WatchGas BAT-1 User manual

D e t e c t i on
WatchGas BAT-1, 2, 3
Breathing Air Quality Test Kit
USER MANUAL
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FULL COMPLIANCE WITH BS EN12021

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
D e t e c t i on
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Full Compliance with BS EN12021
Contents
Contents 2
1 Safety Information 3
2 International Standards 4
3 Technical Specications 5
3.1 Gas Detector Tubes 5
3.2 Manifold 6
3.3 Pressure/Flow Reducer 6
3.4 Hygro Thermometer 6
3.5 Flow Meter 6
3.6 PDM O2detector 7
4 BAT Layout 7
5 Operation Instructions 8
5.1 Preparing For Measuring 8
5.2 Measuring on Compressed Gas Cylinders 9
5.3 Measuring on Compressors 12
6 Gas Detector Tube Procedures 12
6.1 Oil 13
6.1 CO214
6.2 CO 15
6.3 H2O 16
7 Pressure Dewpoint 17
8 Service & Maintenance 18
9 Ordering & After Sales 18

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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1. Safety Information
IMPORTANT!
Failure to perform the procedures detailed within this user guide may impair the performance of this equipment. For
maximum safety and optimal performance please read and follow the following procedures and conditions. The volume
ow and quality of the supplied air should be thoroughly tested at intervals as specied by a competent person after risk
assessment.
The WatchGas BAT kit is to be used to test compressed air for; oil mist, water vapour, Carbon Monoxide (CO), Carbon
Dioxide (CO2), Oxygen (O2), temperature, humidity, ow, pressure and odour in accordance with your local governing body
(see section 2). Gases like NOx, H2S, SO2, NH3, PH3can be detected with optionally available gas detector tubes.
The BAT kit should be checked on the correct ow every 6 months. This can only be performed by a trained and authorized
person. How to perform the ow check can be seen in section 10.
Any attempt to repair components or to substitute components can cause an error and possible damage to components.
Only replace consumable items (Gas Detector Tubes + WatchGas PDM O2) with genuine components specied for use as
direct replacement for the BAT kit. The use of dierent components or attempts to repair components can an cause error
and possible damage to components.
The quality of the air supplied to a breathing apparatus should be tested at least every three months and more frequently
when the quality of the air supplied cannot be assured.
The regulators and ow restrictors are factory set to deliver the required ow rates specied by the manufacturers. Flow
rates can only be adjusted by trained and authorized personnel.
Please use safety glasses when using the BAT-kit, safety glasses are not included .
ADDITIONAL WARNINGS CONCERNING THE USE OF THE WATCHGAS PDM O2:
• Before operating this device, please read the manual carefully.
• If calibration and self-test fail continuously, please do not use the device.
• For the O2detector, perform calibration every 30 days in a fresh air environment, preferably outside.
• Before use, please check the activation date, and if the activation date is passed, please do not use the device. The PDM
O2has a life span of 2 years from start-up. A countdown timer shows the remaining life of the PDM O2. At the end of
the PDM O2life, it automatically shuts o. Once the software shutdown is complete, discard the detector and contact
WatchGas for a replacement.
• Clean detectors with a soft cloth and do not use chemical substances for cleaning.
• To maintain 24 months life time, avoid the below activities except the necessary cases to check events (Max/Min),
lifetime/concentration, and alarm set points. Otherwise, the frequent use of the button will deplete the battery lifetime
less than 24 months. Do not push the button frequently without valid reasons.
• Normal Alarm Use 1 time and 2 minutes per day
• View the serial number on the label at the backside of the device.
• WARNING: Explosion Hazard - The PDM O2contains no serviceable parts.
• WARNING: Substitution of components may impair intrinsic safety.
• WARNING: The PDM O2contains a lithium battery which may leak or explode if the instrument is mistreated. Do not
attempt to disassemble or dispose of in re.
• Never cover or insert foreign objects into the alarm signal opening, the opening must remain clear and free of foreign
objects, otherwise, any alerts made during an alarm state may not be heard or identied.

