G450

Multi-gas Detector

Field Operation Manual

1194 Oak Valley Dr, Ste 20, Ann Arbor MI 48108 USA

(800) 959-0329 • (734) 769-0573 • www.gfg-inc.com

Warranty

GfG Instrumentation warrants our products to be free from defects in material and workmanship when used for their intended purpose, and agrees to remedy such defect or to furnish a new part (at the option of GfG Instrumentation) in exchange for any part of any product we manufacture that under normal use is found to be defective; provided that the product is returned by the purchaser to GfG’s factory, intact, for our examination, with all transportation costs prepaid, and provided that such examinations reveals, in our judgment, that it is defective.

This warranty does not extend to any products that have been subjected to misuse, neglect, accident or unauthorized modifications; nor does it extend to products used contrary to the instructions furnished by us or to products that have been repaired or altered outside of our factory or by a non-authorized service center. No agent or reseller of GfG Instrumentation may alter the above statement.

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. GfG 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.

The G450 has a limited lifetime warranty to the original purchaser

(as long as the instrument is in service). Accessories (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 are warranted for one year from the date of purchase. O and H

2

2

, LEL, CO,

S sensors are covered for 3 years from date of purchase.

Introduction

The purpose of this manual is to provide day-to-day basic information for the G450. Please refer to the accompanying CD-ROM to access the complete user’s manual. The G450 is a handheld detector for personal protection from gas hazards. The instrument measures continuously in diffusion mode and gives visual and audible alarms if a gas-induced danger arises.

The G450 is a safety device and it is up to the user to ensure proper action is taken in the event of an alarm.

The following signal words, as defined by ANSI Z535.4-1998, are used in this guide.

DANGER

WARNING

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.

CAUTION indicates a potentially hazardous situation, which if not avoided, may result in moderate or minor injury.

Safety Information

The G450 must only be operated as specified in this manual, otherwise the instrument’s protection may be diminished. Please refer to ISA-

RP12.13, Part II-1987 for guidance in use of this instrument.

Warnings

WARNING Never substitute any component as this may compromise the

G450s intrinsic safety.

WARNING For safety reasons, this equipment must be operated and serviced by qualified personne l only. Read and understand the instruction manual completely before operating or servicing the G450.

WARNING Instrument should be calibrated before first time use and then on a regular basis. Length of interval will depend on frequency of use and contaminants and/or poisons being exposed to the sensors.

GfG recommends a minimum of 180 days.

WARNING If the combustible sensor may be exposed to a known poison (silicon, sulfur, halogenated compounds, etc), GfG recommends checking it against a known concentration of calibration gas before use.

Design

1

4

5

8

9

Item Description

1 Hook for carrying strap

8

9

6

7

4

5

2

3

Display

Keys

Alarm LEDs

Horn

Diffusion inlets

Contacts for accessories

Screw connectors for pump

Battery pack (accessible from back)

6

7

2

3

Display

2

3

6

7

Item Description

1

Alarm Status (backlight)

Green - No alarms

Orange - Alarm 1

Red - Alarm 2 or 3

2 Clock

3 Flashlight indicator

4 Gases

5 Gas Readings

6 Battery indicator

7 Peak indicator

1

4

5

4

1 2 3

Key Description

1 Activate Peak

Hold to turn on optional flashlight

2 Reset latching alarm

Hold to enter service mode

3 View one gas at a time or STEL/TWA

Press to turn on monitor (when off)

Hold to turn off monitor (approx 5 sec.)

1 + 3 Rotate the display 180°

2 + 3 Enter calibration mode

Battery Installation

Batteries must not be replaced in hazardous locations.

Replace only in non hazardous locations.

Turn the detector off before you replace the batteries. To replace the batteries or battery pack, unscrew the two screws on the front of the detector and pull the whole pack backwards or insert the allen wrench through one of the screw holes to push the pack backwards.

When the alkaline batteries have to be replaced, use the allen wrench to push the two battery cells out through the PCB holes.

When inserting new batteries, check for the correct polarity (see plastic holder). Use only size AA batteries, Duracell MN1500 LR6.

Secure the supply module by replacing the two screws.

Calibration Procedure

Calibration is a two step procedure. The first step is the Fresh

Air AutoCal ® adjustment. In this step the readings of the sensors are automatically adjusted to equal the values expected in fresh air, (20.9% O

2

, 0% LEL combustible gas, and 0 PPM (parts per million) for toxic sensors such as CO and H

2

S).

