1: Input and Output Parameters
Parameter
J1 Pins 2&3
(Power Supply)
J1 Pins 4&5
(4-20 mA loop)
J2 Pins 1&2, 3&4
(RS422 Rx&Tx)
Ui
11.5 V
26.7 V
3.7 V
li
3.27 A
91 mA
2.25 mA
Pi
9.41 W
611 mW
206 mW
Ci
0
68.2 nF
0
Li
0
0
0
Uo
n/a
n/a
5.9 V
Io
n/a
n/a
238 mA
Po
n/a
n/a
350 mW
Co
n/a
n/a
1000 uF
Lo
n/a
n/a
2.5 mH
Lo/Ro
n/a
n/a
404 uH/Ω
4 INSTALLATION
WARNING: IF THE UNIT IS INSTALLED IN A CLASSIFIED LOCATION THEN IT IS THE RESPONSIBILITY
OF THE USER AND INSTALLER TO MAKE CONNECTIONS TO RELATED EQUIPMENT IN A MANNER
CONSISTENT WITH THE LOCATION CLASSIFICATION.
4.1 ASSOCIATED EQUIPMENT
Only H2scan specified cables should be used with this Analyzer. The maximum length for
intrinsically safe operation of both the Power/Analog Cable and the Serial Interface Cable is 10
meters. Refer to the Appendix for Control Drawings.
When operated in a hazardous area, the HY-OPTIMA™ 1700 Analyzer must be connected to
appropriately certified barriers located in a non-hazardous area. The following barriers are approved
for use with this device for an Intrinsically Safe implementation:

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Intrinsically Safe Power Barrier: H2scan’s custom designed barrier supplies 10VDC, 6W power to
the sensor.
Intrinsically Safe Analog Output Barrier (4mA to 20mA): GM International D1054S or
equivalent, One Channel Repeater Power Supply and Trip Amplifiers. Refer to the D1054S
Operating Manual for installation and configuration of this barrier.
Intrinsically Safe Serial Interface Barrier (RS422): GM International D1061S or equivalent,
RS422 / RS485 Fieldbus Isolating Repeater. Refer to the D1061S Operating Manual for installation
and configuration of this barrier. This barrier also requires a null modem cable for communication
between PC and Barrier.
4.2 MOUNTING
While the unit can be mounted in any orientation or position, it is important to consider the possible
sources and areas of accumulation of hydrogen gas. Typical installations are near the ceiling level
above equipment using or storing hydrogen. For earlier detection artificial means of accumulation
such as flat plates or inverted trays can be installed at lower heights to allow hydrogen to reach the
sensor more quickly.
WARNING: IT IS NOT THE INTENT OF THIS MANUAL TO SPECIFY MOUNTING LOCATION(S). IT IS THE
REPONSIBILITY OF THE USER AND INSTALLER TO DETERMINE THE PROPER LOCATION(S) FOR
HYDROGEN DETECTION BASED UPON THE PARTICULAR USES OF HYDROGEN AT THE
INSTALLATION SITE.
Mounting is achieved by 4 mounting tabs that can be rotated to align with flat, angled or moderately
curved surfaces. Mounting hardware should be a 4 mm screw (M4, #8 screw), appropriate for the
surface being mounted upon. The unit can be mounted in any orientation or position.
4.3 CONNECTIONS
Power/Analog Output - Connector 1
Supplied Cable –4 m (12 ft.) standard (Other lengths available).
Wire Color
Description
Red
+10 VDC
Black
10 VDC Return
White
+4 mA to 20 mA
Blue
4 mA to 20 mA Return
Bare
Case Ground
Serial Interface - Connector 2
Supplied Cable –4 m (12 ft.) standard (Other lengths available).

