ToxiLtd® Single Gas Detector Reference Manual

ToxiLtd
®
Single Gas
Detector
Reference
Manual
Biosystems LLC
651 South Main Street
Middletown, CT 06457
(800) 711-6776
(860) 344-1079
Fax (860) 344-1068
Part number 13-266
Version 1.70
18DEC2006
0
THE TOXILTD® PERSONAL PORTABLE GAS DETECTORS
HAVE BEEN DESIGNED FOR THE DETECTION AND
MEASUREMENT OF POTENTIALLY HAZARDOUS
ATMOSPHERIC CONDITIONS.
IN ORDER TO ASSURE THAT THE USER IS PROPERLY
WARNED OF POTENTIALLY DANGEROUS ATMOSPHERIC
CONDITIONS, IT IS ESSENTIAL THAT THE INSTRUCTIONS
IN THIS REFERENCE MANUAL BE READ, FULLY
UNDERSTOOD, AND FOLLOWED.
ToxiLtd® Reference Manual
Biosystems Part Number 13-266
Version 1.70
Copyright 2006
by
Biosystems LLC
Middletown, Connecticut 06457
All rights reserved.
No page or part of this operation manual may be
reproduced in any form without written permission of
the copyright owner shown above.
Biosystems reserves the right to correct typographical
errors.
1
Table of Contents
Certifications........................................................................................ 3
Warnings and Cautions ...................................................................... 3
A.
B.
Signal Words ......................................................................................................... 3
Warnings................................................................................................................ 4
1. Overview......................................................................................... 5
1.1
Methods of sampling .......................................................................................... 5
1.2
Sensors.............................................................................................................. 5
1.2.1
Sensor ranges and resolutions. .................................................................. 5
1.2.2
ToxiLtd O2 warm-up phase ......................................................................... 5
1.2.3
F1: Missing sensor during startup............................................................... 5
1.3
Alarm logic ......................................................................................................... 5
1.3.1
Gas alarms................................................................................................. 5
1.3.2
Silence warning alarms .............................................................................. 6
1.3.3
Calibration due notices ............................................................................... 6
1.3.4
Low battery alarms ..................................................................................... 6
1.4
Design components ........................................................................................... 6
1.5
Standard accessories......................................................................................... 6
1.6
Value pack kits................................................................................................... 7
2. Field Operation .............................................................................. 7
2.1
Turning the ToxiLtd on ....................................................................................... 7
2.1.1
ToxiLtd O2 start up sequence ..................................................................... 7
2.1.2
ToxiLtd start up sequence .......................................................................... 7
2.1.3
Start up sequence ...................................................................................... 7
2.2
Functions ........................................................................................................... 8
2.2.1
View max gas readings .............................................................................. 8
2.2.2
View gas alarm levels................................................................................. 9
2.3
Calibration due notices....................................................................................... 9
2.4
Low battery alarms............................................................................................. 9
2.5
Turning the ToxiLtd off ....................................................................................... 9
2.6
Sampling.......................................................................................................... 10
2.6.1
Sample draw kit usage ............................................................................. 10
3. Calibration.................................................................................... 10
3.1
Verification of accuracy .................................................................................... 10
3.1.1
Verifying accuracy and response: ToxiLtd O2........................................... 10
3.1.2
Verifying toxic sensor performance........................................................... 11
3.2
Effect of contaminants on ToxiLtd sensors ....................................................... 11
3.2.1
Effects of contaminants on oxygen sensors.............................................. 11
3.2.2
Effects of contaminants on toxic gas sensors ........................................... 11
3.3
Fresh air/zero calibration.................................................................................. 12
3.4
Functional (bump) testing for ToxiLtd with toxic gas sensor.............................. 12
3.5
Span Calibration for ToxiLtd with toxic gas sensor ........................................... 13
3.6
Failure to calibrate............................................................................................ 14
3.6.1
Fresh air/zero calibration failure................................................................ 14
3.6.1.1
3.6.2
3.6.2.1
3.6.2.2
Reason for fresh air/zero calibration failures....................................................14
Span calibration failure ............................................................................. 14
Sensor out of range (no CAL)..........................................................................14
No gas............................................................................................................14
2
3.6.2.3
Causes for span cal failure..............................................................................14
3.6.3
Forced fresh air/zero calibration ............................................................... 14
3.7
Fresh air/zero calibration in a contaminated atmosphere ................................. 15
4. Event logging............................................................................... 15
4.1
Initiating communications ................................................................................. 15
Appendices ........................................................................................ 16
Appendix A: Sensor Cross-Sensitivity Chart ................................................................ 16
Appendix B: Default toxic sensor calibration gas settings ............................................ 16
Appendix C: Calibration Frequency ............................................................................. 17
Biosystems Standard Warranty Gas Detection Products............. 18
Certifications
®
The ToxiLtd carries the following certifications:
UL and c-UL, Class I, Division 1, Groups A,B,C,D, Temp Code T4.
UL Class II, Division 1, Groups E,F,G
ATEX Certification:
II 2 G EEx ia IIC T4
UL International DEMKO A/S 04 ATEX 0327520
IECEx Ex ia IIC T4
CQST (China)
Warnings and Cautions
A.
Signal Words
The following signal words, as defined by ANSI Z535.4-1998, are used in the ToxiLtd
Operator’s Guide.
indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
indicates a potentially hazardous situation, which if not
avoided, may result in moderate or minor injury.
CAUTION used without the safety alert symbol indicates a potentially
hazardous situation which, if not avoided, may result in property damage.
3
B.
Warnings
1.
The ToxiLtd personal, portable gas detectors have been
designed for the detection of either oxygen deficiencies or specific toxic gas
accumulations. An alarm condition indicates the presence of a potentially lifethreatening hazard and should be taken very seriously.
2.
In the event of an alarm condition it is important to follow
established procedures. The safest course of action is to immediately leave the
affected area, and to return only after further testing determines that the area is
once again safe for entry. Failure to immediately leave the area may result in
serious injury or death.