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
D e t e c t i on
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Full Compliance with BS EN12021
2. International Standards
Substance Europe USA Canada Australia
Standard BS EN12021 29 CFR
1910.134
CSA Z180.1-00 AS/NZS
1715:1994
Pharmaceutical:
EP 01/2009 : 1238
Pharmaceutical:
USP35-NF30
Oxygen (O2) 21% (+/-1%) 19.5%
-23.5%
20%-22% By
Volume (Dry Air)
19.5%-22% 20.4 – 21.4% 19.5 – 23.5%
Carbon Dioxide
(CO2)
≤ 500 ppm ≤ 100 ppm ≤ 500 ppm ≤ 800 ppm ≤ 500 ppm ≤ 0.05%
Carbon Monoxide
(CO)
≤ 15 ppm ≤ 10 ppm ≤ 5 ppm ≤ 10 ppm ≤ 5 ppm ≤ 0.001%
Oil Mist/Vapor ≤ 0.5mg/m3≤ 5ppm ≤ 1mg/m3≤ 1mg/m3≤ 0.5 mg/m30 mg/m3
Odour/Taste Without Significant
Odour or Taste
Without
Significant
Odour or
Taste
Without Signi-
ficant Odour or
Taste
Without
Significant
Odour or Taste
Without
Significant Odour
or Taste
Without
Significant
Odour or Taste
Water Vapor
(H2O)
Air for compressed
air-line breathing
apparatus shall
have a dewpoint
sufficiently
low to prevent
condensation and
freezing. Where
apparatus is used
and stored at a
known temperature,
the pressure
dewpoint shall be
at least 5oC below
the likely lowest
temperature. Where
conditions of
usage and storage
of the air are not
known, the pressure
dewpoint shall not
exceed -11oC.
4oC (39 oF)
pdp @
50psig.
The pressure
dewpoint of
the compressed
breathing air
shall be at least
5oC (9oF) below
the lowest
temperature to
which any part of
the compressed
breathing air
pipeline or
the accepted
respirator may
be exposed at
any season of the
year.
Airline pressure
should be
at least 5oC
below the
lowest known
temperature
or -11oC if the
lowest is not
known.
≤ 67 ppm 0 ppm
Nitrogen Oxides
(NOx)
≤ 2 ppm ≤ 2.5 ppm
Sulfur Dioxide
(SO2)
≤ 1 ppm ≤ 5 ppm
Table 1

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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Gas Tube Range Liter
air
Flow Sample time
in min.
Colour change -> Shelf life
years
Carbon Monoxide
(CO)
7182524 5 - 70 ppm 1.5 0.3 l/min 5 min White Brownish
Green
2
Carbon Dioxide
(CO2)
7182525 100 – 2000 ppm 1.5 0.3 l/min 5 min White Brownish
Green
2
Water Vapor 7182526 5 – 70 mg/m310 1 l/min 10 min yellow Brownish
Green
2
20 - 160 mg/m35 5 min
Oil Mist 7182523 0.1 - 1 mg/m360 2.5 l/min Please read
instructions
on page 13
White Brownish
Green
2
Optional. available on request:
Nitrogen Oxides 7182528 0.2 - 2.5 ppm 3 0.3 l/min 10 min White /
Light
Blue
Dark Blue 2
0.5 - 6 ppm 1.5 5 min
Water Vapour 7192124 10 – 80 ppm 10 1 l/min 10 min Yellow Brownish
Green
2
30 – 200 ppm 5 5 min
Water Vapour 7192123 2 - 200 mg/m350 2 l/min 25 min Yellow Reddish
Brown
2
Oil Impactor 7192118 0.1, 0.5,
1.0 mg/m3
20 4 l/min 5 min Empty Black dots 2
Sulfur Dioxide 7192116 0.25 – 1 ppm 2 2 l/min 10 min Grey-
blue
White 2
1 – 25 ppm 1 1 l/min 5 min Grey-
blue
White 2
Sulfur Dioxide 7192117 0.5 – 2 ppm 2 0.2 l/min 10 min Grey-
blue
White 2
Phosphine 7192122 0.1 – 4 ppm 1 0.2 l/min 5 min White Greyviolet 2
Ammonia 7192119 0.6 – 9 ppm 1 0,2 l/min 5 min Yellow Blue 2
Hydrogen
Sulfide
7192120 0.04 – 1 ppm 4 0.8 l/min 5 min White Palebrown 2
Hydrogen
Sulfide
7192121 1 – 20 ppm 1 0.17 l/min 6 min White Brown 2
3. Technical Specications
3.1 GAS DETECTOR TUBES
Table 2