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Wire Color
Description
Black
+TxD RS422
Blue
-TxD RS422
White
+RxD RS422
Brown
-RxD RS422
4.4 SETTINGS
Located on the front of the unit next to model number marking, a Status Indicator displays basic unit
functions as described below. Default amber and red Status Indicator LED settings are 1% and 2%
hydrogen by volume, respectively.
Status
Indicator Color
Normal operation / Hydrogen detected is below 1% hydrogen by volume
GREEN
Warm-up / Hydrogen detected between 1% and 2% hydrogen by volume
AMBER
Hydrogen detected above 2% hydrogen by volume / Unit fault detected
RED
The unit’s operational and output settings have been configured at the manufacturer with settings
specified at the time of purchase. Settings may be changed through the use of serial port.
WARNING: If settings are changed from those set by the manufacturer then it is the user’s
responsibility to understand the implications to the connecting equipment monitoring the unit.
5 STARTUP
Power must be applied to the unit before connecting the serial cable. Power is connected via the Power/
Analog signal connector. The serial cable can be connected any time after power has been applied to the
unit. Once power is applied, the unit executes a warm-up sequence lasting about 5 minutes. The status
LED will be amber in color during warm-up. It will become green, amber, or red when the unit is ready.
The following operations will be completed in this warm-up sequence:
Heat the sensor to operating temperature.
Perform the Power-On-Self-Test (POST).
The analyzer is designed to be exposed to air with no hydrogen most of the time. For optimal performance
keep any hydrogen exposure to the sensor to less than one hour. If the hydrogen exposure exceeds this
time, the sensor may need to be reconditioned by leaving it powered on in air for a few days.
5.1 SETTINGS
Located on the front of the unit next to model number marking, a Status Indicator displays basic unit
function as described below. Default amber and red Status Indicator LED settings are 1% and 2%
hydrogen by volume, respectively.
Status
Indicator Color
Normal operation / Hydrogen detected is below 1% hydrogen by volume
GREEN
Warm-up / Hydrogen detected between 1% and 2% hydrogen by volume
AMBER
Hydrogen detected above 2% hydrogen by volume / Unit fault detected
RED
The unit’s operational and output settings have been configured at the manufacturer with settings
specified at the time of purchase. Settings may be changed through the serial port.
WARNING:
IF SETTINGS ARE CHANGED FROM THOSE SET BY THE MANUFACTURER THEN IT IS THE USER’S
RESPONSIBILITY TO UNDERSTAND THE IMPLICATIONS TO THE CONNECTING EQUIPMENT
MONITORING THE UNIT.
Although the unit will respond to 90% or better of a concentration change within 60 seconds, the
signal will continue to settle. This period varies with concentration and other conditions. For best

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results in long-term monitoring, allow the unit to settle for a period of one (1) hour in the gas
composition being monitored prior to use.
6 OPTIMUM UNIT PERFORMANCE
For maximizing the performance of the sensor, the following steps are recommended.
Verify that all electrical connections and made as recommended. Switching the polarity can cause damage
to the unit. Ensure that the DC power supply utilized is appropriate and does not have large peak-to-peak
noise.
Perform a Field calibration after the installation and conditioning steps described in the Start-up section are
completed. DO NOT use 0% H2 as the lower calibration gas. Instead use hydrogen concentration that is
slightly lower than the expected lowest hydrogen concentration (for e.g. if 1% is the expected lowest H2
concentration, then use 0.5% H2 as the lower calibration gas.
For the second calibration gas use a concentration that is slightly higher than the expected maximum H2
concentration.
If the analyzer gets exposed to extended periods of H2, condition the sensor as described in the Start-up
section and follow-up with a Field calibration, if needed.
6.1 PRESSURE EFFECTS
The analyzer is hydrogen specific and sensitive to only the hydrogen partial pressure in the air.
Since changes in total gas pressure will affect the hydrogen partial pressure, they will also affect the
sensor readings. For instance, at one atmosphere pressure, a 2% H2 concentration will be reported
as 2% from the unit. At .9 atm, the reading will decrease to 1.8%.
Normal atmospheric pressure fluctuations may also manifest as small hydrogen changes.
At the factory, the units are typically calibrated at one atmosphere pressure.
Performing the field calibration will compensate for altitude induced inaccuracy.
7 OPERATION
7.1 ANALOG OUTPUT
The following parameters are set at the factory per customer specification at time of order, however
they are user configurable via the serial port.
The user can request for a specific output current or there are analog output ranges the user can
select from, which are listed below. The analog output the user selects is scaled to the user’s
hydrogen range of interest. All of this is initially set at the factory per customer specification at the
time of order. Below is the table for standard analog output current ranges:
Current Range
Selection
Analog Output
Range
Power-On Self
Diagnostic Output
Error Output
Standard
4 mA to 20 mA
22 mA
3 mA
Optional
0 mA to 20 mA
0 mA
20 mA
The selected Analog Output Range is scalable from the low to high levels of the hydrogen sensitivity
range. The user can change to another current range of the analog output in the field. Please refer
to the “I” command.
7.2 DISPLAY
The upper row of the LCD indicates a numerical value for the percent hydrogen concentration or
peak hydrogen value. The lower row of the LCD is used to display the hydrogen meter, a
logarithmic bar graph ranging from 0.001% (10 ppm) to 100% hydrogen by volume. An open box on