The accuracy of ToxiLtd instruments equipped with a toxic
gas sensor should be checked periodically with known concentration calibration
gas. Failure to check accuracy can lead to inaccurate and potentially dangerous
readings. ToxiLtd instruments equipped with an oxygen sensor should be
periodically calibrated in fresh air.
A ToxiLtd equipped with a toxic gas sensor that fails
calibration may not be used until testing with known concentration test gas
determines that accuracy has been restored, and the instrument is once again fit
for use. Instruments equipped with an oxygen sensor that fail calibration may
not be used until testing with fresh air determines that accuracy has been
restored and the instrument is once again fit for use. An instrument that cannot
be calibrated or is found to be out of tolerance must be replaced immediately.
Do not reset the calibration gas concentration setpoints in
the ToxiLtd unless the concentrations of your calibration gas differ from the
concentrations of the calibration gas that is normally supplied by Biosystems for
use in calibrating the ToxiLtd.
Use of non-standard calibration gas and/or calibration kit
components when calibrating the ToxiLtd can lead to dangerously inaccurate
readings and may void the standard Biosystems warranty.
Biosystems offers calibration kits and long-lasting cylinders of test gas
specifically developed for easy calibration. Customers are strongly urged to
use only Biosystems calibration materials when calibrating the ToxiLtd.
Substitution of components may impair intrinsic safety.
3.
4.
5.
6.
7.
For safety reasons the ToxiLtd must be operated by
qualified personnel only. Read, understand and follow the directions set forth in
this reference manual before operating the ToxiLtd.
The ToxiLtd has been tested for intrinsic safety in
9.
Explosive Gas/AIR (max. 21.0% O2).
8.
10.
Do not open the ToxiLtd. There are no user serviceable
parts inside of the instrument.
4
1.
1.1
Methods of sampling
The ToxiLtd may be used in diffusion
mode, or with the manual sample draw kit
that is available separately. In either
mode, the atmosphere must reach the
sensor for the instrument to register a
reading. In diffusion mode, the
atmosphere reaches the sensor by
diffusing through the sensor port on the
front of the instrument. Normal air
movements are enough to carry the
sample to the sensor. During remote
sampling, the gas sample is drawn into
the sensor compartment through the
probe assembly and a length of tubing.
See section 2.6 for more details on
sampling the atmosphere.
1.2
Sensors
Toxic sensor versions of the ToxiLtd use
an electrochemical toxic gas sensor. The
ToxiLtd O2 uses a galvanic oxygen
sensor. Both types of sensor have been
designed to minimize the effects of
common interfering gases. These
sensors provide accurate, dependable
readings for gases commonly
encountered in industrial applications.
1.2.1 Sensor ranges and resolutions.
Overview
The ToxiLtd is a single sensor gas
detector that is designed to detect either
oxygen (O2) or one of a variety of toxic
gases. The ToxiLtd’s sensor type is
shown on the front of the instrument and
is also shown on the display during the
startup sequence.
ToxiLtd gas detectors are disposable
instruments that are designed to operate
for 2 full years from the date of activation.
ToxiLtd models equipped with an oxygen
sensor must be activated within 6 months
of the manufacturing date. If the
instrument is not turned on by the “must
be activated by date”, the instrument will
activate itself and the 2-year countdown
will begin automatically.
Upon delivery, the screen of the ToxiLtd
will be blank except for the negated horn
icon.
If the “must be activated by date” has
passed and the instrument has activated
itself, the instrument will show three lines
on the screen with the negated horn icon.
Sensor
CO
H2S
SO2
O2
Contact Biosystems or your distributor
if three lines are displayed when you
first receive the detector.
The ToxiLtd is delivered with a preinstalled lithium thionyl chloride (LiSOCl2)
battery capable of powering the
instrument for the full 2 years of the
instrument’s operating life. After the 2year instrument life cycle is up, the
instrument will turn itself off.
Note: Early production runs of the
oxygen version of the ToxiLtd were
referred to as the “OxyLtd”. The
instructions contained in this manual
that refer to the ToxiLtd Oxygen (O2)
are valid for the OxyLtd with similar
instrument firmware.
Range
0-1000 PPM
0 -200 PPM
0 – 20 PPM
0-30%/Vol.
Resolution
5 PPM
2 PPM
0.1 PPM
0.2%/Vol.
1.2.2 ToxiLtd O2 warm-up phase
The ToxiLtd O2 requires a one-hour
warm-up phase from the moment of
activation until actual use. See section
2.1.1 for further details.
1.2.3 F1: Missing sensor during
startup
If the ToxiLtd fails to detect the sensor
during startup, it will show “F 1” with the
caution symbol following the software
version screen at startup. This is covered
in greater detail in section 2.1.3.
1.3
Alarm logic
1.3.1 Gas alarms
When an alarm set point is exceeded a
loud audible alarm sounds, the bright red
LED alarm light flashes and the display
will indicate whether it is a warning alarm
5
or a more serious danger alarm. If the
ToxiLtd is equipped with the optional
vibrating alarm, it will also be activated
during an alarm condition.
For oxygen sensor-equipped instruments,
the warning alarm is sounded for oxygen
enrichment and the danger alarm is
sounded for oxygen deficiency.
Instruments equipped with a toxic gas
sensor have two ascending alarm set
points. The lower alarm set point is the
warning alarm, while the higher alarm set
point is the danger alarm.
activated when the battery voltage is
reduced to specific levels.
For more details on the battery alarm,
see section 2.4 below.
1.4
Design components
Case: The instrument is enclosed in a
solid PC (polycarbonate) case with TPE
(rubber) overmold.
Front face: The front face of the
instrument houses the LCD display,
MODE button, sensor port, LED and
audible alarm port.
LCD display: The liquid crystal display
(LCD) displays gas readings, messages
and other information.
