ion science TVOC User manual

TVOC User Manual V2.6
______________________________________________
Part No 849215 www.ionscience.com

TVOC MANUAL Ion Science Ltd
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DECLARATION OF CONFORMITY
Manufacturer: Ion Science Ltd, The Way, Fowlmere, Cambridge, SG8 7UJ, UK
Product: TVOC
Product Description: An intrinsically safe fixed continuous monitor comprising of a photo-ionisation
detector for detecting and measuring volatile organic compounds with a 4-20mA
output
Directive 94/9/EC ATEX
Identification: II 2G Ex ia IIC T4 (-20oC ≤Ta ≤+50oC)
Notified Body: Baseefa Ltd, 1180, Buxton, UK
EC Type Examination Certificate(s)
Baseefa05ATEX0277 latest supplement Baseefa03ATEX742/2 issued 24th November2008
IECEx BAS 06.0057 latest revision no.1 issued 20th November 2008
Standards
BS EN 60079-0:2006 Electrical Apparatusfor Potentially Explosive Atmospheres –General Requirement
BS EN 60079-11:2007 Explosive Atmospheres - Equipment Protection by Intrinsic Safety ‘i’
BS EN 61010-1:2001 Safety requirements for electrical equipment formeasurement, control and
laboratory use –General requirements
Directive 2004/108EC Electrical Equipment –Electromagnetic Compatibility (EMC)
BS EN 50270:1999 Electromagnetic compatibility. Electrical apparatus for the detection and
measurement of combustible gases, toxicgases or oxygen
BS EN 61000-6-6:2001 Electromagnetic Compatibility (EMC) Generic standards. Emission standard for
residential, commercial and light industrial environments
With respect to BS EN 50270:1999, the TVOC achieves performance criteria A (the apparatus continues to operate as
intended before and after the test) except at spot frequencies where it achieves criteria B (the apparatus continues to
perform after the test but during the test a degradation of performance is seen). See technical specificationfor details.
Other Standards
BS EN ISO 9001:2000 Quality Management Systems –Requirements
BS EN 13980:2002 Potentially Explosive Atmospheres –Application of Quality Systems
On behalf of Ion Science Ltd, I declare that, on the date this product accompanied by thisdeclaration is
placed on the market, the product conforms to all technical and regulatory requirementsof the above listed
directives.
Name: MarkStockdale Position: Technical Director
Signature: Date: 20th November2008

TVOC MANUAL Ion Science Ltd
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Contents Page
1 –Statements . . . . . . 5
2–Introduction to TVOC . . . . . 6
3 –Packing List . . . . . . 7
4 –TVOC Set up . . . . . . 8
Selector pins . . . . . . 8
Cycle times . . . . . . 9
5 –Installation . . . . . . 10
Location . . . . . . 10
Mounting . . . . . . 11
Cable requirements . . . . . 12
Power requirements . . . . . 12
Non Intrinsically Safe (IS) applications . . 12
Intrinsically Safe (IS) applications. . . 14
Initial calibration . . . . 16
6 –Operation . . . . . . . 17
Start up. . . . . . . 17
Cycle times . . . . . . 17
LED’s . . . . . . . 18
Selector pins . . . . . . 18
Calibration mode . . . . . 19
7 –Calibration . . . . . . 20
Calibration routine . . . . . 20
Setting the zero . . . . . . 21
Setting the gas tolerance . . . . 22
Setting the span . . . . . 22
Display lamp life . . . . . 23
8 –Maintenance . . . . . . 24
Cleaning and replacing the PID lamp . . . 24
Fuse rupture and replacement . . . . 27
Lamp warranty statement . . . . 27
9 –Diagnostics . . . . . . 28
10 –Spare parts . . . . . . 30
11 –Technical Specifications . . . . 31