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the bar indicates the last peak value obtained and filled boxes indicate current value. The following
figure describes how to interpret the hydrogen meter:
7.3 KEYPAD
A 5 button keypad is used to alter the LCD, change settings and initiate special functions from the
Configuration Menu:
Pressing ▲(up arrow button) displays the peak hydrogen reading.
Pressing ▼(down arrow button) displays the current percent hydrogen concentration.
Pressing ►(right arrow button) clears the peak hydrogen value.
Pressing and holding the ENTER button invokes the Configuration Menu.
Pressing ▼(down arrow button) scrolls down through function menus or scroll down through a
numerical range.
Pressing ▲(up arrow button) scrolls up through function menus or scroll up through a numerical
range.
Pressing the ENTER button or ►(right arrow button) selects the function.
Pressing ◄(left arrow button) backs out of menus.
7.4 CONFIGURATION MENU
The following functions will be found in the Configuration Menu:
Information Disp –model information
Firmware Rev –firmware revisions
Serial Number –model serial number
Calibration Date –date of the last factory calibration
Set Alert/Alarm –Define hydrogen level that will trigger the alert and alarm signals.
Alert Level –the level of hydrogen that will cause the LED to turn amber
Alarm Level –the level of hydrogen that will cause the LED to turn red
Set H2 Range –Define hydrogen sensitivity range (standard factory setting: 0% to 5% hydrogen by
volume).
Low H2 Range –The lowest level of hydrogen (standard factory setting: 0% hydrogen by
volume) to correspond with the low range analog output setting.
High H2 Range –The highest level of hydrogen (standard factory setting: 5% hydrogen by
volume) to correspond with the high range analog output setting.
Configure IDAC –define analog output range (standard factory setting: 4mA to 20mA)
Low Range –low level analog output (standard factory setting: 4mA) to correspond with
lowest level of hydrogen range
High Range –high level analog output (standard factory setting: 20mA) to correspond with
highest level of hydrogen range
Error –analog output (standard factory setting: 3mA) of error status
> 0.002
> 0.005
> 0.010
> 0.022
> 0.046
> 0.100
> 0.220
> 0.460
> 1.000
> 2.200
> 4.600
> 10.00
> 22.00
> 46.00
> 100.0
> 0.001
Hydrogen = 4.67%

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Not Ready –analog output (standard factory setting: 2mA) of self-diagnostic test
Field Calibrate
Calibrate Sensor –Field Calibration procedure
Clear Field Cal - restores the instrument to the last factory calibration
Exit –exit Configuration Menu to standard display output setting
8 SERIAL COMMUNICATION
The user can monitor and control the unit via serial communication via the serial interface.
8.1 SOFTWARE
Software that communicates over the serial port is typically called a “terminal emulator”. Any two-
way terminal emulators (HyperTerminal, Telnet, etc.) or purpose-built software (using LabView,
Visual Basic, C++, etc.) can be used to establish serial communication with the unit.
XP and previous versions of Windows came with a terminal emulator called “Hyper Terminal”.
Newer versions of Windows do not. These versions require installing a third-party program. There
are many inexpensive or free programs available. FoxTerm, a free program, is used extensively by
H2scan.
8.2 CONNECTION
Connect the sensor to the serial port, using whatever barriers and adapters are required.
If a USB adapter is used, install the driver according to its instructions.
In Windows, look at the ports using the Device Manger.
A built-in port will be “COM1”.
The port assigned to the USB adapter could have any number, but it will be called something like
“USB Serial Port (COM7)” or “I-756X (COM3)”. Below is an example.
Note the port number that Windows has assigned.
8.3 FORMAT AND SETTINGS
RS232 (RS422 optional)
19200 Baud
8 bit data
1 stop bit
No parity
No Handshaking
8.4 COMMAND LEVELS
The unit can be communicated with and configured via the use of commands as described below.
Two levels of communication outputs are available:
Level 0 –Default level used for data monitoring and basic functions providing a continuous
stream of data readings