Visual alarm (LED) / IrDA port: A bright
red LED (Light-Emitting Diode) alarm light
provides a visual indication of the alarm
state. The LED also functions as the IrDA
port.
MODE button: The large push-button on
the front of the instrument is called the
MODE button. The MODE button is used
to turn the ToxiLtd on and off, to view the
MAX screen and to initiate the automatic
calibration sequence.
Sensor port: The sensor port is located
at the upper left corner of the instrument.
A filter prevents unwanted contaminants
from entering the sensor.
Audible alarm orifice: A cylindrical
resonating chamber contains the loud
audible alarm.
Bottom surface: The belt clip attaches to
the bottom surface of the instrument.
Sensor Warning Alarm Danger Alarm
CO
35 PPM
100 PPM
H2S
10 PPM
20 PPM
SO2
2 PPM
5 PPM
O2
23.5%/Vol.
19.5%/Vol.
Default Warning and Danger Alarm
Settings
In the event of an
alarm condition it is important to follow
established procedures. The safest
course of action is to immediately
leave the affected area, and to return
only after further testing determines
that the area is once again safe for
entry. Failure to immediately leave the
area may result in serious injury or
death.
1.3.2 Silence warning alarms
The ToxiLtd’s audible and vibrating (if so
equipped) alarms can be turned off during
an alarm condition by pressing the MODE
button if this function has been enabled
with BioTrak software. The visual warning
alarm light and readings will continue to
indicate the alarm.
1.3.3 Calibration due notices
The ToxiLtd includes calibration due
notices that are displayed when the
instrument is due for calibration.
For more information on the calibration
due notices, see section 2.3 below.
1.3.4 Low battery alarms
The battery in the ToxiLtd is designed to
power the instrument for a full two years
from the date it is turned on. In the
unlikely event that the battery runs out of
power prior to the completion of the 2-year
operational lifespan, the ToxiLtd includes
two battery warning alarms that are
Figure 1. Exterior front view.
1.5
Standard accessories
Standard accessories with every ToxiLtd
include installed sensor and battery,
6
reference manual and calibration/sample
draw adapter.
1.6
Value pack kits
ToxiLtd value packs include all standard
accessories, calibration fittings, 34-liter
cylinder of calibration gas, and fixed flow
rate regulator in a foam-lined, hard-shell
carrying case.
2.
instrument chirps, then release the MODE
button.
2.1.1 ToxiLtd O2 start up sequence
ToxiLtd O2 models require a one-hour
warm-up period prior to use. Once the
MODE button is pressed and held for 5
seconds, the instrument will begin a 60minute countdown. The instrument will be
ready to use in 60 minutes.
Field Operation
Field operation of the ToxiLtd is controlled
entirely through the MODE button, which
is located on the front of the instrument.
The MODE button is used to turn the
ToxiLtd on and off (if desired), to access
MAX gas readings for the current session
and to initiate the fresh air/zero and span
calibration sequences.
2.1
Turning the ToxiLtd on
The ToxiLtd is effectively disabled when it
leaves the Biosystems Factory. Upon
arrival, the screen will be blank other than
the negated horn icon.
→
When the warm-up period concludes, the
instrument will show three dashes with
the negated horn symbol.
Once three lines are shown, press and
hold the MODE button for 1 second to
start the instrument. The start-up
sequence will begin. Proceed to section
2.1.3.
2.1.2 ToxiLtd start up sequence
ToxiLtd models equipped with a toxic gas
sensor do not require a warm up period.
Upon arrival, press and hold the MODE
button for 5 seconds. The ToxiLtd will
immediately proceed to the start-up
sequence.
2.1.3 Start up sequence
During the start-up sequence, the
instrument performs an electronic self test
that will take approximately 30 seconds to
complete. During the self-test sequence,
the audible alarm will “chirp” and all
sections of the display will be lit.
Note: If the ToxiLtd arrives with three
lines showing on the screen, it is an
indication that the “must be activated
by date” has passed and the
instrument has already turned itself on.
Contact Biosystems or your distributor
for further instructions.
The ToxiLtd is a disposable instrument.
Once activated, it will operate
continuously for 24 months. In the
unlikely event that the battery runs out of
power prior to the completion of the 2-year
operating cycle, the ToxiLtd must be
returned to Biosystems or an authorized
service center for the installation of a new
battery.
Do not open the
ToxiLtd. There are no user serviceable
parts inside of the instrument.
To initialize the ToxiLtd press and hold the
MODE button for 5 seconds until the
The ToxiLtd will then display the “on”
screen followed by software version.
→
If the sensor has become disconnected or
removed from the instrument during
7
shipping, the screen will show “F 1” with
the caution symbol following the software
version screen.
Following the danger alarm level, the
ToxiLtd will begin standard operation and
will display the number of months
remaining in the 24-month lifecycle of the
instrument. During an alarm condition,
the instrument will display the current gas
reading.
For the first full month of use following
initialization the display will show 23 full
months remaining.
If “F 1” is shown, the instrument will
automatically shut down and show three
lines on the screen.
If “F 1” is shown and the ToxiLtd shuts
itself down, contact Biosystems or you
local distributor for further information.
Once the sensor is recognized, the serial
number screens will be shown. Note that
the 6 digit serial number is shown on two
screens. In this case, the instrument
serial number is 123456.
Once the instrument determines that
there are 90 days of operation remaining,
the instrument will indicate 90 days and
proceed to count the days down until the
instrument reaches 0 days and turns itself
off.
→
→
2.2
Functions
As stated above, the ToxiLtd will show the
amount of time remaining in the product’s
lifecycle during normal operation unless
there is an alarm present. The ToxiLtd
will display gas readings while it is in
alarm.
2.2.1 View max gas readings
From the months remaining or the current
gas readings screen, press the MODE
button once to view the MAX gas values
screen. The MAX figure represents the
highest gas value reading that has been
recorded by the instrument during the
current operating session or during the
last 24 hours of operation.
