Gasman User Manual Issue 11 Sept 2015

Instructions specific for use in hazardous areas The following instructions apply to equipment covered by certificate number:

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Baseefa04ATEX0383 Flammable Gas IECEx BAS 05.0038 Flammable Gas Baseefa04ATEX0384 Oxygen or Toxic Gas IECEx BAS 05.0039 Oxygen or Toxic Gas The following information covers all relevant points listed in clause 1.0.6 of the EHSR’s of the ATEX directive.

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The certification marking is as follows: 5.

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1.

2.

The equipment may be used in Zones 1 and 2 for flammable versions and Zones 0, 1, and 2 for toxic and oxygen versions, for Group IIA, IIB, and IIC gases and vapours for Temperature Classes T1, T2, T3 and T4 The equipment is certified for use in ambient temperatures in the range –20°C

to +65°C (-4 to +149 F). The equipment should not be used outside these ranges. Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN60079-0:2004 + Amds 1 & 2, EN60079-1:2004 and EN6007911:2006, as certified by Baseefa. Compliance with gas detection performance standards EN50054, EN50057, EN61779-1, EN50104 and EN50270 has been certified by Lloyd’s Register Repair of this equipment and gas sensor replacement shall be carried out by the manufacturer or in accordance with the procedures in the manual and by trained personnel. If the equipment is likely to come into contact with aggressive substances, then it is the responsibility of the user to take suitable precautions that prevent it from being adversely affected, which may compromise the certification level. The rechargeable battery must only be charged in non-hazardous (safe) areas by connection to the specified Crowcon charger. Only the following cell types may be fitted in the battery compartment of the non-rechargeable battery pack: CR2 of the following brands only: Panasonic, GP, Energiser and Maxell. Do not fit a Duracell battery. The cells must only be changed in a nonhazardous (safe) area. The equipment is not certified for use in atmospheres containing more than 21% oxygen.

From the 1st November 2010, EN6007929 part 1 has been harmonised under the ATEX directive 94/9/EC. Therefore to comply with the ATEX directive, portable apparatus sensing flammable gases should have a functional check with gas before each day of use. Other testing regimes may be employed depending on local circumstances.

Area Classifications: Zone 0:

An area classified as Zone 0 is an area in which an explosive mixture of gas is continuously present or present for long periods.

Zone 1:

An area classified as Zone 1 is likely to have ignitable concentrations of flammable gases, vapours or liquids present under normal operating conditions.

Zone 2:

An area classified as Zone 2 is not likely to have ignitable concentrations of flammable gases, vapours or liquids present under normal operating conditions.

© Copyright Crowcon Detection Instruments Ltd 2015. All rights are reserved. No part of the document may be photocopied, reproduced, or translated to another language without the prior written consent of Crowcon Detection Instruments Ltd.

Safety information: • Read and understand all instructions in the operation section of this manual before use. • Do not substitute components as this may impair intrinsic safety and invalidate warranty. • Observe all warnings and instructions marked on the unit and within this manual. • Observe site health and safety procedures for gases being monitored and evacuation procedures. • Understand the screen display and alarm warnings prior to use. • If this product is not working properly, read the troubleshooting guide or contact your local Crowcon Office or agent.. • Ensure qualified service personnel change sensors and operating system. • Ensure maintenance , service and calibration are carried out in accordance with the procedures in the manual and by trained personnel.

Gasman

Personal Single Gas Monitor Contents Unpacking... 1 I. Introduction... 7 II. Operation... 9 III. Batteries... 14 IV. Alarm indications... 16 V. Fixing Accessories... 18 VI. Flow sampling... 19 VII. Maintenance and Calibration... 23 VIII. PC interface and software... 26 IX. i-module replacement... 28 X. Specification... 30 XI. Accessories and spare parts... 31 XII. Troubleshooting guide... 34 Appendix: Limitations of sensors... 35

Gasman

Unpacking

Gasman

Personal Single Gas Monitor Thank you for purchasing the new Gasman Personal Gas Monitor. Gasman has redefined portable gas monitoring and will give you years of unparalleled service and reliability. Please read the instructions carefully before use. Keep the manual for future reference.