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Level 1 –Password protected level used for configuration of user-settable parameters;
interactive single-line data output per command
8.5 COMMAND SUMMARY
The RETURN or ENTER key is the last character of the command string. If either key is pressed
without a command string the result is an invalid command and will resume continuous display if in
Level 0 or return to prompt if in Level 1.
Level 0 Commands
Keystroke
Description
ESC
Stops continuous display to enter a password or command. If in level zero, the
continuous display will resume after executing one command.
sp(spacebar)
Pressing the Space key while the serial output is active will display a label line
showing the heading for each column of data.
A
Average readings.
C
Clear peak hydrogen value.
=<password>
Enter the password to change security level. A null or invalid password returns to
the default security level.
Level 0 password = “0”
Level 1 password = “h2scan”

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Level 1 Commands
Keystroke
Description
A <Alert> <Alarm>
Set the Alert and Alarm levels in %H2.
C
Clear peak hydrogen value.
D <page>
Display Product Information. Enter page number 0-6 or A for all pages, default is
page 0.
0 –Product information
1 –User configuration
2 –Manufacturing information
3 –Product configuration
4 –Sensor characterization data
5 –Hydrogen calibration data
6 –Temperature calibration data
A –All of the above
F
Field Calibration
G < fmt> <opt>
Start or resume the sensor operation: if needed, heat the ASIC, setup the sensor,
and output data on serial port; this restores default settings (refer to the FORMAT
and OPTIONS section).
H <low> <high>
Set the hydrogen reporting range: <low> to <high> in %H2.
I <low> <high> <err>
<not rdy>
Set the DAC current output range: <low> to <high>; error output <err>; and not
ready output <not rdy> milliamps. Possible range from 0 to 20 milliamps.
L < fmt> <opt>
Print current hydrogen reading. Used to poll for hydrogen readings. Default
format <fmt> is current setting (refer to the FORMAT <fmt> and OPTIONS <opt>
sections).
P <atm>
Select atmospheric pressure of gas.
Factory default pressure is 1 ATM.
S
Stop the sensor: turn off heater, set Bias to zero, set DAC outputs to zero, and
stop reporting data on the serial output.
V <low> <high>
<err> <not rdy>
Set the DAC voltage output range: <low> to <high>; error output <err>; and not
ready output <not rdy> in volts. Possible range from 0 to 5 volts.
X
Clear field calibration data (returns to last factory calibration data).

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Format <fmt> - The Format <fmt> string is a two character hexadecimal representation of an 8 bit
value derived from the following table. The user determines which data are needed and selects that
bit value. Once all selections are made the values are summed bitwise and then converted to a two
place hexadecimal value. To aid in the conversion, a 4 bit to hexadecimal conversion table follows.
Format: Bit Value Identifiers
Serial output Format <fmt> parameter: select the desired
columns of data from this list, add the bit value for each column
bitwise, and convert into two hexadecimal characters using the
4 bit-to-Hexadecimal table in EXAMPLE 3.
Description
Bit Value
Include time stamp
1
0
0
0
0
0
0
0
Include raw ADC values
0
1
0
0
0
0
0
0
Include PCB temperature
0
0
1
0
0
0
0
0
Include sensor temperature
0
0
0
1
0
0
0
0
Include resistor reading
0
0
0
0
0
1
0
0
Include overall hydrogen reading
0
0
0
0
0
0
1
0
Include peak hydrogen reading
0
0
0
0
0
0
0
1
Options <opt> - The Options <opt> string is a two character hexadecimal representation of an 8 bit
value derived from the following table. The user determines which data are needed and selects that
bit value. Once all selections are made the values are summed bitwise and then converted to a two
place hexadecimal value. To aid in the conversion, a 4 bit-to-Hexadecimal conversion table follows.
Options: Bit Value Identifiers
Serial output Options <opt> parameter: select the desired status messages
from this list which will appear in the MESSAGES column, add the bit value
for each column bitwise, and convert into two hexadecimal characters using
the 4 bit-to-Hexadecimal table in EXAMPLE 3.
Description
Bit Value
Calculation Errors
0
0
0
0
0
1
0
0
Heater State
0
0
0
0
0
0
1
0
4 bit
value
Hexadecimal
Character
0000
0
0001
1
0010
2
0011
3
0100
4
0101
5
0110
6
0111
7
1000
8
1001
9
1010
A