TVOC MANUAL Ion Science Ltd
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1 Statements
Responsibility for use
TVOC detects a large range of gases, which are potentially dangerous from both a poisoning and/or an
explosive perspectiv e. TVOC has a number of selectable features allowing the detector to be used in a
variety of applications. Ion Science Ltd can accept no responsibility for the incorrect adjustment of features
that cause harm or damage to persons or property. It is the users’responsibility to respond appropriately to
the readings delivered.
!Warning!
1. Substitution of components may impair intrinsic safety and result in unsafe conditions.
2. For reasons of safety, TVOC must only be operated and serviced by qualified personnel.
3. Please read and understand this user manual fully before installing, operating or servicing TVOC.
Quality assurance
TVOC has been manufactured in compliance with ISO9001:2000, which ensures that the equipment supplied
to our customers has been designed and assembled reproducibly, from traceable components, and leaves
Ion Science calibrated to stated standards.
Disposal
Dispose of TVOC and its components in accordance with all local and national safety and environmental
requirements. This includes the European WEEE (Waste Electrical and Electronic Equipment) directiv e. Ion
Science Ltd offers a take back serv ice. Please contact us for more information.
Contact Ion Science Ltd
By Post Ion Science Ltd
The W ay
Fowlmere
Cambridge
SG8 7UJ
UK
By Telephone +44 ( 0) 1763 208503
By Fax +44 ( 0) 1763 208814
By Email [e-mail]

TVOC MANUAL Ion Science Ltd
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2 Introduction to TVOC
TVOC is a fixed continuous monitor for the detection and measurement of total volatile organic compounds,
which can be dangerous from both a poisoning and explosive perspectiv e. Total VOC’s are detected using
PID (Photoionisation Detection) technology).
TVOC has a number of user selectable features which define its operation and will be application dependent.
The user can define the detection ranges or 0.01 - 10ppm, 0.1 –100 ppm or 1 –1,000 ppm (Default);
detection units, either ppm or mg/m3; and the duty cycle time i.e. the frequency that the instrument takes a
measurement. Duty cy cles are explained in more detail in section 4, TVOC set up, and section 6 Operation.
IMPORTANT: if the 10ppm range is selected the TVOC will require a calibration using 10ppm Isobutylene
before use.
The default settings of TVOC are:
Detection range –0.1 –1000 ppm
Units - ppm
Duty cycle - 5 seconds ON / 55 seconds OFF
TVOC gives a continuous 4 –20 mA output which can be integrated into a DCS control system to give an
indication of VOC levels in the operating environment.
In addition to the 4 –20 mA output TVOC has an LCD display showing gas concentration and 4 colour LED’s.
LED functions are as follows:
Green - is an indicator of TVOC’s working status
Red - is the fault indicator
Yellow x 2 - are calibration status indicators
Please see section 7 Calibration for more information on LED status.
For installation requirements please refer to sections 5 and 10 of this manual. For Intrinsically Safe (IS)
installations please also refer to the TVOC ATEX certificate for further details. Before attempting an
installation, please fully read and understand this user manual.
TVOC does require regular calibration onsite please see section 7 Calibration for information. TVOC
calibration mode is accessed v ia a magnetic read switch system.
The TVOC intrinsic safety rating permits its deployment in all hazardous areas of the quoted (or less
demanding) rating. That is, in areas where explosive gases (of Group IIA, IIB and IIC) are intermittently
present (Zone 1) within an ambient temperature range of -20°C and +60°C.

TVOC MANUAL Ion Science Ltd
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3 Packing List
All items of equipment shipped by Ion Science Ltd are pack ed in suitable containers and enclosed in a shock
absorbing filling which affords a considerable degree of protection against physical damage.
Contents should be carefully removed and checked against the packing list. Any discrepancies between the
contents and the packing list must be reported to Ion Science Ltd within 10 days of receipt of shipment. Ion
Science cannot be held responsible for shortages not reported with in the period.
Standard TVOC instrument
Item Description Qty
1. TVOC instrument 1
2. TVOC Manual 1
TVOC Calibration Tool Kit
Item Description Qty
1. Calibration magnet 1
2. Calibration adaptor 1
3. Calibration connector 1
4. Aspirator 1
5. Carbon filter 1
6. Allen keys 1
3. Calibration
Connector
1. Calibration
Magnet
6. Allen Keys X 2
4. Aspirator
2. Calibration
Adaptor
5.
Carbon
Filter

