PortaSens II Model C16 Operating and Maintenance Manual Rev I Sept 2014

PortaSens II

Portable Gas Leak Detector, Model C16

PRODUCT WARRANTY Analytical Technology, Inc. (Manufacturer) warrants to the Customer that if any part(s) of the Manufacturer's products proves to be defective in materials or workmanship within the earlier of 18 months of the date of shipment or 12 months of the date of start-up, such defective parts will be repaired or replaced free of charge. Inspection and repairs to products thought to be defective within the warranty period will be completed at the Manufacturer's facilities in Collegeville, PA. Products on which warranty repairs are required shall be shipped freight prepaid to the Manufacturer. The product(s) will be returned freight prepaid and allowed if it is determined by the manufacturer that the part(s) failed due to defective materials or workmanship. This warranty does not cover consumable items, batteries, or wear items subject to periodic replacement including lamps and fuses. Gas sensors, except oxygen sensors, are covered by this warranty, but are subject to inspection for evidence of extended exposure to excessive gas concentrations. Should inspection indicate that sensors have been expended rather than failed prematurely, the warranty shall not apply. The Manufacturer assumes no liability for consequential damages of any kind, and the buyer by acceptance of this equipment will assume all liability for the consequences of its use or misuse by the Customer, his employees, or others. A defect within the meaning of this warranty is any part of any piece of a Manufacturer's product which shall, when such part is capable of being renewed, repaired, or replaced, operate to condemn such piece of equipment. This warranty is in lieu of all other warranties (including without limiting the generality of the foregoing warranties of merchantability and fitness for a particular purpose), guarantees, obligations or liabilities expressed or implied by the Manufacturer or its representatives and by statute or rule of law. This warranty is void if the Manufacturer's product(s) has been subject to misuse or abuse, or has not been operated or stored in accordance with instructions or if the serial number has been removed. Analytical Technology, Inc. makes no other warranty expressed or implied except as stated above.

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PortaSens II

Portable Gas Leak Detector, Model C16

Table of Contents PRODUCT WARRANTY ...2 SPECIFICATIONS ...4 INTRODUCTION ...5 PORTASENS II ...5 PACKAGE CONTENTS ...6 REFERENCE DRAWINGS ...6 SMART SENSOR ...11 CHANGING THE SENSOR ...11 SENSOR RESPONSE TIMES ...12 GAS INTERFERENCES...13 OPERATION ...15 QUICK START ...15 STARTUP SEQUENCE ...16 GAS CONCENTRATION READING ...17 SOFT KEYS ...17 SHUTDOWN...17 BATTERIES ...18 LED INDICATOR...19 RESPONSE TEST ...20 INLET AND OUTLET EXTENSIONS ...21 ANALOG OUTPUT ...21 OPERATING MODES ...22 Sample Mode ...22 ALARMS...24 LOW FLOW ALARM (“PUMP TROUBLE”) ...25 DEVICE CONFIGURATION ...27 VIEWING THE CONFIGURATION...27 CHANGING THE CONFIGURATION ...27 ALARM SETTINGS...28 Set Point (S.P.)...28 Function (FUNC) ...28 DISPLAY SETTINGS ...31 Range (RANGE) ...31 Blanking (BLANK) ...31 Averaging (AVG) ...31

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SAMPLE MODE SETTINGS ...33 Sampling Time (SAMP) ...33 Measuring Time (MEAS) ...33 Clearing Limit (CLEAR) ...33 SENSOR CALIBRATION ... 35 Zero Calibration (ZERO) ...35 Span Calibration (SPAN) ...35 PRESSURIZED GAS SOURCES...36 ZERO AND SPAN CALIBRATION STEPS ...36 DATA LOGGER ... 38 DATA LOGGER OPERATION AND SETTINGS ...38 Clear (CLEAR) ...38 Interval (INT) ...38 C16LOG ... 41 INSTALLATION ...41 Installing on Windows 7 & 8 ...41 Installing on Windows XP ...41 RS232-to-USB Adapter ...41 Connecting the Device ...41 STARTING C16LOG ...42 Version 2.0 and Higher ...42 Earlier Versions ...42 USING C16LOG...42 Configure Tab ...43 Important Note for Windows, Version 7 and Higher ...43 Download Tab ...45 OUTPUT FILES ...46 MAINTENANCE ... 48 Intake Pump Filter...48 TROUBLE ... 48 SPARE PARTS ... 49 SMART SENSOR MODULES (MODEL H10) ...50