To perform a Fresh Air AutoCal ® adjustment:

1.

2.

3.

4.

5.

6.

7.

8.

9.

Make sure the instrument is located in a fresh air environment

(20.9% oxygen, and no measurable flammable or toxic contaminants)

Turn the instrument on and allow the readings to stabilize fully.

Attach the calibration adapter to the instrument.

The instrument will automatically recognize that the adapter is attached, and display the AutoCal ® menu screen.

Push the “Air” button to initiate the Fresh Air adjustment.

The instrument will automatically count down, then begin the adjustment process.

The display will list the sensors installed, and show a checkmark by each sensor as the adjustment is completed.

After completing the fresh air adjustment the instrument will return to normal operation.

Make sure to remove the calibration adapter before using the instrument to detect gas.

The second step in a full calibration is the AutoCal ® Gas adjustment. In this step the sensitivity of the sensors is automatically adjusted while the sensors are exposed to known concentration calibration gas.

A single cylinder of all-in-one (Quad Mix) calibration gas may be used to automatically calibrate CO, H same time.

2

S and LEL sensors all at the

To initiate AutoCal ® Gas calibration using all-in-one (Quad-Mix) calibration gas:

1.

2.

3.

4.

5.

6.

7.

Make sure the instrument has been properly Fresh Air adjusted before proceeding to the Gas adjustment.

Attach the calibration adapter to the instrument. (If the adapter is already attached, momentarily remove and replace the adapter to display the AutoCal ® menu screen.)

Turn the regulator on to begin flowing calibration gas to the sensors.

You will be prompted to verify that gas has been applied.

Press “Yes” to continue.

Press “CAL” to make the Gas AutoCal ® adjustment.

The display will show an hourglass icon by each sensor while it is being adjusted; then a check mark when the adjustment is complete.

Make sure to remove the calibration adapter before using the instrument to detect gas.

Sensors may initially fail the Fresh Air or Gas Calibration adjustment. It is usually worthwhile to repeat the failed procedure at least once.

1.

2.

3.

4.

5.

6.

7.

Make sure that the sensors (especially the combustible sensor) have had a chance to warm up completely before beginning the Fresh Air or Cal Gas adjustment. Five minutes is usually sufficient.

Before making a Fresh Air adjustment, make sure that the calibration adapter and tubing do not contain trapped calibration gas.

Make sure the air used for the Fresh Air adjustment does not contain measurable contaminants such as solvent vapors, cigarette smoke or engine exhaust.

Make sure that the calibration gas cylinder has not run out of gas.

Make sure the calibration gas cylinder, tubing and adapter are properly connected to the instrument.

If the sensor still fails calibration, consult the GfG factory for additional advice.

Any sensor that fails to calibrate properly must be replaced before using the instrument.

Maintenance and Inspection

Maintenance includes service, calibration and adjustment, as well as repair if it is necessary. Gas monitoring devices can react differently depending on environmental conditions. It is important, independent from maintenance duties, to test the device before putting it into operation each day. Bump testing before each use is highly recommended. The casing can be cleaned with a damp cloth. Never use solvents or detergents!

Alarms

If the measured gas concentration exceeds a pre-set threshold, the monitor will give audible and visual alarms.

Alarm Type Sensors

# of alarms

Description

Instantaneous

Value (AL)

Oxygen

Combustibles

Toxic gases

3

3

2

An instantaneous alarm is activated immediately if the gas concentration exceeds or falls below a pre-set threshold.

The alarm values are adjustable.

Short Term

Value (STEL) Toxic gases

Long Term

Value (TWA)

Toxic gases

1

1

The short-term value

(STEL) is the average concentration over a short period of time (e.g.

15 minutes). The STEL alarm is not latching; it resets automatically as soon as the concentration falls below the threshold.

The long-term value

(TWA) refers to an

8-hour shift and calculates the average concentration. The TWA alarm cannot be reset. It is only de-activated if the detector is switched off.*

To reset an “over range” CH

4

(LEL) alarm, move the instrument to a clean air environment and press the RESET button and answer yes to “Fresh air?” Make sure the atmosphere in the vicinity of the

CH

4

sensor is free of contaminants.