TVOC MANUAL Ion Science Ltd
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Diagram 4.1
4 TVOC Setup
4.1 Selector Pins
TVOC has a number of settings that can be selected by the user
via a row of 4 selector pins mounted on the reverse side of the
main PC B. Diagram 4.1 shows the location of the functional
selector pins labelled - A, B, C & D.
The selector pins absence or presence determines the chosen
setting.
TVOC is shipped with all 4 selector pins fitted as shown in
diagram 4.2.
Diagram 4.3 demonstrates the removal of 1 selector pin.
Diagram 4.1
Diagram 4.2
Diagram 4.3

TVOC MANUAL Ion Science Ltd
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4 TVOC Setup
The following table shows the selector pin combinations and the corresponding function.
a= Selector pin fitted
r= Selector pin removed
Selector pin
A B C D Range Displayed units
a(n/a) aaa1000 ppm (Default)
a(n/a) axa100 ppm
a(n/a) xaa10 ppm
a(n/a) aax2280 mg/m3
a(n/a) axx228 mg/m3
a(n/a) xax22.8 mg/m3
Selector pin ‘B’and ‘C’selects the ranges - 10ppm, 100ppm or 1,000ppm
Selector pin ‘D’selects the units - ppm’or ‘mg/m3
Selector pin ‘A’- C urrently not used
IMPORTANT: if the 10ppm range is selected the TVOC will require a calibration using 10ppm Isobutylene
before use. (See the calibration section of this manual)
NOTE: * TVOC is shipped with all selector pins fitted as standard
* TVOC only reads the selector pin settings when power is connected.
Alway s ensure power is disconnected from TVOC before changing
setting or carry ing out maintenance.
* Never place selector pins on the programming port connector.
* Ensure static build up is discharged before touching components.
4.2 Duty Cycle
The TVOC has a variable duty cycle whereby the lamp is ON for 5 seconds and then OFF for a user set
period between 0 to 5 minutes in 1 second increments. The 4 –20 mA output is updated at the end of each
cycle. As standard the TVOC duty cycle is 1 minute –the lamp is ON for 5 seconds and OFF for 55 seconds.
The lamp OFF time is fully adjustable by the user. Please see section 6.1 of this manual for full instructions.

TVOC MANUAL Ion Science Ltd
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5 Installation
5.1 Location
There are many variables involved in defining the optimum location for a gas detector. Obvious though it
may sound, the most important rule is:
·A detector will not detect gas unless gas actually reaches the detector.
TVOC should be mounted in the location most lik ely to detect gas.
·TVOC must be mounted vertically with the sensor underneath the case. This avoids dust and debris
blocking the access to the detector cell.
·Mount TVOC higher if detecting VOC gases that are lighter than air or lower if detecting VOC gases
that are heavier than air (but never on the floor). This should maximise detection.
·Mount TVOC in an area that has good air circulation. Restricting natural air current may result in
delayed detection.
·Never mount TVOC in direct sunlight or over a heat source such as a radiator. This may cause TVOC to
exceed its certified working range.
·Do not mount TVOC where it’s subjected to rain fall, water, aerosols, mist or heavy condensation.
·Mount TVOC in areas that are easily accessible for servicing.
·Percentage v ariations in the composition of air (78% Nitrogen, 21% Oxygen and 1% Argon) may
affect the detected signal.
Please refer to the technical spe cifications of the instrument i n Section 10 of this manual before
beginning a TVOC installation.

TVOC MANUAL Ion Science Ltd
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5 Installation
5.2 Mounting
Dimensions for mounting TVOC are given in Diagram 5.2.1 below.
Diagram 5.2.1
NOTE: The TVOC case can be used as a template when mark ing out fixing holes but do not drill
through the fixing holes.

TVOC MANUAL Ion Science Ltd
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5 Installation
5.3 Cable requirements
Ion Science Ltd suggests using screened cables for both power in and signal out. Cable screens must
be terminated at the TVO C enclosure using EMC cable glands.
5.4 Power requirements
5.4.1 Non Intrinsically Safe (Non IS) applications:
Input power 5 - 28Vdc. 65mA max.
4-20mA power 8-35Vdc. 22mA
4 Wire Sy stem
Diagram 5.4.1
3 Wire Sy stem (a)

TVOC MANUAL Ion Science Ltd
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5 Installation
3 Wire Sy stem (b)
!WARNING!
Non Intrinsically Safe (Non IS) applications
When the unit is installed with a non IS rated power supply the IS details on the front of the unit are not
appropriate for the system. The IS label should be covered up or blocked out. This will prevent safety
discrepancies and or mis-use in the future should the equipment be moved or the site be re-defined as a
hazardous area.