PortaSens II

Portable Gas Leak Detector, Model C16

SPECIFICATIONS Gas Sensor

Accepts H10 “Smart Sensor” gas sensor modules (not included)

Range

Sensor dependent (see Smart Sensor Modules on page 50, or contact ATI)

Display

Backlighted, graphics LCD

Accuracy

Sensor dependent (typically ± 5% of value, limited by cal. gas)

Sensitivity

1% of sensor module range

Repeatability

± 1% of sensor module range

Input/Output

RS-232 for transfer of logged gas readings 0-1 VDC analog (requires optional cable)

Data Logger

1, 5, 10, and 15 minute intervals 12,000 samples (8 days@1 minute interval) C16Log application for transferring data (CD and Online)

Alarms

Three level alarms, configurable for high or low alarm (or disable) Low battery alarm Low flow rate alarm Alarm notifications provided by LCD and beeper

Power

Primary: D-cell battery, alkaline recommended, 75 hours operation Backup: Internal, rechargeable battery, 6 hours operation 115VAC (std.) battery charger (220VAC avail.)

Operating Temp.

-25º to +55º C

Humidity

0-95% Non-condensing

Construction

Glass filled nylon, PVC, and stainless steel

Accessories

10” Flexible Wand, Teflon lined Battery Charger (3) Intake Filters Outlet Barbed Fitting Flow Meter RS-232 Cable (DB9 Female) CD (C16Log downloader) Storage case Bypass-T Fitting (for calibration)

Shipping Weight

3 lbs. (1.4 Kg.)

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PortaSens II

Portable Gas Leak Detector, Model C16

INTRODUCTION PortaSens II The PortaSens II is a rugged, hand-held device used to detect leaks of toxic gas, and also to detect oxygen displacement or deprivation. It adapts quickly to measure different gasses by inserting the appropriate gas sensor module. The modules retain all of the calibration and configuration settings for the target gas, such as the full scale range and alarm settings. The device features a battery powered intake pump with a flexible wand for sampling. Readings and settings are presented on a backlighted, graphics LCD, with four “soft keys”, and a beeper to notify you about alarms and other events. Readings may be recorded and transferred to a PC using a supplied application, C16Log. The program outputs ASCII csv files for importing into applications, like Microsoft Excel®. The application operates on Microsoft Windows ® 98,XP, 2000, and Windows 7 & 8. For more information, see C16Log on page 41. Power is provided from one primary (non-rechargeable), D-cell battery, and switches automatically to a secondary (rechargeable) battery when the primary is removed, or its power drops below an acceptable level1.

1 The internal secondary battery should be charged prior to use if it has been more than three weeks after

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PortaSens II

Portable Gas Leak Detector, Model C16

Package Contents The following items are included. o PortaSens II Gas Leak Detector (Figure 1) o Sampling Wand (Figure 2) o Outlet Tube Barbed Fitting (Figure 2) o Sensor Keeper2 (Figure 6) o Flow Meter (Figure 7) o Storage Case o Spare Alkaline D-Cell battery o Battery Charger o RS-232 Cable o C16Log CD ROM (PC version, only) o Calibration “T”

Reference Drawings

Figure 1. PortaSens II, Front View (ATI-0401)

2 H10 sensors are normally ordered separately.

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PortaSens II

Portable Gas Leak Detector, Model C16

Figure 2. PortaSens II,Rear View (ATI-0403)

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PortaSens II

Portable Gas Leak Detector, Model C16

Figure 3. PortaSens II, Side View (ATI-0402).

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PortaSens II

Portable Gas Leak Detector, Model C16

Figure 4. C16 Port (8-position MINI-DIN, female receptacle)

Table 1. C16 Port Pin Assignments Pin No.

Signal

I/O

Description

1

/CTS

Input

Clear to send - assert to suspend device output.

7

2

/RTS

Output

Request to send – asserted by device before transmit.

8

3

RX

Input

Receive data - device receives data on this pin.

3

4

Sig. Com.

Signal common (note: same as AOut Com.)

5

5

TX

Output

Transmit data – device transmits data on this pin.