The sensor type will be shown next.
During the display of the warning alarm
level, the LED alarm light will flash twice
and the audible warning alarm will sound
twice. The audible warning alarm is slow
and warbling.
During the display of the danger alarm
level, the LED visual alarm will flash twice
and the audible danger alarm will sound
twice. The audible danger alarm is louder
and a higher frequency than the warning
alarm.
Note: To reset the max readings level,
fresh air/zero calibrate the instrument
as discussed in section 3.3.
8
The MAX screen will be shown for 5
seconds. The instrument will then
automatically return to the months or days
remaining screen (unless an alarm
condition is present).
thirty days. Different versions of software
may have different calibration intervals.
2.4
Low battery alarms
When the ToxiLtd determines that there
are less than 7 days of battery life
remaining, the battery icon will be lit.
Note that “MONTHS” or “DAYS” and
the number of months or days of
operating life remaining are still shown
when the battery icon is lit.
2.2.2 View gas alarm levels
To view the current gas alarm levels, from
the current gas reading screen, press and
hold the MODE button for about 5
seconds until the display test screen is
showed.
When the ToxiLtd determines that there
are less than 8 hours of battery life
remaining, the battery icon and the
triangular warning symbol on the LCD will
be shown. At this point the audible alarm
will begin to chirp once per minute.
When the battery reaches a level where it
can no longer power the instrument, the
ToxiLtd will sound the high/danger audible
alarm while displaying OFF with the
danger, caution and battery icons.
Release the MODE button. The software
will proceed through the software version
and serial number screens before
showing the alarm levels.
→
The instrument will then return to normal
operation and display the months
remaining screen.
2.3
Calibration due notices
When the ToxiLtd is due
for fresh air calibration “0CAL will be displayed at
the bottom of the current
gas readings screen along
with the warning symbol.
When the ToxiPro is due
for a bump test the
calibration bottle icon will
be displayed at the bottom
of the current gas readings
screen.
When the ToxiPro is due
for span calibration the
calibration bottle icon will
be displayed at the bottom
of the current gas readings
screen along with the warning symbol.
The default fresh air/zero calibration
interval for the O2 version of the ToxiLtd
with instrument firmware version d7.0 is
Press MODE to turn the instrument off. If
the MODE button is not pressed, the
instrument will remain in alarm for as long
as it can before shutting itself down. The
following screen will be shown after the
instrument is shut down.
In the event that the instrument actually
shuts itself down due to low battery levels,
it will automatically launch the IrDA
connection subroutine so that data in the
instrument may be downloaded to
BioTrak.
2.5
Turning the ToxiLtd off
To turn the ToxiLtd off, press and hold the
MODE button. After 5 seconds, the
instrument will light up all segments on
the display. After 3 more seconds, the
display will show “IrDA”. Continue to hold
the MODE button for an additional 15
9
seconds after “IrDA” is shown. The
following screen will be shown after the
instrument is shut down.
the bulb for every one foot of sampling
hose for the sample to reach the
sensors. Then continue to squeeze
the bulb for an additional 45 seconds
or until readings stabilize.
6. Note the gas measurement readings.
CAUTION: Hand aspirated remote
sampling only provides continuous
gas readings for the area in which the
probe is located when the bulb is
being continuously squeezed.
Note: Each time a reading is desired, it
is necessary to squeeze the bulb a
sufficient number of times to bring a
fresh sample to the sensor
compartment and to then continue
squeezing the bulb for an additional 45
seconds or until readings stabilize.
Note: Turning the ToxiLtd off will have
no effect on the operational life of the
instrument. The ToxiLtd will operate
for 24 months from the activation date
regardless of whether the instrument is
turned on or off.
2.6
Sampling
The ToxiLtd may be used in either
diffusion or sample-draw mode. In either
mode, the gas sample must enter the
sensor compartment for the instrument to
register a gas reading.
In diffusion mode, the atmosphere
reaches the sensor by diffusing through
the sensor port on the front of the
instrument. Normal air movements are
enough to carry the sample to the sensor.
The sensor reacts quickly to changes in
the concentration of the gas being
measured.
It is also possible to use the ToxiLtd to
sample remote locations with the handaspirated sample-draw kit that is available
separately. During remote sampling, the
gas sample is drawn into the sensor
compartment through the probe assembly
and a length of tubing.
2.6.1 Sample draw kit usage
1. Connect the shorter piece of hose
from the squeeze bulb to the sample
draw adapter. Connect the longer end
of the hose to the sample probe.
2. Attach the sample draw adapter to the
ToxiLtd.
3. Cover the end of the sample draw
probe assembly with a finger, and
squeeze the aspirator bulb. If there
are no leaks in the sample draw kit
components, the bulb should stay
deflated for a few seconds.
4. Insert the end of the sample probe into
the location to be sampled.
5. Squeeze the aspirator bulb several
times to draw the sample from the
remote location to the sensor
compartment. Allow one squeeze of
3.
Calibration
The ToxiLtd features fully automated
calibration functions. Instruments
equipped with an oxygen sensor only
require the fresh air/zero calibration, while
toxic sensor-equipped instruments require
both fresh air/zero and span calibrations.
The MODE button is used to initiate the
automatic calibration sequence.
Calibration adjustments are made
automatically by the instrument.
3.1
Verification of accuracy
Biosystems recommends regular
verification of accuracy for all of our gas
detection products in order to maximize
worker safety. For a discussion of
Biosystems’ Calibration
Recommendations, see Appendix C.
3.1.1 Verifying accuracy and
response: ToxiLtd O2
The ToxiLtd O2 uses a galvanic oxygen
sensor that puts out a continuous
electrical signal (as long as oxygen is
present), which the detector converts into
a reading. As the oxygen sensor ages,
the output signal tends to diminish
gradually, which can eventually lead to
erroneous readings.
The display on the ToxiLtd O2 only shows
a reading when it is in alarm, so it is
difficult to know exactly when to fresh
air/zero calibrate the detector.