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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Full Compliance with BS EN12021
Outlets: 4
Standard Flow:
Flow is adjustable
according to the
required flow of
the tubes.
Outlet 1: 0.3
L/min
Pressure 25 - 300 bar reducing
to 4.5 bar
Measuring Range 20-99% RH
0-50oC
Display Accuracy +/-5 %RH; +/-1oC
Display Resolution 1%RH; 0.1oC
Display Update 10 secs
Battery AG13
Flow range: 0.2 – 3 LPM
3.2 MANIFOLD
3.3 PRESSURE / FLOW REDUCER
3.4 HYGRO THERMOMETER
3.5 FLOW METER
Table 3
Table 4
Table 5
Table 6

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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Measuring range: 0-30% Vol
Resolution: 0.1% Vol
Life time: 24 months
7192115 Temperature & Relative Humidity Meter
7182517 0.2 - 3 lpm Calibration Flow Meter
7182515 Manifold for 4 tubes
7182520 4 Rubber Tube Holders
7182516 Pressure / Flow Reducer 25-300 bar to 4.5 bar
7182518 Timer / Stopwatch
7182521 Tube Tip Breaker
7182523 10 Gas Detector Tubes for Oil 0.1 - 1mg/m3
7182524 10 Gas Detector Tubes for CO 5 - 70ppm
7182525 10 Gas Detector Tubes for CO2100 - 2000ppm
7182526 10 Gas Detector Tubes for H2O 5 - 160 mg/m3
7182530 10 Gas Detector Tubes for NOx 0.2 - 6ppm
(Available on request)
7192116 10 Gas Detector Tubes for SO20.25 - 1 ppm
(Available on request)
7192117 10 Gas Detector Tubes for SO20.5 - 2 ppm
(Available on request)
7192118 10 Oil Impaktor
(Available on request)
7192122 10 Gas Detector Tubes for PH30.1 - 4 ppm
(Available on request)
7192119 10 Gas Detector Tubes for NH30.6 - 9 ppm
Available on request)
7192120 10 Gas Detector Tubes for H2S 0.04 - 1 ppm
Available on request)
7192121 10 Gas Detector Tubes for H2S 1 - 20 ppm
Available on request)
7181411 WatchGas PDM O2Gas Detector 0 - 30% Vol
Available on request)
7182528 200 bar adapter (Only in BAT-2)
7182529 300 bar adapter (Only in BAT-2)
3.6 PDM O2DETECTOR AVAILABLE ON REQUEST
Table 7
4. BAT layout
Manual
Suitcase Keys
Air Quality Analysis Form
7182514 BAT-1 total kit
7182528 BAT-2 total kit
Coming soon BAT-3 total kit
Table 8
Figure 1: BAT-Kit layout