2

6

AOut

Output

Analog output – 0-1 VDC output, proportional to gas concentration reading: AOut = gas_rdg/sensor_range * 1.0 VDC

N/C

7

N/C

Not connected.

N/C

8

AOut Com.

Analog output common (note: same as Sig. Com.)

N/C

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DB9 Pin on Cable 03-0201

PortaSens II

Portable Gas Leak Detector, Model C16

Figure 5. H10 Gas Sensor Module (not included)

00-0981 H10 Sensor Keeper Replace Battery every Six (6) Months

Figure 6. Sensor Keeper

Figure 7. Flow Meter

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PortaSens II

Portable Gas Leak Detector, Model C16

SMART SENSOR The PortaSens II measures gas concentration levels using “Smart Sensor” modules, which store their calibration and configuration settings, such as, zero, span, range, and alarm levels. This allows them to be quickly changed to detect leaks of different toxic gasses, or to detect oxygen displacement or deprivation. The modules are calibrated before leaving the factory and require only routine calibration, which may be performed by trained personnel on site using traceable gas standards and methods. A more economical solution may be to return them periodically to the factory for certified calibration. Contact ATI for details about the “Calibration Certification” program for Smart Sensor modules. Figure 8. H10 "Smart Sensor" module. Four modules may be kept in the battery-powered, “Sensor Keeper” (Figure 6 on page 10), which maintains the electro-chemical sensor cell, “on bias”, and ready for use (recommended). Gas sensor modules must be ordered separately. For a complete list of modules and their operating range, see Smart Sensor Modules (Model H10) on page 50. Note Sensors may take up to 12 hours to stabilize (bias) if not stored in the Sensor Keeper, or not installed in the device.

Changing the Sensor Referring to Figure 2 on page 7, loosen the two thumb screws and remove the flow manifold lid on the rear of the device. If a sensor module is already installed, grab the sides with your index finger and thumb, and pull straight up. Slide the new module into the recess, connector first, and rotate it to align the groove on the sensor with the guide in the recess. Press down on the sensor to seat the connector. The face of the sensor module should be flush with the outer surface of the recess. Replace the manifold lid and hand-tighten the thumb screws. Start the device and verify air flow through the sampling wand using the supplied flow meter. See Figure 7 on page 10. If power is on when the sensor is removed, the device displays “SENSOR MISSING”. At startup, and when the sensor is reinstalled with power applied, it displays the entire startup sequence, as detailed in the Startup Sequence on page 16.

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PortaSens II

Portable Gas Leak Detector, Model C16

Sensor Response Times The table below lists the time required to obtain readings of 66%, and 90%, of an instantaneous exposure to various gasses. The times listed are for the sensor only, and do not include travel time through the wand or tubing, or digital damping by the device. They are provided only for estimating the sampling period required for a representative reading. Table 2. Gas Response Times SENSOR TYPE

66% RESPONSE

90% RESPONSE

Oxidant Sensors (except H2O2)

20 seconds

60 seconds

Hydrogen Peroxide

40 seconds

120 seconds

Ammonia

30 seconds

120 seconds

Carbon Monoxide

10 seconds

30 seconds

Hydrogen

20 seconds

60 seconds

Oxygen

15 seconds

45 seconds

Nitric Oxide

10 seconds

20 seconds

Phosgene

70 seconds

300 seconds

Hydrogen Chloride

50 seconds

240 seconds

Hydrogen Fluoride

50 seconds

240 seconds

Hydrogen Cyanide

40 seconds

120 seconds

Hydrogen Sulfide

20 seconds

60 seconds

Nitrogen Dioxide

10 seconds

40 seconds

Sulfur Dioxide

10 seconds

40 seconds

Hydride Gases

30 seconds

70 seconds

Hydrocarbon Gases

40 seconds

90 seconds

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PortaSens II

Portable Gas Leak Detector, Model C16

Gas Interferences Some sensors exhibit a minor sensitivity to non-target gases and vapors. Table 3 lists the crosssensitivity factors of sensors to various, “interference” gases. To use the table, find the sensor type along the top, and then scan down the column for the factor corresponding to one of the interference gases listed on the left. Multiplying the factor times the concentration of the interference gas produces the reading that would be displayed by the device. For example, an SO 2 sensor exposed to 1 PPM of HCN would produce a reading of 0.15 PPM. See notes following the table for additional comments.