Biosystems recommends that the fresh
air/zero calibration be performed regularly
on the ToxiLtd O2. The fresh air/zero
10
calibration takes less than ten seconds to
perform and does not require an external
gas source when it is performed in a fresh
air environment.
Simply take the ToxiLtd O2 to an area
where the atmosphere is known to be
fresh and perform a fresh air/zero
calibration adjustment as discussed below
in section 3.3. If fresh air is not available,
see section 3.7 below for instructions on
fresh air calibration in contaminated air.
Biosystems also recommends that the
response of the oxygen sensor be
regularly verified by either of the two
following methods:
• Expose the O2 sensor to a known
concentration of gas containing less
than 19% oxygen. If the descending
oxygen alarm is set to 19.5% the
instrument should go into alarm a few
seconds after the gas reaches the
sensor face.
• Breath test: Hold your breath for 10
seconds, then slowly exhale directly
onto the face of the sensor (in the
same way you would to fog up a piece
of glass). If the descending oxygen
alarm is set to 19.5%, the instrument
should go into alarm after a few
seconds.
3.1.2 Verifying toxic sensor
performance
Verification is a two-step procedure for
ToxiLtd instruments equipped with a toxic
gas sensor.
Step one is to take the ToxiLtd to an area
where the atmosphere is known to be
fresh and perform a fresh air/zero
calibration as discussed below in section
3.3. The fresh air/zero calibration takes
less than ten seconds to perform and
does not require an external gas source
when it is performed in a fresh air
environment.
Step two is to test sensor response by
exposing the sensor to a test gas of
known concentration. This is known as a
functional (bump) test. Readings are
considered to be accurate when the
display is between 90%* and 120% of the
expected values as given on the
calibration gas cylinder. If readings are
accurate, there is no need to adjust your
gas detector. See section 3.4 for further
details concerning the functional/bump
test.
If the readings are inaccurate, the
instrument must be span calibrated before
further use as discussed in section 3.5.
* The Canadian Standards Association
(CSA) requires the instrument to
undergo calibration when the
displayed value during a bump test
fails to fall between 100% and 120% of
the expected value for the gas.
Accuracy of
ToxiLtd instruments equipped with a
toxic gas sensor should be checked
periodically with known concentration
calibration gas. Failure to check
accuracy can lead to inaccurate and
potentially dangerous readings.
See Appendix C for a discussion of
calibration frequency.
3.2
Effect of contaminants on
ToxiLtd sensors
The atmosphere in which the ToxiLtd is
used can have lasting effects on the
sensors. Sensors may suffer losses in
sensitivity leading to degraded
performance if exposed to certain
substances.
There are two basic types of sensors that
may be installed in the ToxiLtd: galvanic
oxygen or electrochemical toxic. Each
type of sensor uses a slightly different
detection principle, so the kinds of
conditions that affect the accuracy of the
sensors vary from one type of sensor to
the next.
3.2.1 Effects of contaminants on
oxygen sensors
Oxygen sensors may be affected by
prolonged exposure to "acid" gases such
as carbon dioxide. The oxygen sensors
used in Biosystems instruments are not
recommended for continuous use in
atmospheres containing more than 25%
CO2.
3.2.2 Effects of contaminants on
toxic gas sensors
Biosystems “substance-specific”
electrochemical sensors have been
carefully designed to minimize the effects
of common interfering gases.
“Substance-specific” sensors are
designed to respond only to the gases
11
that they are supposed to measure. The
higher the specificity of the sensor, the
less likely the sensor will react to other
gases, which may be incidentally present
in the environment. For instance, a
“substance-specific” carbon monoxide
sensor is deliberately designed not to
respond to other gases that may be
present at the same time, such as
hydrogen sulfide (H2S) and methane
(CH4).
Although great care has been taken to
reduce cross-sensitivity, some interfering
gases may still have an effect on toxic
sensor readings. In some cases the
interference may be positive and result in
readings that are higher than actual. In
other cases the interference may be
negative and produce readings that are
lower than actual and may even cause the
instrument to display negative readings for
the target gas.
See Appendix A for cross-sensitivity
data.
3.3
Fresh air/zero calibration
To initiate the fresh air/zero calibration
procedure:
1. From the current gas reading screen,
press the MODE button three times
within two seconds. The ToxiLtd will
briefly display “CAL” and then begin a
5-second countdown with the 0-CAL
icon lit.
span calibration is not required, allow
the countdown to reach 0 without
pressing the MODE button.
If the instrument is equipped with an
oxygen sensor, calibration is complete
when the instrument returns to the
current gas reading screen.
Note: The maximum reading value
(MAX) will be automatically reset
following a successful fresh air/zero
calibration.
Fresh air/zero
calibrations may only be performed in
an atmosphere that is known to
contain 20.9% oxygen and 0 PPM toxic
gas. Performing fresh air/zero
calibrations in an atmosphere that is
not comprised of 20.9% oxygen and 0
PPM toxic gas may lead to inaccurate
and potentially dangerous readings.
3.4
Functional (bump) testing for
ToxiLtd with toxic gas sensor
The accuracy of the ToxiLtd with a toxic
gas sensor may be verified at any time by
a simple functional (bump) test.
To perform a functional (bump) test, do
the following:
1. Turn the ToxiLtd on and wait at least
three minutes to allow the readings to
fully stabilize.
2. Make sure the instrument is located in
fresh air.
3. Perform a fresh air/zero calibration as
discussed in section 3.3 and allow the
instrument to return to the current gas
readings screen.
→
2. Press the MODE button before the
end of the 5-second countdown to
begin the fresh air/zero calibration.
The fresh air/zero calibration has been
successfully initiated when the ToxiLtd
alternates between the following two
screens:
↔
3. For instruments equipped with a toxic
gas sensor, the fresh air/zero
calibration is complete when the
instrument begins another 5-second
countdown for the span calibration. If
Figure 3.4: Bump-test/span calibration setup for toxic sensor-equipped instruments.