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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Full Compliance with BS EN12021
5. Operating Instructions
5.1 PREPARING FOR MEASURING
Warning
First follow these steps before performing the test in 5.2 or 5.3.
First it is important to determine the detection limit of the oil typ using table 9 below.
Determine sampling time according the threshold value to be detected using table 10 below.
Oil Detection limit Indication colour
Anderol 500 8 μg yellowish brown
Anderol 555 12 μ g yellowish brown
Anderol 750 19 µg beige brown
Anderol 755 16 µg beige brown
Castrol Product 9104 8 µg beige brown
Castrol: Variocut G 600 9 μg beige brown
Castrol: Variocut G 500 9 μg beige brown
Dräger U10822/U10823 40 μg yellowish brown
Lenardt&Wagner LW 9001 15 μg pale beige
Liqui Moly 500 / SAE 30 17 μg yellowish brown
Liqui Moly 750 / SAE 40 40 μg yellowish brown
Mobil DTE Oil Heavy Medium 7 μg beige brown
Mobil Rarus 425 5 μg yellowish brown
Mobil Rarus 427 10 μg yellowish brown
Mobil Rarus 827 25 μg yellowish brown
Mobil SHC 629 Lageröl 8 μg pale beige
Parane dünnüssig/low viscosity (Merck Art. 107174) 8 μg beige
Shell Comptella ÖL SM 8 μg brown
Shell Corena Öl P 150 7 μg pale beige
Shell Ensis Motorenöl 30 9 μg beige brown
Shell Ondina 933 6 μg pale beige
Texaco Compoil EP VDL 150 7 μg brown
Detection
limit
Evaluated detection
limit 0.1 mg/m3
Evaluated detection
limit 0.3 mg/m3
Evaluated detection
limit 0.5 mg/m3
Evaluated detection
limit 1.0 mg/m3
5 µg 25 min 8 min 5 min 3 min
10 µg 50 min 17 min 10 min 5 min
15 µg 75 min 25 min 15 min 8 min
20 µg 100 min 33 min 20 min 10 min
25 µg 125 min 42 min 25 min 13 min
30 µg 150 min 50 min 30 min 15 min
40 µg 200 min 67 min 40 min 20 min
50 µg - 83 min 50 min 25 min
Table 9: Detection limits
Table 10: Measurement time for evaluated reference value

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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Figure 2: 200 & 300 bar compressor adapters
Figure 4: Pressure reducer
Figure 3: Screwing the adapter on the pressure reducer.
Figure 5: Connecting manifold to the pressure reducer
Figure 6: Checking the outlet ow with the ow meter Figure 7: Connecting rubber tube holders to the manifold
1. Clean the valve of compressed gas cylinders or char-
ging connections of the compressor with a brief burst of
air.
2. Chose and connect the adapter suitable for the pre-
script maximum pressure of the compressor charging
panel (300 or 200 bars). When using the BAT kit on a gas
cylinder, you can skip this step.
3. Insert and rmly t the nozzle of manifold on the pres-
sure reducer as shown in g. 5.
2. The ow rate of air through each port of manifold
can be conrmed if necessary by using the ow meter
provided with the kit. (To measure the ow rate connect
tubing of ow meter to the desired manifold port- Fig. 6)
3. Insert the detector tube holders in the manifold ports-
Fig. 7.
4. Flush device for sucient time to make the test device
free from other gases if any.
1. Slowly open cylinder valve.
5.2 MEASURING ON COMPRESSED GAS CYLINDERS
(for measuring on compressors go to 5.3)

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit User Manual
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When the test device is clean and dry ushing for 2 min. is sucient. If the condition of the device is not known, or if during
a previous measurement higher values were found than are permissible according to EN 12021, ushing at 2 l/min. must
be continued. This must be done until 2 water vapour measurements, made at an interval of approx. 15 min., give identical
results within the permissible measuring accuracy range. It then can be assumed that the test device is suciently clean for
making measurements.
Liquid/water (droplets) can only be removed from the test device through long ushing with dry, if necessary warm air.
Observe the arrow on the detector tube. The arrow points in the ow direction of the test air; therefore, after inserting the
tube, the arrow must point away from the test device.
Each outlet of the manifold is made for a particular detector tube. The ow has been engraved above each outlet on the
blue manifold:
• CO20.3 l/min
• CO 0.3 l/min
• H2O1 l/min
• Oil 2.5 l/min
Figure 8: Hygro-Thermometer with gas funnel: Checking
the outlet ow with the ow meter
Figure 9: Connecting the gas funnel to the 0.3 outlet
5. Check the temperature and relative humidity of the
breathing with the Hygro-Thermometer. Place the cone
in one of the rubber tube holders of a 0.3 outlet. Hold the
back of Hygro- Thermometer on the cone for 1.5 minutes.
Write down the readings on the Air Analysis Form.