Unpacking Remove the Gasman Personal Gas Monitor from the packaging. The Gasman accessories will be located in the bottom of the box. Check the contents are complete, you should have: • Gasman unit with alligator pocket clip; • A configuration report detailing the sensor installed, alarm settings and a calibration certificate; • Calibration flow cap and tubing; • User manual. Optional battery chargers and other accessories will be packed in a separate box.

Battery check

The Gasman Personal Gas Monitor has two battery options: Li-ion rechargeable or non-rechargeable batteries. The label on the back of the detector will have either NR (non-rechargeable) or R (rechargeable) to indicate which battery option is within the detector.

Rechargeable units Gasman uses a Li-ion battery pack and should arrive with sufficient charge so that the unit can be used straight out the box. However, if this is the first time you have used the Gasman unit, you may need to charge the battery to attain the full operating time. (The actual operating time will depend on the types of sensor installed.) The flammable Gasman will operate for at least 12 hours on a fully charged battery. 1

Unpacking

Gasman

Warning: rechargeable units Only charge the rechargeable Gasman Personal Monitor with a Crowcon Gasman charger. Failure to comply could invalidate safety certification, warranty and safety; and may result in permanent damage to the unit. Non-rechargeable units. Gasman uses a CR2 battery which can be easily field replaced. Ensure only the correct types of battery are fitted to maintain compliance with certification (see Battery check on page 1).

Gasman IR CO2 Personal Single Gas Monitor The Gasman IR CO2 personal single gas monitor an infrared gas sensor for CO2 detection. This version of Gasman is not designed or certified for use in a hazardous area, and the safety certification data in Section X is not applicable. Operation and maintenance of the Gasman IR CO2 is essentially the same as for other Gasman units but with the following points to note. CO2 is present in ambient air at a background concentration of just under 400ppm (0.04%). In any enclosed environment the ambient CO2 concentration will increase as a result of respiration and if the room is poorly ventilated concentrations well in excess of 1000ppm (0.1%) can occur. CO2 levels in the outdoor air will also be enhanced by any emitted CO2 e.g. from vehicle exhausts or boiler flues venting to atmosphere so it is normal to see fluctuating levels of CO2 on the display whether indoors or outside.

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Gasman

Quickstart guide

Quickstart guide 1. Getting started Gasman familiarisation

Gas Sensor

Gas name label

Alarm LEDs

Sounder outlet

Operator Button

Operator LCD Display Screen

Switching on Gasman requires little setting up. Follow these simple steps to get your unit ready for use. 1. Ensure the unit is in clean air. 2. Switch on. Press and hold the operator button for approximately 3 seconds until the red LEDs flash. The operator display screen will light up and the unit will begin a warm up sequence. HS The user should now check the detector goes through the warm up sequence detailed below. In the case of any deviations the Gasman should be returned to your local Crowcon office or Service agent. 2

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Quickstart guide

Gasman warm up sequence a) The Gasman will demonstrate the alarm LEDs, sounder, vibration alerts, and the operator display screen. The sounder may be silenced by pressing the button.

Gasman

LEDs Alarm test Sounder Alarm test

H2S

Vibrator Alarm test

The Gasman screen will show the following display during the warm up sequence. This will take approximately 20 seconds. 0.0

OK ppb ppm vv/v

ppm

Note: these screens may differ depending on what sensor is being used. b) Autozero If Autozero is enabled (default), the unit will display the Autozero confirm screen: the display will alternate between ‘ZERO’ and ‘????’. Press the operator button with a single click to confirm Zero. If the operator button is not pressed within the 10 second time out, Gasman will proceed directly to Run mode without performing Zero. Screen Icons Autozero confirm

Warm up OK

OK

OK

ppm

No Autozero OK ppm

Flashing icon Gasman running normally

AL - 1 Alarms AL - 2 Battery life

0.0 Autozero

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Gasman

Quickstart guide

Confidence signals In normal Run mode, Gasman will emit a short beep accompanied by a blue LED flash every 10 seconds and the OK icon flashes to show operational health. These confidence signals can be disabled using the PC software.

2. In the event of an alarm Alarm signals In the event of gas concentrations exceeding the alarm thresholds for the gas being monitored, Gasman will activate the alarm signals. Alarm signals

H 2S ppm

The red and blue alarm LEDs will flash, the sounder will emit a loud, fast series of beeps, the internal vibrator alarm will activate. The operator screen will display the alarm level and gas reading alternately. See the figure to the left. AL - 1 - Alarm level one AL - 2 - Alarm level two

1. When the gas level returns to normal, press the operator button. This will reset your Gasman unit to normal Run mode. If the gas level is still within alarm limits, the button will have no effect. The Gasman alarm is set to latch by default. The unit will still continue in alarm mode even when the gas level returns to normal, until the button is pressed and the alarm is cleared.