4. Apply the calibration gas as shown in
12
alternate between “GAS” and the
expected concentration of calibration
gas.
figure 3.4.
5. Wait for the readings to stabilize.
Forty-five seconds to one minute is
usually sufficient.
6. Note the readings. Readings are
considered accurate if they are
between 90%* and 120% of the
expected value. If the readings are
considered accurate, then the
instrument may be used without
further adjustment. If readings are
considered inaccurate, the instrument
must be adjusted using the “span”
calibration procedures discussed in
section 3.5 before further use.
*The Canadian Standards
Association (CSA) considers bump
test readings accurate when the
displayed values fall between 100%
and 120% of the expected value for
the gas. To meet the CSA
requirement, an instrument must
undergo calibration when the
displayed value during a bump test
fails to fall between 100% and 120%
of the expected value for the gas.
3.5
Span Calibration for ToxiLtd
with toxic gas sensor
Span calibration should be performed
when a functional (bump) test has shown
that the instrument’s gas readings are not
between 90%* and 120% of the expected
values as given on the calibration gas
cylinder (as discussed in section 3.4).
*To meet the CSA requirement, an
instrument must undergo calibration when
the displayed value during a bump test
fails to fall between 100% and 120% of
the expected value for the gas.
Prior to performing a span calibration,
perform a fresh air/zero calibration as
discussed in section 3.3. After successful
completion of the fresh air/zero
calibration, the instrument will begin a
second five-second countdown with the
calibration gas bottle icon highlighted.
↔
2. Apply calibration gas as shown above
in figure 3.4. Once calibration gas is
detected, the readout will change to
show the gas reading. Note that the
negated horn symbol is shown to
indicate that the alarms are not
operating because the instrument is in
calibration mode.
3. The calibration is fully automatic from
this point on. Once the instrument
successfully completes the span
calibration, it will emit three short
beeps and display the maximum span
calibration adjustment value for two
seconds.
Note: The maximum span calibration
adjustment value shown is an
indication of the relative health of the
sensor. As a sensor loses sensitivity,
the maximum adjustment level will
approach the calibration gas
concentration, letting you know when
the sensor is losing sensitivity.
4. The instrument will then return to
normal operation.
Note: Once the calibration cycle is
completed, the ToxiLtd automatically
returns to normal operation and the
gas alarms may be activated.
Disconnect the calibration assembly
immediately after calibration.
Use of nonstandard calibration gas and/or
calibration kit components when
calibrating the ToxiLtd can lead to
inaccurate and potentially dangerous
1. Press the MODE button before the
countdown is complete to initiate the
span calibration. The display will
13
readings, and may void the standard
Biosystems warranty.
3.6
Failure to calibrate
3.6.1 Fresh air/zero calibration failure
In the event of fresh air/zero calibration
failure, the “no” and “CAL” screens will be
alternately displayed as shown below with
the “0-CAL” segment lit. The instrument
will then return to the gas reading screen.
current gas readings screen and the
warning symbol and the calibration bottle
icon will be shown, which signifies that the
instrument failed the last attempt to span
calibrate.
↔
3.6.2.2 No gas
In the case of a span calibration failure in
which calibration gas is not detected, the
“no” and “GAS” screens will be alternately
displayed as shown below with the
calibration bottle icon highlighted.
Following a fresh air/zero calibration
failure, the triangular warning symbol and
“0-CAL” indicator will remain lit until a
successful fresh air/zero calibration is
performed.
↔
When the instrument returns to the
current gas readings screen, the warning
symbol and the calibration bottle icon will
be shown, which signifies that the
instrument failed the last attempt to span
calibrate.
3.6.1.1 Reason for fresh air/zero
calibration failures
Fresh air/zero calibration failures often
result from the attempt to calibrate the
instrument in a contaminated atmosphere.
Fresh air/zero calibration failures can also
result from sensor failures.
3.6.2 Span calibration failure
The ToxiLtd is designed to recognize two
distinct types of span calibration failure:
failures that occur due to sensor response
outside the sensor’s normal range for
calibration and failures that occur when
the instrument fails to recognize any
calibration gas whatsoever.
3.6.2.3 Causes for span cal failure
Span calibration failures can be caused
by the following:
1. Expired calibration gas.
2. Calibration gas whose concentration
fails to match the concentration
expected by the instrument.
3. Inappropriate regulator. The ToxiLtd
must be calibrated using a 1.0
liter/minute fixed flow regulator.
4. Sensor failure.
3.6.3 Forced fresh air/zero calibration
If a fresh air/zero calibration fails in an
atmosphere known to be fresh, the
ToxiLtd can be forced to fresh air calibrate
as follows.
1. Follow instructions 1 and 2 in section
3.3 to begin the fresh air/zero
calibration sequence.
2. As soon as the alternating right and
3.6.2.1
Sensor out of range (no
CAL)
If the instrument recognizes calibration
gas, but the sensor response is not within
the range to calibrate the instrument, span
calibration will fail and the “no” and “CAL”
screens will be alternately displayed.
↔
After displaying “no” and “CAL” three
times, the instrument will return to the
14
Service Department for a Return
Authorization (RA#) prior to shipping the
instrument.
4.1
Initiating communications
To initiate communications, simply hold
the MODE button as if you are turning the
instrument off. The ToxiLtd will briefly
light all segments in the display after
about 5 seconds. Continue to hold the
MODE button for an additional 2-3
seconds until the “IrdA” screen is shown
and the LED/IrDA port blinks. Then
release the MODE button.
left 0’s are shown on the screen, press
and hold the MODE button.
↔
3. The forced fresh air/zero calibration is
complete when the instrument emits
three short beeps. Units equipped
with an oxygen sensor will then return
to gas detection mode. Units
equipped with a toxic gas sensor will
then move on the span calibration
procedure.