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To implement the “G” command (“Go” command, refer to LEVEL 1
COMMANDS table) to have the following serial output columns
reported from the monitor: Time Stamp, Overall Hydrogen Reading,
the Peak Hydrogen Reading, Calculation Errors, and the Heater
state.
From the FORMAT <fmt> table above, you identify your desired
columns with its corresponding bit value:
<fmt> Descriptions <fmt> Bit Value
Time Stamp 1000 0000
Overall Hydrogen Reading 0000 0010
PCB Temperature 0010 0000
Sensor Temperature 0001 0000
<fmt> 4 Bit Value Combination: 1011 0011
Now use the 4 BIT-TO-HEXADECIMAL table above to convert this 4 bit value combination into a
two place hexadecimal value:
<fmt> Two Place Hexadecimal Value : B3
From the OPTIONS <opt> table above, you identify your desired columns with its corresponding bit
value:
<opt> Descriptions <opt> Bit Value
Calculations Errors 0000 0100
Heater State 0000 0010
<opt> 4 Bit Value Combination: 0000 0110
Again, use the 4 BIT-TO-HEXADECIMAL table to convert this 4 bit value combination into a two
place hexadecimal value:
<opt> Two Place Hexadecimal Value : 06
To have the Time Stamp, Overall Hydrogen Reading, the Peak Hydrogen Reading, Calculations
Errors and Heater State columns continuously reported, you will implement the “G” serial command
as follows at the H2scan: command prompt:
H2scan: G B3 06
Time stamp Pcb Temp Snsr Temp %H2 Messages
264 28.8530 124.50800 0.0000
280 29.1979 124.50910 0.0000
296 29.5169 124.51110 0.0000
1011
B
1100
C
1101
D
1110
E
1111
F

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 17 of 31
9 MAINTENANCE
9.1 CLEANING
If the unit is exposed to debris, condensates or other material that may collect over the sensor tip
then the unit should be cleaned by a gentle wiping with a clean lint-free cloth or paper.
10 CALIBRATION
Calibration can be accomplished through the serial port or the keypad. Calibrations do not cause any wear
on the sensor and can be accomplished as often as desired. Analog outputs can be monitored.
10.1 FACTORY CALIBRATION –
Contact H2scan to make arrangements for a comprehensive Factory Calibration by H2scan’s factory
trained technicians; optional NIST traceable certificate available upon request. An annual Factory
Calibration is advisable to optimize performance.
10.2 FIELD CALIBRATION
In the event the Field Calibration procedure seems to not be effective, H2scan recommends the unit
be shipped back to the factory for a comprehensive evaluation and Factory Calibration.
11 FIELD CALIBRATION
11.1 CALIBRATION INTERVAL
H2scan recommends that the system calibration be carried out every 90 days.
11.2 GASES
Field Calibration requires the availability of ambient, hydrogen-free air and one or two certified gases
with a nominal hydrogen value by volume in a balance of air. The flow rate required is 0.5 ± 0.2
slpm. One gas will correct any offset error while two gasses will also correct any gain error. It is
recommended to use two gasses to obtain superior calibration accuracy.
DO NOT use 0% H2 as the lower calibration gas. Instead use hydrogen concentration that is slightly
lower than the expected lowest hydrogen concentration. For the second calibration gas use a
concentration that is slightly higher than the expected maximum H2 concentration.
Custom Field Calibration Kits are available from H2scan.
The accuracy of the gas bottle concentration will directly affect the measured accuracy by the units.
During factory calibration, the units are calibrated with high accuracy gases (as high as +/- 0.02%). It
is strongly recommended that the user perform calibration with similar high accuracy gases to
maintain the highest accuracy.
11.3 TIMES
Each calibration gas should be applied for at least 10 minutes for the most accurate results. Actual
times required may vary.
11.4 GAS CONNECTION
Gases are applied to the unit via the gas application kit available from H2scan.
11.5 PROCEDURE
During the Field Calibration process any previously completed Field Calibrations are cancelled. As a
result, during the routine the unit may display a hydrogen concentration that is different from the
applied gas concentration. This is normal. Once the procedure is completed, the readings will be
corrected to display the right concentrations for all subsequent exposures.
NOTE: Field calibration must ALWAYS be done at the customer’s local atmospheric pressure.