3. Switch off unit and storage Switching off 1. Press and hold the button for 5 seconds until the display shows OFF. The display will count down to switch off.

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Quickstart guide

Gasman

Storing conditions In order to optimise sensor performance and lifetime, your Gasman unit should be stored in a safe, non-hazardous area, at 0-20°C and 20-90% RH.

4. Additional information For battery recharging information go to section III. For fixing accessories go to section V. For sampling section go to section VI. For calibration information go to section VII. For troubleshooting guide go to section XII.

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Gasman

Introduction

I. Introduction Thank you for purchasing the new Gasman Personal Single Monitor. Gasman is a portable Single Gas detector, designed to be carried or worn by individuals working in hazardous environments such as confined spaces. It is suitable for use in classified hazardous areas. Gasman monitors a single gas and displays its reading on a display screen. Alarm warnings are given through a combination of a loud audible alarm, a bright visual alarm of blue/red flashing LEDs and an internal vibrator. Gasman can be fitted with a wide range of modular, or plug and play gas sensors. The sensor carries an intelligent processor which contains calibration and sensor information. Gasman is battery operated and is available with rechargeable batteries or dry cell battery options. The dry cell battery option is only available for toxics and oxygen Gasman units. A battery charger for single and multiple Gasman units is available for rechargeable units, see section XI for more information. At Crowcon we recognised the need for a reliable and robust personal monitoring system, which is both small, light and easy to use. Gasman has a single operator button, and an intelligent user-friendly display with automatic backlight. The gas level is continuously monitored providing normal gas readings, peak readings and time weighted averages (TWA). Gasman is available as a diffusion sampling instrument, see section XI for sampling accessories. Configuration and data/event logging is handled by Crowcon Portables PC software, the PC communication link is provided as a link on the charger interface unit. Gasman’s compact shape and design makes it comfortable to wear, with a non-slip grip for better handling. Extra accessories such as pocket clip, hard hat clip, shoulder strap and chest harness, can be purchased. Gasman has been designed from top to bottom to bring you a lighter, compact design with single button operation for ease of use, maintenance and extreme reliability.

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Introduction

Gasman

i-module gas sensor Gasman uses unique plug and play i-module sensor technology. Each sensor unit incorporates its own intelligent processor holding sensor configuration and calibration data. Different sensors can be purchased, and once inserted, are immediately ready to run. Flammable units are only available with rechargeable batteries. Plug and play will ease maintenance time and cost, and the intelligent modular system will remove the need to calibrate the sensor. Gasman can be reconfigured by purchasing additional pre-calibrated i-modules from Crowcon or your local office. After fitting a new i-module, it is recommended that a gas test is carried out on the detector before use.

Reliable, anti-shock mechanics and robust housing The Gasman housing is built from resilient material, giving it strength and flexibility to withstand the hardest of working conditions, water and dust tight to IP65 with a non-slip grip. If the unit is dropped, there will be no disruption of power or function, ensuring reliability and service for years to come.

Software The internal software in Gasman has been designed and written in accordance with the requirement of IEC 61508 to ensure quality and integrity of operation. Gasman has been designed to give a truly reliable personal gas monitoring system. The internal circuitry includes an independent watchdog. The software monitors for any malfunction within the unit and will display an error warning to the user should they occur.

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Gasman

Operation

II. Operation 2.1 Switch-on sequence 1. Ensure the unit is in clean air. NB. For CO2 detectors see zeroing, Section VII.

2. Switch on Press and hold the operator button for approximately 3 seconds until the red LEDs flash. The instrument begins with testing all the LCD segments on the operator display screen, the red and blue alarm LEDs, sounder and internal vibrator alert. The sounder may be silenced by pressing the button. The unit enters a warm up mode and displays a sequence of screens, see page 3 for more details. At the end of warm up, the Autozero menu will be displayed. The Autozero function can be disabled or set to run automatically, without user confirmation: Autozero will not appear. See section VIII PC Interface and software.