Performing the
forced fresh air/zero calibration in a
contaminated atmosphere may lead to
inaccurate and potentially dangerous
readings.
3.7
Fresh air/zero calibration in a
contaminated atmosphere
To perform the fresh air/zero calibration in
a contaminated atmosphere, it is
necessary to use special calibration gas,
whose composition is identical to that of
fresh air. Biosystems offers the “Zero Air”
calibration gas cylinder as part number
54-9039, which contains 0 PPM toxic gas
and 20.9% oxygen.
1. Apply “Zero Air” calibration gas to the
instrument as shown above in figure
3.4 for at least 15 seconds or until the
readings fully stabilize.
2. Perform the fresh air/zero calibration
procedure as described in section 3.3.
3. Once the fresh air/zero calibration is
complete, disconnect the calibration
assembly and move on to the span
calibration if necessary as described in
section 3.5.
4.
Align the infrared port at the top front of
the ToxiLtd with the PC’s infrared port and
proceed with the download. The ToxiLtd
should be located 1-2” (2.5-5cm) from the
IrDA Port.
Position of IrDA Module and ToxiLtd
During download.
If 30 seconds pass and the ToxiLtd has
not detected an infrared interface, it will
return to normal operation.
Event logging
Each ToxiLtd includes a built-in event
logger that stores instrument readings and
other data whenever a reading exceeds a
pre-set alarm point.
Incident information can be extracted
through a PC with BioTrak software and a
functioning IrDA port. The ToxiLtd may
also be returned to Biosystems to have
the information extracted.
If you need to return the instrument to
Biosystems, call Biosystems Technical
15
Appendices
Appendix A: Sensor Cross-Sensitivity Chart
The table below provides the cross-sensitivity response of the ToxiLtd toxic gas sensors to common interference gases. The values are ToxiLtd as
a percentage of the primary sensitivity or the reading of the sensor when exposed to 100ppm of the interfering gas at 20ºC. These values are
approximate. The actual values depend on the age and condition of the sensor. Sensors should always be calibrated to the primary gas type.
Cross-sensitive gases should not be used as sensor calibration surrogates without the written consent of Biosystems.
SENSOR
Carbon
Monoxide
(CO)
Hydrogen
Sulfide
(H2S)
Sulfur
Dioxide
(SO2)
CO
H2S
SO2
NO
NO2
Cl2
ClO2
H2
HCN
HCl
NH3
C2H4
C2H2
100
10
5
10
-15
-5
-15
50
15
3
0
75
250
0.5
100
20
2
-20
-20
-60
0.2
0
0
0
n/d
n/d
1
1
100
1
-100
-50
-150
0.2
n/d
n/d
0
(+)
(+)
n/d = no data, (+) undetermined positive, (-) undetermined negative n/d = no data, (+) undetermined positive, (-) undetermined negative
Appendix B: Default toxic sensor calibration gas settings
ToxiLtd
Part Number
54-45-01
54-45-02
54-45-03
Description
CO
H2S
SO2
Carbon monoxide
Hydrogen sulfide
Sulfur dioxide
Default
Calibration Gas
Setting
50 PPM CO
25 PPM H2S
10 PPM SO2
Calibration Gas Part Number
58 or 103 Liter
34 Liter
54-9033
54-9034
54-9037
54-9036
54-9057
54-9058
16
Appendix C: Calibration
Frequency
One of the most common
questions that we are asked at
Biosystems is: “How often
should I calibrate my gas
detector?”
Sensor Reliability and Accuracy
Today’s sensors are designed to
provide years of reliable service.
In fact, many sensors are
designed so that with normal use
they will only lose 5% of their
sensitivity per year or 10% over a
two-year period. Given this, it
should be possible to use a sensor
for up to two full years without any
significant loss of sensitivity.
Verification of Accuracy
With so many reasons why a
sensor can lose sensitivity and
given the fact that dependable
sensors can be key to survival in a
hazardous environment, frequent
verification of sensor performance
is paramount.
There is only one sure way to
verify that a sensor can respond to
the gas for which it is designed.
That is to expose it to a known
concentration of target gas and
compare the reading with the
concentration of the gas. This is
referred to as a “bump” test. This
test is very simple and takes only
a few seconds to accomplish. The
safest course of action is to do
a “bump” test prior to each
day’s use. It is not necessary to
make a calibration adjustment if
the readings fall between 90%*
and 120% of the expected value.
As an example, if a CO sensor is
checked using a gas concentration
of 50 PPM it is not necessary to
perform a calibration unless the
readings are either below 45 PPM
or above 60 PPM.
*The Canadian Standards
Association (CSA) requires the
instrument to undergo
calibration when the displayed
value during a bump test fails to
fall between 100% and 120% of
the expected value for the gas.
Lengthening the Intervals
between Verification of
Accuracy
We are often asked whether there
are any circumstances in which
the period between accuracy
checks may be lengthened.
Biosystems is not the only
manufacturer to be asked this
question! One of the professional
organizations to which Biosystems
belongs is the Industrial Safety
Equipment Association (ISEA).
The “Instrument Products” group
of this organization has been very
active in developing a protocol to
clarify the minimum conditions
under which the interval between
accuracy checks may be
lengthened.
A number of leading gas detection
equipment manufacturers have
participated in the development of
the ISEA guidelines concerning
calibration frequency. Biosystems
procedures closely follow these
guidelines.
If your operating procedures do
not permit daily checking of the
sensors, Biosystems recommends
the following procedure to
establish a safe and prudent
accuracy check schedule for your
Biosystems instruments:
1.
During a period of initial use
of at least 10 days in the
intended atmosphere, check
the sensor response daily to
be sure there is nothing in the
atmosphere that is poisoning
the sensor(s). The period of
initial use must be of sufficient
duration to ensure that the
sensors are exposed to all
conditions that might have an
adverse effect on the sensors.
2.
If these tests demonstrate
that it is not necessary to
make adjustments, the time
between checks may be
lengthened. The interval
between accuracy checking
should not exceed 30 days.