TVOC MANUAL Ion Science Ltd
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5 Installation
5.4.2 Intrinsically Safe (IS) applications: Entry parameters
Input power Ui = 18V Ii = 800mA Pi = 1.2W Ci = 0mF Li = 0mH
4-20mA power Ui = 30V Ii = 200mA Pi = 1.2W Ci = 0mF Li = 0mH
For information only please see ATEX certificate before installation
Ion Science Ltd suggest using the following Zener Barriers for IS approved applications. Use competent
installation engineers and ask them for installation and application adv ice.
POWER SUPPLY: Suggested barriers for INLET power supply
Manufacturer Manufacturers pt no. Type Cable length estimate
Pepperl+Fuchs Z715 Zener barrier ~ 1115 meters
Pepperl+Fuchs KFD2-SD2-EX1.1065 Galvanic isolator ~ 1217 meters
MTL 7715P+ Zener barrier ~ 772 meters
Stahl 9901/01-158-270-101 Zener barrier ~ 500 meters
Stahl 9143/10-156-065-10 Galvanic isolator
SIGNAL OUTPUT: Suggested barriers for 4-20mA OUTLET
Manufacturer Manufacturers pt no. Type
Pepperl+Fuchs Z728 Zener barrier
Pepperl+Fuchs KFD2STC4-Ex1 Galvanic isolator
MTL MTL7787 Zener barrier
MTL MTL5042 Galvanic isolator
Stahl 9001/01-280-110-141 Zener barrier
Stahl 9160/13-11-11 Galv anic isolator
NOTE
·All cable lengths are estimated for zone 1 IIC installation of the equipment
·Using 1mm2C.S.A conductor S.T.P cables with capacitance per meter of 250pF/m, L/R ratio of
25uH/Wconductor resistance at 20°C of 18.4W/km.
·Calculation assumes cables are at 50°C.
WARNING! Intrinsically Safe (IS) applications
·Units should not be powered using non IS power supplies prior to installation in an IS application.
·If non IS power is supplied the unit will require inspection by Ion Science Ltd or an Ion Science
Approved Service Centre prior to installation in an IS application.
·TVOC fuses may not be replaced in the field.
·If a fuse is blown TVOC will require inspection by Ion Science Ltd or and Ion Science Approv ed Service
Centre before it is used in an IS application.

TVOC MANUAL Ion Science Ltd
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5 Installation
Diagram 5.4.2.1 Control equipment sensing 4 –20 mA at supply rail
Diagram 5.4.2.2 Control equipment sensing 4 –20 mA to 0V
Diagram 5.4.2.3 Control equipment sensing (3 wire)

TVOC MANUAL Ion Science Ltd
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5 Installation
5.5 Initial calibration
TVOC is calibrated at Ion Science before dispatch using 100ppm Isobutylene. However if y ou wish to
calibrate your TVOC once it is installed Ion Science recommends that the TVOC is left to run on its chosen
settings (see Section 4 TVOC Set up) for 24 hours before an initial calibration is carried out, to allow the
instrument to settle into the work ing environment.

TVOC MANUAL Ion Science Ltd
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6 Operation
6.1 Start Up
After electrical power is connected, TVOC runs through a ‘Start up’routine, which lasts for approximately 1
minute. During this ‘Start up’routine TVOC demonstrates the following characteristics:
* The LCD screen display s the software v ersion number
* The GREEN LED flashes
* The 4 –20 mA output is set to 4 mA (0.0 ppm)
NOTE: I the 0-10ppm range is selected the TVO C will require calibration using 10ppm Isobutylene before
user (See the calibration section of this manual)
During this ‘Start-up’time the user can adjust the lamp OFF time as referred to in Section 4.2. This time can
be adjusted from 0 to 5 minutes in 1 second increments.
6.2 Cycle times
To extend PID lamp life and the time between servicing, TVOC includes a
variable duty cycle, (see section 4.2) whereby the lamp is switched ON
and OFF. The length of time between servicing and calibration is
increased where longer OFF times are selected. However the length of
time between servicing also depend on ambient air quality, the higher
VOC concentration detected by the instrument then the shorter the time
between servicing.
6.2.1 A djusting the lamp OFF time
There are two stages to adjusting the lamp OFF time. The first stage adjusts the seconds (0-59) and the
second stage adjusts the minutes (0-5). To adjust the lamp OFF time the magnetic switch must be activated
during the ‘Start-up’time.
NOTE: Please read this entire procedure before attempting to adjust the lamp OFF time.
1 –During the 1 minute ‘Start up’routine place the calibration magnet over the top
right hand corner of the Ion Science logo. Two numbers on the LCD screen will flash.
2 - This indicates the lamp OFF time in seconds.
3 –Placing the calibration magnet back over the logo will cause the number to role between 0 and 59
seconds. Remove the magnet when the desired time is displayed.
4 –After 5 seconds the display will show another two numbers and flash.
5 –This indicates the lamp OFF time in minutes.
6 –Again place the calibration magnet over the logo to rotate the numbers between 0
and 5 minutes. Remove the magnet when the desired time is displayed.