*Note: To avoid possible personal injury, do not turn off the detector during a work shift. TWA, STEL and Max readings are reset when the G450 is turned off

•

•

•

•

•

•

•

Service

Service consist of the maintenance, inspection and repair of the gas monitoring device. The function test has to be performed before the first operation and at least once a year and comprises:

Status of the zeropoint

Charging status of the battery

Pump and diffusion inlet

Display with zero gas and standard test gas and adjustment, if necessary

Alarm signal release, e.g. with alarm test gas

Constantly amplified signal with standard test gas

Response time

Any repair of the G450 must be done according to the manufacturer’s instructions and with genuine spare parts.

Troubleshooting

Symptom

No power

Solution

Check/charge battery

No gas response Check/replace sensor (see complete user manual)

Alarms in clean (fresh) air Perform autozero

Specification

Dimensions: 2.5x4.3x2.0 in (90x140x55 mm)

Weight: 10 oz (280 g) with O

2

/LEL/CO/H

2

S sensors

Climate conditions:

Temperature: -4 to +122°F (-20 to +50°C)

Humidity: 5 to 95% r.h. (non-condensing)

Pressure: 700 to 1300 hPa

Detection Range: Please refer to complete operating manual “Sensor Types and

Detection Ranges”

Sensor type: Please refer to complete operating manual “Sensor Types and

Detection Ranges”

Alarm Conditions: Alarm 1, alarm 2, alarm 3, TWA, STEL, battery, confidence blip

Vibrating alarm: standard

Audible alarm: 103 dB at 30 cm (1 foot)

Display: Illuminated LCD full graphic display

Visual alarm: Bright, 360° wraparound LEDs plus heterochromatic (green/orange/ red) backlight display

Backlight: Automatic when a key is pressed or any alarm condition is activated

Self-test: Initiated upon start up.

Calibration: Manual or automatic.

User options: Location ID, User ID, Confidence blip, audible alarm levels

(103 dB, 95 dB, or off), display contrast, time, next inspection date, language selection, adjustable alarm levels, disable vibrating alarm, latching alarm 2, sensor deactivation, security code, combustible sensor (0-100% LEL or 0-5% vol), set span values, autosave and datalogging (mode and interval)

Battery operating time: Up to 24 hours

Approved batteries: GfG NiMH rechargeable battery pack or Duracell MN1500

LR6

Battery charger: GfG cradle or smart cap charger

Charge: up to 4 hours

Warranty: Limited lifetime on instrument and electronics; 3 yrs from date of purchase for O

2

, LEL, CO, and H

2

S sensors.

Approvals: cCSAus

Approved: Class I, Division 1, Group A, B, C, and D

Class I, Zone 0: Ex ia IIC T3

Standards: ATEX: II 2G EEx ia d IIC T3/T4

CSA C22.2 No. 152-M1984

UL 913

ANSI / ISA-12.13.01-2000

EMI/RFI resistance: EMC directive 89/336/EEC

Caution

WARNING

WARNING by qualified personnel only. Read and understand the user manual completely before operating or servicing this device.

WARNING

Substituting components may hinder intrinsic safety.

For safety reasons, this equipment must be operated and serviced

Do not use the detector if it is damaged. Before you use the detector, inspect the case. Look for cracks or missing parts.

WARNING

WARNING

If the detector is damaged or something is missing, contact GfG

Instrumentation, Inc. immediately.

Calibrate the detector before first-time use and then on a regular schedule, depending on use and sensor exposure to poisons and contaminants.

WARNING GfG recommends that you “bump test” the sensors before each use to confirm their ability to respond to gas. To do this, expose the detector to a gas concentration that exceeds the alarm set points. Manually verify that the audible and visual alarms are activated. Calibrate if the readings are not within the specified limits.

WARNING It is recommended that the combustible sensor be checked with a known concentration of calibration gas after any known exposure to catalyst contaminants/poisons (sulfur compounds, silicon vapors, halogenated compounds, etc).

WARNING The combustible sensor is factory calibrated to 50% LEL methane.

If monitoring a different combustible gas in the % LEL range, calibrate the sensor using the appropriate gas.

WARNING

WARNING

High off-scale readings may indicate an explosive concentration.

Only the combustible gas detection portion of this instrument has been assessed for performance by CSA International.

WARNING Protect the combustible sensor from exposure to lead compounds, silicones and chlorinated hydrocarbons. Although certain organic vapors (such as leaded gasoline and halogenated hydrocarbons) may temporarily inhibit sensor performance, in most cases the sensor will recover after calibration.

WARNING For use only in hazardous locations where oxygen concentrations do not exceed 20.9% volume (v/v).

WARNING Any rapidly increasing reading followed by a declining or erratic reading may indicate a gas concentration beyond the upper scale limit, which may be hazardous.