3.
When the interval has been
extended the toxic and
combustible gas sensors
should be replaced
immediately upon warranty
expiration. This will minimize
the risk of failure during the
interval between sensor
checks.
4.
The history of the instrument
response between
verifications should be kept.
Any conditions, incidents,
experiences, or exposure to
contaminants that might have
an adverse effect on the
calibration state of the
sensors should trigger
17
immediate re-verification of
accuracy before further use.
5.
Any changes in the
environment in which the
instrument is being used, or
changes in the work that is
being performed, should
trigger a resumption of daily
checking.
6.
If there is any doubt at any
time as to the accuracy of the
sensors, verify the accuracy
of the sensors by exposing
them to known concentration
test gas before further use.
Gas detectors used for the
detection of oxygen deficiencies,
flammable gases and vapors, or
toxic contaminants must be
maintained and operated properly
to do the job they were designed
to do. Always follow the guidelines
provided by the manufacturer for
any gas detection equipment you
use!
If there is any doubt regarding
your gas detector's accuracy, do
an accuracy check! All it takes is a
few moments to verify whether or
not your instruments are safe to
use.
One Button Auto Calibration
While it is only necessary to do a
“bump” test to ensure that the
sensors are working properly, all
current Biosystems gas detectors
offer a one button auto calibration
feature. This feature allows you to
calibrate a Biosystems gas
detector in about the same time as
it takes to complete a “bump” test.
The use of automatic bump test
and calibration stations can further
simplify the tasks, while
automatically maintaining records.
Don't take a chance
with your life.
Verify accuracy frequently!
Please read also Biosystems’
application note: AN20010808
“Use of ‘equivalent’ calibration
gas mixtures”. This application
note provides procedures to
ensure safe calibration of LEL
sensors that are subject to
silicone poisoning.
Biosystems website is located at
http://www.biosystems.com
Biosystems Standard Warranty Gas Detection Products
General
Biosystems, LLC (hereafter Biosystems) warrants gas detectors, sensors and accessories manufactured and
sold by Biosystems, to be free from defects in materials and workmanship for the periods listed in the tables
below.
Damages to any Biosystems products that result from abuse, alteration, power fluctuations including surges
and lightning strikes, incorrect voltage settings, incorrect batteries, or repair procedures not made in
accordance with the Instrument’s Reference Manual are not covered by the Biosystems standard warranty.
The obligation of Biosystems under this warranty is limited to the repair or replacement of components
deemed by the Biosystems Instrument Service Department to have been defective under the scope of this
standard warranty. To receive consideration for warranty repair or replacement procedures, products must
be returned with transportation and shipping charges prepaid to Biosystems at its manufacturing location in
Middletown, Connecticut, or to a Biosystems Authorized Warranty Service Center. It is necessary to obtain a
return authorization number from Biosystems prior to shipment.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES AND
REPRESENTATIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE WARRANTY OF
FITNESS FOR A PARTICULAR PURPOSE. BIOSYSTEMS WILL NOT BE LIABLE FOR LOSS OR
DAMAGE OF ANY KIND CONNECTED TO THE USE OF ITS PRODUCTS OR FAILURE OF ITS
PRODUCTS TO FUNCTION OR OPERATE PROPERLY.
Instrument & Accessory Warranty Periods
Product(s)
Warranty Period
5
PhD , PhD Lite, PhD Plus, PhD Ultra, Cannonball3, MultiVision,
Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra, ToxiVision, Ex Chek
ToxiPro®, MultiPro
ToxiLtd®
Toxi3Ltd®
Mighty-Tox
Mighty-Tox 2
Prorated credit is given towards repair or purchase of a new unit of
the same type.
IQ Systems, Series 3000, Airpanel, Travelpanel, ZoneGuard,
Gas9Chek1 and Gas9Chek4
Battery packs and chargers, sampling pumps and other
components, which by their design are consumed or depleted during
normal operation, or which may require periodic replacement
As long as the instrument is in service
2 years from date of purchase
2 years after activation or 2 years after
the “Must Be Activated By” date,
whichever comes first
3 years after activation or 3 years after
the “Must Be Activated By” date,
whichever comes first
90 days after activation or 90 days after
the “Must Be Activated By” date,
whichever comes first
0 – 6 months of use 100% credit
6 – 12 months of use
75% credit
12 – 18 months of use
50% credit
18 – 24 months of use
25% credit
One year from the date of purchase
One year from the date of purchase
Sensor Warranty Periods
Instrument(s)
Sensor Type(s)
5
PhD Plus, PhD Ultra, PhD , PhD Lite,
Cannonball3, MultiVision, MultiPro, ToxiVision,
ToxiPro®, Ex Chek
Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra
All Others
O2, LEL**, CO, CO+, H2S &
Duo-Tox
All Other Sensors
CO, CO+, H2S
All Other Sensors
All Sensors
Warranty Period
2 Years
1 Year
2 Years
1 Year
1 Year
** Damage to combustible gas sensors by acute or chronic exposure to known sensor poisons such as
volatile lead (aviation gasoline additive), hydride gases such as phosphine, and volatile silicone gases
emitted from silicone caulks/sealants, silicone rubber molded products, laboratory glassware greases,
spray lubricants, heat transfer fluids, waxes & polishing compounds (neat or spray aerosols), mold release
agents for plastics injection molding operations, waterproofing formulations, vinyl & leather preservatives,
and hand lotions which may contain ingredients listed as cyclomethicone, dimethicone and polymethicone
(at the discretion of Biosystems Instrument Service department) void Biosystems’ Standard Warranty as it
applies to the replacement of combustible gas sensors.
18
ToxiLtd
®
c-UL Version
ATEX / CQST Version
IECEx Version
Gas
O2
H2S
CO
SO2
Firmware Ver. _______
Vibrating Motor
Belt Clip
Serial # ______________
Activation Date
19