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Battery check Use this time to check there is sufficient charge in the battery pack

Calibration check During the warm up sequence, if the next calibration date is due in less than 31 days, ‘CAL - nn’ will be displayed (where nn is the number of days to the next calibration). If calibration is already overdue, the Gasman unit will display a warning message ‘CAL’. The instrument can still function, but it is strongly recommended the unit is sent for calibration as soon as possible. Press the button to continue to Run mode. The Gasman can be set, using Portables PC software, to lock out in the event of the calibration due date expiration in order to prevent further operation of the detector until a calibration is preformed.

3. Autozero Press the operator button with a single click to confirm If Autozero Autozero. Flammable and toxic units will be set to read zero NB. fails, a warning and oxygen units set to read 20.9%. If the operator button message will be displayed. is not pressed within 10 seconds Gasman will proceed directly to normal operation without performing a zero. Switch off To switch off the unit, press and hold the operator button for 5 seconds. The display will count down from 5 until the unit counts down to shut off. 9

Operation

Gasman

2.2 Run mode

The Gasman unit displays the gas reading on the operator display screen. A typical display is shown below: OK ppm

The sensor channel will display the current value of the gas being monitored and the unit of measurement, the ‘OK’ symbol will flash indicating unit is working correctly. Familiarise yourself with the gas being monitored in your unit. Ensure you understand site health and safety procedures. For information on Peak and TWA readings, go to section 2.4.

Screen Icons Warm up

OK

Flashing icon Gasman running normally

AL - 1 Alarms AL - 2 Battery life

0.0 Autozero

Confidence signals To reassure users the unit is working correctly, the Gasman unit will emit a short confidence beep accompanied by a blue LED flash every 10 seconds and the OK icon will flash continuously.

2.3 Display symbol guide Battery Full

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A full battery is represented by a battery icon showing full three bars. A low battery charge will show 1 bar. When zero bars are shown the battery icon flashes and the sounder will emit warning beeps. If the battery becomes too low for operation the Gasman will switch off. A low battery warning will alarm prior to switch off.

TWA alarm Gasman will display the TWA alarm for toxic gases when the 15 minute or 8 hour Time Weighted Average alarm threshold is passed. Gasman will display ‘LTWA’ and ‘STWA’. When a TWA alarm threshold is reached the TWA alarm cannot be cleared.

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Gasman

Operation

2.4 Display options

Gasman provides four additional selectable displays: Peak display When Peak mode is selected the instrument shows the highest value for flammable and toxic gases, or the lowest value for oxygen since switch on or last Peak Reset. This is useful for vertical entry checks where the Gasman can be lowered down the shaft rather than using a sampling tube and for viewing peak exposure at the end of a shift. TWA display Shows the 15 minute and 8 hour TWA, for toxic gases, monitored since last turn on. Peak Reset Before a Peak entry test is performed select this menu option to clear any previously stored Peak value.

0.0

Zero Performs Zero on your Gasman unit. (Please ensure you are in clean air).

How to display the menu 1. To view the additional display option menu, double-click the button. The menu icons will appear on the screen, as shown below.

H2S

OK

OK

ppm

0.0 0.0

ppm

Note: Only toxic gas monitoring units will display the TWA menu option.

2. Press the operator button with a single click to scroll across the list. When the underscore appears under your choice, double-click the operator button. This will select the option. If Peak or TWA is selected, Gasman will display the icon on the operator screen. 11

Operation

Gasman

Peak test When performing a Peak test, such as a vertical entry check, previous readings can be cleared by selecting the Peak Reset menu option .

1. Scroll menus

2. Select Peak display 0.0

OK

OK

ppm

ppm

Zero To perform Autozero, select the Zero function from the menu. When Zero is completed, the instrument will return to normal Run mode. 3. Run mode The Gasman is now ready to use. Familiarise yourself with the gas being monitored in your unit and make sure you understand site health and safety procedures in the event of alarm conditions.

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Gasman

Operation

2.5 Logging Gasman incorporates both data and event logging which can be accessed using the RS232 communications link available with the Single Way Charger Interface (part No.C01940), using Crowcon Portables PC software. See section VIII. Data is recorded every minute (this rate can be adjusted using the PC software). The log can record 900 hours of data at 1-minute intervals. Gasman also records the time and date for a number of operating and diagnostic events including: • Switch on and switch off; • Level 1, Level 2 and TWA, alarm on, alarm off and the peak level during the alarm; • Zero, calibration and gas test with success or failure; • Flammable sensor saver on and off; • The battery condition is logged every switch on and switch off while the instrument is operating, and certain configuration changes are also logged; • The Event log can record over 4800 events.