Table 3. Cross-sensitivity Factors

Sensor Type NH3

O3

HF

HCI

NH3

--

CO

0.01

0.005

H2

0.002

0.01

NO

0.08

1.5

O2

*

Cl2

-0.5

O3

Interference Gas

CI2

HCl

-0.5

HCN

0.1

HCN

-0.05

H2S

SO2

CO H2

H2O2 O2 NO

NO2

Hydride (4) SiH4

0.01

--

0.1

0.05

-0.05

(0.05)

0.1

--

0.03

-0.06

-0.005

*

0.01 0.01

0.4

0.08

0.1 *

0.09

2.0

*

*

*

*

-0.2

-0.4

1.0

-0.01 (-0.1)

-0.2

0.05

--

1

-0.05

-0.2

-0.4

1.0

(-0.1)

-0.2

-0.005

0.02

-0.06

(-0.01)

-0.2

0.05 (0.2)

HF

0.01

--

0.4

*

(0.04)

-0.05

-0.1

--

0.05

*

-0.5

*

0.014

2

--

*

--

0.3

1

0.5

*

0.0003

0.08

--

-0.08

COCl2 H-C

0.1

0.2

-0.1

0.8 *

0.1

0.05

0.2

0.5

0.1

2

2

--

H2S

1.0

-0.1

-0.1

-0.3

3

NO2

0.08

0.2

0.15

0.2

0.2

0.01

SO2

-0.1

-0.01

-0.01

1

0.5

0.4

0.08

Hydride

1.5

0.2

SiH4

1.5

0.2

--

6

-5.0

-0.3

-0.1

--

-0.001 (-0.1)

0.04

-1

0.1

--

0.42

-0.8

(0.5)

0.1

0.2

0.4

0.1

1

6

-3.5

--

5

2

0.1

0.3

6

2

0.005 (0.5)

--

2

2

-1.5

CO2 CH4 CH3SH

0.3

-0.04

-0.03

-0.1

1

C2H2

0.3 .0005

C2H4 C2H6O

0.015

0.05

0.02

0.002

1.7

0.1

0.1

0.002

0.3

0.1

0.1

0.015

0.015

COCl2

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0.02

0.1

0.005

1

-0.02

0.0001 (0.5)

0.05

1.2

-0.01

(0.1)

0.02

1

-0.07

(0.02)

0.1

0.7 --

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PortaSens II

Portable Gas Leak Detector, Model C16

Notes on Interference Table: 1.

2. 3. 4. 5. 6. 7. 8.

Sensors marked with an asterisk (*) in the oxygen column are 3 electrode sensors that require a minimum of 5% oxygen to operate properly. Hydrogen sensors require oxygen levels at least two times the maximum percent hydrogen value to be measured. The data on the chlorine sensor also applies to bromine, chlorine dioxide, fluorine, and iodine sensors. Data on the hydride sensor refers to arsine, phosphine, diborane, hydrogen selenide, and germane sensors. Response is not exactly 1:1 for all hydrides. Contact ATI for details if exact response is needed. Data in ( ) refers to PPM versions of the hydride sensors relative to phosphine. Response is not exactly 1:1 for all hydrides. Contact ATI for details. The sensor column marked “H-C” stands for hydrocarbon sensors. These include ETO (ethylene oxide), formaldehyde, alcohol, acetylene, and vinyl chloride sensors. Data in this table represents exposures to low PPM levels of the interfering gas. Very high concentrations of any interfering gas may cause either short term or long term response from a sensor. Interference factors may vary over sensor lifetime. Calibration with interference gas is not recommended in most cases. Contact factory for more information. Empty cells in table indicate insignificant cross-sensitivity.

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PortaSens II

Portable Gas Leak Detector, Model C16

OPERATION Quick Start The PortaSens II is simple to operate. After removing the device from the storage case, install a gas sensor module (see Changing the Sensor on page 11) and plug the sampling wand into the inlet port of the manifold (Figure 2 on page 7). Note The “INLET” and “OUTLET” ports on the manifold must not be blocked.