TVOC MANUAL Ion Science Ltd
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6 Operation
7 - After 5 seconds the entire output frequency is displayed.
8 - After a further 5 seconds the set frequency will be set in the
TVOC memory.
9 - TVOC then continues through the standard start-up routine.
If you are unhappy with the update frequency you have set you can adjust the time by placing the
calibration magnet over the logo during the 5 seconds after the total time has been shown (point 8 abov e).
NOTE: The total duty cycle time includes the 5 seconds lamp ON time. Therefore if you wish your total duty
time to be approximately 2 minutes set the lamp OFF time to 1 minute 55 seconds.
At the end of the ‘Start up’routine TVOC will enter the selected monitoring routine.
6.3 LED’s
The GREEN LED indicates TVOC’s working status
ON Indicates the PID lamp is OFF
Flashing Indicates the PID lamp is ON
The RED LED indicates Fault status
ON Indicates TVOC cannot function correctly. The 4-20mA output drops
to 3.5mA.
URGENT attention is required.
Flashing Indicates the last calibration carried out was outside expected
limits. The instrument will continue working but serv ice is required.
Please see Section 7 Calibration for YELLOW LED status.
6.4 Selector pins
TVOC has a range of options that are selected via the selector pins on the back of the main PCB (please see
Section 4 TVOC Set up).
The options are shown below with the defaults highlighted in bold:
1-1000ppm or 0.01 - 10 ppm or 0.1 - 100 ppm
ppm units or mg/m3units

TVOC MANUAL Ion Science Ltd
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6 Operation
6.5 Calibration mode
TVOC calibration mode can be accessed using the calibration
magnet supplied in the TVOC calibration tool kit (Part number:
A-845214).
To enter calibration place the magnet over the top right of the
Ion Science Logo until the state changes (i.e. an LED illuminates
and/or the display changes).
Ensure the magnet is withdrawn away from the magnetic switch
by at least 1 cm once a change has occurred.
6.6 Calibration gases
TVOC has three (3) ranges that can be selected however the 0-10ppm range requires the instrument is
calibrated by the user before use. The 0-100ppm and the 0-1000ppm ranges can initially run using the
Factory calibration carried out during the instruments manufacture, however because the 0-10 ppm range is
more sensitive and more susceptible to environmental and system tolerances the instrument must be
calibrated using 10ppm Isobuty lene before use.
If the 0-10 ppm range is selected TVOC will display the following
screen to indicate that a calibration is required before it can be used.
Follow the calibration instructions before use.

TVOC MANUAL Ion Science Ltd
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7 Calibration
7.1 Calibration routine
Ion Science recommends calibrating TVOC after any maintenance or lamp cleaning is carried out and on a 3
monthly basis to ensure TVOC is working to specification.
NOTE: Please read this entire calibration procedure before attempting a calibration.
TVOC calibration has 4 stages:
1. Setting the ZERO (Using clean gas v ia carbon filter)
2. Setting the gas tolerance (90 –110 ppm Isobutylene on 0-100 ppm and 0-1000 ppm ranges)
(9 - 11ppm Isobutylene on the 0-10ppm range)
3. Setting the SPA N (Using the SPAN gas)
GREEN
STATUS LED
ZERO LED
SPA N LED
FA ULT LED