WARNING Extended exposure of the G450 to certain concentrations of combustible gases and air may stress detector elements, which can seriously affect the device’s performance. If an alarm occurs due to a high concentration of combustible gases, recalibration should be performed, or if needed, the sensor replaced.

WARNING Do not test the combustible sensor’s response with a butane cigarette lighter; doing so can damage the sensor.

WARNING Do not expose the detector to electrical shock and/or severe continuous mechanical shock.

WARNING Do not attempt to disassemble, adjust or service the detector unless instructions for that procedure are contained in the manual and/or that part is listed as a replacement part.

WARNING Electromagnetic interference (EMI) signals may cause incorrect operation of this detector

Sensor Specifications

MK376-5 Electrochemical sensor for oxygen O

2

Response time t50: <10 sec

Pressure

Humidity

Temperature

0%...90% r.h.:

-20...+50°C: max. ±0.2Vol.% or

±2.5% of range max. ±0.5Vol.% or

±2.5% of display t90: <20 sec

(referred to 1000 hPa)

(referred to 50% r.F.)

(referred to 20°C)

Expected lifetime: 3 years in air

MK344-5/-6 Electrochemical sensor for carbon monoxide CO

Response time t50: <15 sec t90: <45 sec

Pressure (referred to 1000 hPa)

Humidity

Temperature -10...+40°C:

Temperature

Cross sensitivities:

Expected lifetime:

-20...+50°C:

(referred to 50% r.F.) max. ±3ppm or ±7% of display max. ±3ppm or ±15% of display

(referred to 20°C)

(referred to 20°C)

H2S<4%; C2H4<50%; H2<40%; NO<9%;

NO2<±5%; SO2=Cl2=C2H60=0% (*1)

3 years

MK429-5/-6 Electrochemical sensor for hydrogen sulfide H

2

S

Response time t50: <15 sec

Pressure t90: <45 sec

(referred to 1000 hPa)

Humidity

(referred to 50% r.h.)

Temperature

Temperature

Cross sensitivities:

Expected lifetime:

-10...+40°C:

-20...+50°C: max. ±2ppm or ±10% of display max. ±2ppm or ±15% of display

(referred to 20°C)

(referred to 20°C)

SO2≈ 20%; NO2<-20%; CO<1%; NO<0,2%;

H2<0,1%; (*1)

3 years

MK211-6 Catalytic combustion sensor for combustible gases and vapours

Response time: t90: <30 sec

Pressure

(referred to 1000 hPa)

Humidity

Temperature

Cross sensitivities at 50%LEL:

5%...90% r.h.:

-20...+ 50°C: max. ±5% of range or

±15% of display max. ±3% of range or

±10% of display

(referred to 55% r.h.)

(referred to 20°C)

2.00Vol.% H2: approx.160%;0.70Vol.% C4H10: approx.72%;

2.20Vol.% CH4: 100%;0.70Vol.% C5H12: approx.71%;

0.85Vol.% C3H8: approx.85%;0.50Vol.% C6H14: approx.55%;

The above information refers to the detection range for methane. It may vary from sensor to sensor and depends on the gas concentration and on the age of the sensor .

Expected lifetime: 3 years

Accessories and Replacement Parts

Part Number Description

4002-001 Batteries, alkaline (AA)

4003-450

1450-202

Battery hardware kit (includes 6 screws and hex key)

Battery pack, alkaline (without batteries) with vibrator

1450-211

1450-212

1650231

7771-450

Battery pack, rechargeable NiMH with vibrator

Battery pack, rechargeable NiMH with vibrator and lights

Cable, data downloading / USB interface (for PC)

Calibration adapter with tubing

1450225

4001-650

4001-650V

1450001

1450005

1450004

1450003

Calibration connector

Charger, plug-in (110 VAC) wall pack (for use with drop-in charger)

Charger, vehicle

Oxygen Sensor

Combustible (LEL)

Carbon Monoxide (CO)

Hydrogen Sulfide (H

2

S)

GfG Instrumentation, Inc.

1194 Oak Valley Dr.

Suite 20

Ann Arbor, MI 48108

USA

US/Canada: (800) 959-0329

US/Canada Fax: (734) 769-1888

International: +1 734 769 0573

International Fax: +1 734 769 1888

Website: www.gfg-inc.com

Worldwide Manufacturer of Gas Detection Solutions

7004-451 Rev. 1 (Jan 09)