To start the device, press and release button 1 (the green button below the display). You should hear a beep, and the internal pump should begin run. If a sensor is installed, the device reads the sensor memory, performs an internal test, and presents the sensor configuration on a number of review displays, before reaching the main display. Otherwise, the pump motor is turned off, and the display appears as that shown in Figure 10, below. During the startup sequence, you may press the Skip button to advance directly to the main display (the sequence is shown in Startup Sequence on page 16). The Main Display appears at the end of the startup sequence, and is depicted in Figure 9, below. The gas concentration reading appears in large, numeric digits, with the units of measurement on the right, and the gas symbol just below it. The example below shows an ammonia sensor is installed, but the units and symbol depend on the installed sensor. The display also indicates which battery is currently powering the device (see Batteries on page 18 for details about this indication). P

0 OFF

PPM NH3

MENU

SMPL

Figure 9. Main display with ammonia sensor installed. Figure 10 shows the display when a sensor is not installed. If a sensor is installed at this point, the device will present the startup sequence, as described above (and detailed in Startup Sequence on page 16).

P SENSOR MISSING OFF

Figure 10. Sensor missing display. Note A response test is recommended prior to use in the field (see Response Test on page 20).

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PortaSens II

Portable Gas Leak Detector, Model C16

Startup Sequence The startup sequence for a typical device with an ammonia sensor is shown in the table below. The gas symbol, range, and alarm settings will vary according to the installed sensor. No. D1

Display

Description Uploading sensor configuration and calibration settings.

LOADING SENSOR

Testing hardware and software.

D2 SELF CHECK

Tests completed successfully.

D3 SELF CHECK PASSED

D4

100 HOLD

D5

C 

W

HOLD A

HOLD

D8

PPM NH3

NEXT

SKIP PPM NH3

NEXT

SKIP

D9

NEXT

P

Warning set point. The set point is 25 PPM, and the symbol, , indicates the alarm activates at, or above, the set point. Alarm operation is detailed on page 22. Alarm set point. The set point is 50 PPM, and the symbol,, indicates the alarm activates at, or above, the set point. Alarm operation is detailed on page 22.

Device and sensor revision levels.

x.xx y.yy

NEXT

SKIP

0 OFF

Caution set point. The line under C indicates the caution level is set at -20 PPM; the symbol, , indicates the alarm activates at, or below, the set point. Alarm operation is detailed on page 22.

SKIP

Firmware Rev Sensor Rev HOLD

Range setting (full scale). The “Soft Keys” appear along the bottom line (see Soft Keys on page 17).

Minimum and maximum range of the sensor.

Range 50 PPM to 500 PPM HOLD

D10

SKIP

50



SKIP

PPM NH3

NEXT

25



D7

MENU

20 HOLD

D6

NEXT

PPM NH3

PPM NH3

MENU

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SMPL

Main Display shows current gas concentration, units of measure, and gas symbol. The symbol in the upper left indicates which battery is providing power.

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PortaSens II

Portable Gas Leak Detector, Model C16

Gas Concentration Reading The gas concentration reading appears on the device display Range Resolution with the units of measure, and the gas symbol. The range setting of 0.00 to 4.99 0.01 the device determines the resolution of the reading, as shown in the 5.0 to 49.9 0.1 table on the right, and is independent of the units of measure. It is not 50 and above 1 used to limit, or “clip”, readings, but does limit other settings. Averaging is used to stabilize the reading, and Blanking is used to filter small reading fluctuations near zero, and suppress negative readings. See Display Settings on page 31 for details about the operation and configuration of these settings.

Soft Keys The four push buttons on the front panel are context sensitive, which means their function changes according to the requirements of the user interface. The device normally displays a label just above the button to indicate the function that will be performed when the button is pushed3. The button, with its displayed label, is referred to as a “soft key”. Throughout this manual, the term “key” is used most often to refer to the labeled button, and “button” is used when no label appears above it. For example, during the startup sequence above, button 1 (the left most button) is labeled “HOLD”. It is referred to as the “HOLD key” and is used to halt the display sequence. Button 2 is labeled “NEXT”. It is referred to as the “NEXT key” and is used to advance to the next display. Finally, button 4 (the right-most button) is labeled “SKIP”. It is referred to as the “SKIP key” and is used to advance directly to the Main Display.