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 18 of 31
11.6 CALIBRATION USING THE SERIAL INTERFACE
Press “Esc”
The unit will return the command prompt “H2scan:”
Type “f” then hit “Enter” and follow prompts to field calibrate the sensor with two gas concentrations

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OPERATING MANUAL
90000012 R8 Page 19 of 31
FIELD CALIBRATION STEPS
Display
User response
H2scan:
Type “ f” to run field calibration
Ready to Calibrate (Y/N)?
Type “ y”
Gas1 for res (Y/N)?
Type “ y” to proceed
Cal Gas: X.XXX%H2 (Y/N)?
Type “ n” if incorrect
Enter gas:
Enter the hydrogen concentration % by volume
Cal Gas: X.XXX%H2 (Y/N)?
Type “ y” if correct
Settle time: X min (Y/N)?
Type “ n” if incorrect
Enter time:
Enter the duration in minutes for gas #1
Settle time: X min (Y/N)?
Type “ y” if correct
Apply X.XXX%H2: Ready
(Y/N)? y
Type “ y” if correct
Streaming data…
Taking Average…
cap=0.00000 res=x.xxxxx
Calibration Gas #1 finished.
Gas2 for res (Y/N)?
Type “ y” if desired for better accuracy
Cal Gas: X.XXX%H2 (Y/N)?
Type “ n” if incorrect
Enter gas:
Enter the hydrogen concentration % by volume
Cal Gas: X.XXX%H2 (Y/N)?
Type “ y” if correct
Settle time: X min (Y/N)?
Type “ n” if incorrect
Enter time:
Enter the duration in minutes for gas #2
Settle time: X min (Y/N)?
Type “ y” if correct
Streaming data…
Apply X.XXX%H2: Ready
(Y/N)?
Type “ y” if correct
Taking Average…
cap=0.00000 res=X.XXXX
Calibration Gas #2 finished.
Calibration complete.
Cal Gas: 0%H2 (Y/N)?
Apply hydrogen-free air to the Sensor. Type “y”.
Streaming data…
Taking Average…
cap=0.00000 res=0.0000
0%H2 finished
Cal Gas: 0%H2 (Y/N)?
Apply hydrogen-free air to the Sensor. Type “y”.
Streaming data…
Taking Average…
cap=0.00000 res=0.000
0%H2 finished
Enter Month:

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 20 of 31
Enter Day:
Enter Year:
11.7 CALIBRATION USING THE KEYPAD
See the appendix for the keypad field calibration procedure.
12 CLEAR FIELD CAL
The Clear Field Calibration function restores the instrument to the last factory calibration.
12.1 CLEAR FIELD CAL USING THE SERIAL INTERFACE
Press “Esc”
The unit will return the command prompt “H2scan:”
Type “x” then hit “Enter” and follow the prompt to clear the field calibration.
12.2 CLEAR FIELD CAL USING THE KEYPAD
See the appendix for the keypad clear field calibration procedure.
13 MESSAGES
In this section XXX refers to a number
13.1 WARMUP_XXX
Warmup_XXX is displayed when the sensor is turned on or reset. It will start at a time programmed
at the factory and count down to 0.
13.2 SETTLE
When the sensor is waiting for the die temperature to stabilize, “Settle” (truncated on the LCD) is
displayed. The settling time varies depending on the sensor and local conditions and could take up
to five minutes.
13.3 WAIT_XXX
This message usually appears counting down a delay.
For example, during field calibration the sensor is expecting the gas to be applied for a certain
length of time. In this case WAIT_XXX will appear counting down the remaining time.
Wait_100 continuously displayed is a special case. It appears when the sensor is waiting for an
event that will not occur at a particular time. Once this event occurs it changes to a counter
initialized to some value (Wait_XXX) and counts down from there.
During field calibration “Wait_100” commonly appears in the third stage in which it is waiting for 0%
after 2% hydrogen. In this case the event for which it is waiting is 0% hydrogen, so it could display
“Wait_100” between settling and 0%. If 0% occurs before the temperature settles, it will display
“Settle” until the temperature is stable, then “Wait_XXX” which will count down to zero.
If it is displayed for more than five minutes, cycle the power to the unit. It should return to normal
operation.
13.4 HTROFF
The “htroff” error could be caused by one of several error conditions that cause the 2605 to turn off
the sensor heater. Sometimes the error occurs because of a transient condition (“glitch”). If “htroff”
is displayed, cycle the power to the unit. It should return to normal operation. If the error is
permanent, the unit must be returned to H2scan for examination.