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Batteries

Gasman

III. Batteries 3.1 Rechargeable batteries

Recharge time for the Li-ion batteries is less then 6 hours (less, if they are not fully discharged). Rechargeable batteries will typically last 12+ hours for flammable units.

3.2 Gasman Charging Unit There are 3 models of charging units available for Gasman; a single way drop in charger unit, a single way charger unit with integral PC Interface, and a multiway charger unit. The multiway charger unit can accommodate up to 5 Gasman units. Note: the multiway charger unit does not have a PC interface option. The charger units are powered by a nominal 12 V dc input. Power Supplies are available with UK, EUR or US pins, alternately a universal 90-260 V power supply is available for any other configuration. The multiway charger includes a universal power supply. A vehicle lighter socket lead can also be supplied, please see section XI Parts and Accessories. Communications and charging are only permitted via Crowcon charger/ charger-interface C01940.

Charging the batteries Power 1. Ensure you are in a supply safe area. 2. Plug the charger power supply into a mains socket, and connect to the 12 V dc charger lead. 3. To charge your Gasman, simply drop the Gasman into the charger in an upright position with the screen facing outwards, see diagram below: 14

Gasman

Batteries

The Gasman should normally be switched Power supply off for charging. During charging the red LED on the front of the charger unit will be lit. When 12 V dc charging is complete the red LED is extinguished. During charging, the display will show the battery icon sweeping from empty to full. On removing Gasman from the charger unit, if the Gasman is on, the display icon will update in 20 seconds to show actual charge state. Chargers with dual LEDs are no longer suitable for use with the current Gasman. We recommend that such chargers be replaced with the newer model shown above (see Section XI, Accessories and spare parts, p32). H2S

The charging time will be longer if the unit is switched on during charging.

When Gasman is fully charged and switched on the battery icon will display three full bars.

3.3 Changing rechargeable batteries

It is recommended that rechargeable batteries should be changed by an authorised Crowcon service centre only.

3.4 Non-rechargeable batteries

Gasman uses a Lithium Cell battery pack which will give up to two years of operation. Always switch the Gasman off before opening the case to change the battery.

To replace the battery, ensure you are in a safe, non-hazardous area. Remove the back cover and remove the battery*. Insert the replacement battery into the instrument and securely fasten the back cover. Note: When a non-rechargeable detector is placed in the charger/charger interface the red LED will not illuminate and the detector will not charge. * Note: later versions of the Gasman will have a tab in place to aid removal of the battery. 15

Alarm indications

Gasman

IV. Alarm indications Gasman provides two instantaneous alarm levels, designated level 1 and level 2. For toxic gas sensors, there are also two TWA alarms, one for short term exposure (STEL): based on a 15 minute time weighted average, and the second TWA alarm is for long term exposure (LTEL): based on a 8 hour time weighted average. Alarm configurations are set via the Crowcon Portables PC software. The following settings can be made: Alarm thresholds for each sensor: Level 1 and level 2 instantaneous alarms. Alarm trigger: This can be set to rising levels of gas concentration, or as falling. Oxygen units are set to falling for deficiency monitoring. Alarm latching: Alarms can be set to be latched or unlatched. Latched alarms will require the button to be pressed in order to clear the alarm once the hazard has passed. This is the default setting. Unlatched alarms will clear automatically when the gas hazard has passed, but not until then. Alarm mute: The sounder can be set to mute for level 1 alarm only; pressing the operator button during an alarm condition i.e. presence of hazardous gas, will silence the sounder and stop the vibration alarm. The alarm LEDs will continue to flash. Alarm sounder tone: Different distinctive tones can be selected for the each alarm condition to achieve the best performance for the monitoring conditions available. In the event of a Time Weighted Alarm (TWA) In the event of the 15 minute or the 8 hour TWA being triggered, Gasman will go into alarm and display a TWA warning with the toxic gas readings. Neither the 15 minute nor the 8 hour TWA alarm can be cleared. 16