Shutdown To turn off the device, press and hold the OFF key on the Main Display, D10, until the device displays, “POWER DOWN”, then release the key. No. D10

Display P

0 OFF

Instructions Press and hold the OFF key until the display changes to D11 (approximately 3 seconds).

PPM NH3

MENU

SMPL

Release the key when this display appears.

D11 POWER DOWN

3 Exceptions to this are starting the device (the display is not yet active) and entering Configuration mode (no label

appears above the button).

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PortaSens II

Portable Gas Leak Detector, Model C16

Batteries The primary battery is a standard, alkaline D-cell. It is housed in the handle of the device and will operate the device continuously for approximately 75 hours. If the primary battery becomes discharged, or disconnected, a secondary (rechargeable) battery will supply power for up to 6 hours. The device indicates which battery is currently supplying power by the symbol that appears in the upper left corner of the display. P

0 OFF

PPM NH3

MENU

SMPL

…primary battery …secondary battery …battery charger is connected Power is drawn from the primary battery first. When the primary battery is low, the ‘P’ symbol will flash for about one hour. The device will eventually begin to beep once per minute, before switching over to the secondary battery. When the secondary batter is low, the ‘S’ symbol will flash for about an hour, and again the device will beep once per minute, before the secondary battery is discharged. When both batteries are discharged, the instrument will shut off and not restart until one or both of the batteries have been restored. It is not unusual for power to switch between batteries for a period of time. The primary battery recovers after being switched off, and eventually, recovers enough to be switched back on. This process repeats for some time, until the primary battery is fully discharged. An A/C charger is supplied for the secondary battery. The jack is located under the rubber seal on the side of the device (see Figure 3 on page 8). When charging, the LED will light steady. The device may be operated continuously while charging.

Warning Use only the battery charger supplied by ATI for this device. Connecting a different charger may result in permanent damage to the battery or other electronic components.

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PortaSens II

Portable Gas Leak Detector, Model C16

LED Indicator The LED on the panel indicates battery status. It lights steady when the charge cable is connected. When the cable is disconnected, the LED flashes once every six seconds to indicate the device is capable of starting (one, or both, batteries are ready). If the LED is off, both batteries are discharged, and the device will not start. In this condition, any sensor installed in the device may lose bias, and will require several hours to stabilize after restoring battery power. Table 4 summarizes the battery status indications. Table 4. LED Battery Status Indicator

On (steady)

  

Device is off Charge cable connected Secondary battery charging

Flashing

  

Device is off Charge cable disconnected Battery power is available for start up

Off (steady)

 

Device is on, or, Device is off, charge cable is disconnected, and no battery power is available.

Reminder Keep the sensor modules in the Sensor Keeper when not in use.

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PortaSens II

Portable Gas Leak Detector, Model C16

Response Test A response test is recommended before each use. Table 5 lists methods for generating gas that are appropriate for a target gas. Contact ATI for details on other methods. Table 5. Gas Generation Methods. Target Gas

Quick Test Material and Method

Oxidant Sensors (except H2O2)

Dry calcium hypochlorite or liquid bleach

Hydrogen Peroxide

Sodium bisulfite in plastic bottle

Ammonia Sensor

Household ammonia solution

Carbon Monoxide

Cigarette smoke

Hydrogen

No simple test. Must test with cylinder hydrogen

Oxygen

Unit should read air levels

Nitric Oxide

No simple test. Must test with nitric oxide

Phosgene

No simple test. Must test with phosgene

Hydrogen Chloride

(2) drops of conc. HCl in plastic bottle

Hydrogen Fluoride

Dry calcium hypochlorite or liquid bleach

Hydrogen Cyanide

Sodium bisulfite in plastic bottle

Hydrogen Sulfide

Sodium sulfide in plastic bottle

Nitrogen Dioxide

Dry calcium hypochlorite or liquid bleach

Sulfur Dioxide

Sodium bisulfite in plastic bottle

Hydride Gases

No simple test. Must test with hydride gas.

Hydrocarbon Gases

Rubbing alcohol

Many of these methods produce high gas levels in closed containers. It is best to approach the opening of the container, slowly, with only the tip of the wand, to reduce the level of exposure at the sensor. While a high exposure will not harm the sensor, it may take several minutes for it to recover. Warning Do not draw liquid into the wand - only sample the air space just above the liquid.

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