Operation Manual - GFG Instrumentation, Inc

Operation Manual - GFG Instrumentation, Inc
G450
Operation Manual
Operation and
Maintenance Manual
Worldwide Manufacturer of Gas Detection Solutions
GfG Products for Increased Safety
Congratulations on your purchase of a high technology product from GfG
– you have made an excellent choice!
Our detectors are characterized by reliability, safety, peak performance
and economic efficiency. They comply with national and international
directives.
This manual will help you operate the detector quickly and safely.
Please take note of these instructions before putting the device into
operation!
If you have any questions, please feel free to contact us.
GfG Instrumentation, Inc.
1194 Oak Valley Drive, Ste 20
Ann Arbor, MI 48108 USA
Phone:
Fax:
E-mail:
Website:
(800) 959-0329 or (734) 769-0573
(734) 769-1888
[email protected]
www.gfg-inc.com
Table of Contents
Page
Introduction...........................................5
For Your Safety ....................................5
Application and Purpose.......................5
Design ..................................................6
Operation...............................................7
Detection Mode ....................................7
Turning the Device On..........................7
Turning the Device Off..........................9
Display Illumination...............................9
Individual Gas Display /
Rotating the Display .............................9
Battery ................................................10
Alarms ................................................11
Resetting Latching Alarms..................12
STEL, TWA,
Maximum / Minimum Values...............12
Peak – Adjusting Peak Values............12
Service Mode......................................13
Main Menu..........................................13
Location – Entering a Location ...........14
User – Entering User Name................14
Datalogger..........................................15
Datalogger (sample screen shots)......16
Confidence Blip ..................................17
AutoCal® .............................................18
Options ...............................................18
Service Menu......................................18
System Menu......................................19
Time .................................................20
Inspection.........................................20
Information .......................................20
Options.............................................21
Latching Alarm Function...................21
Sensor – Enable...............................21
AutoCal® – Air ..................................22
AutoCal® – Gas ................................22
Sensor Menu ......................................22
Zeroing – Adjust Zero Point..............23
Calibration ........................................24
Alarms – Adjust Alarm Thresholds ...25
Calibration Dates..............................25
Page
Information .......................................26
CH4 Unit .............................................26
Activate Lights ....................................26
Replacing the Batteries and the
Rechargeable Battery Pack Module ...26
Charging the Optional
NiMH Battery Pack .............................27
Cleaning .............................................27
Maintenance and Inspection...............28
Service – Repair .................................28
Accessories and Replacement Parts..29
Sensor Types and Detection Ranges .30
Sensor Specifications .........................31
Technical Data ...................................32
Caution...............................................33
Warranty ..............................................34
G450/460 Motorized Pump .................35
Application and Use..............................35
Special Conditions for Safe Use ...........35
General Description and Design ...........36
Sampling Inlet.......................................36
Connecting the Pump ...........................37
Operational Hints ..................................37
Turning the Pump On ...........................37
Turning the Pump Off ...........................38
Confidence Signal.................................38
Low Flow Alarm ....................................38
Power Supply........................................38
Battery Replacement ............................39
Test Battery Capacity ...........................40
System Fault.........................................40
Appendix...............................................41
Cleaning ...............................................41
Changing the Filter ...............................41
Inspection .............................................41
Maintenance and Regular
Function Check.....................................41
Service..................................................41
Replacement Parts and Accessories ....42
Technical Data......................................43
Introduction
For Your Safety
Like any piece of complex equipment, the GfG G450 will do the job it is
designed to do only if it is used and serviced in accordance with the
manufacturer's instructions.
CAUTION: For safety reasons, this equipment must be operated and
serviced by qualified personnel only. Read and understand
the instruction manual completely before operating or
servicing this device.
The warranties made by GfG with respect to the product are voided if the
product is not used and serviced in accordance with the instructions in
this manual. Please protect yourself and your employees by following
them. The above does not alter statements regarding GfG's warranties
and conditions of sale and delivery.
Application and Purpose
The G450 is a handheld detector for personal protection from gas
hazards. The detector measures continuously in diffusion mode and gives
visual and audible alarms if a gas-induced danger arises. The G450 is
designed for conformity with ATEX II2G Ex ia IIC T4 or T3, for use in
hazardous locations, and carries the following approvals:
cCSAus
Class I, Division 1, Group A, B, C, and D
Hazardous locations Temp code T3
CSA C22.2 No. 152
ANSI / ISA-12.13.01-2000
5
Design
Hook for carrying strap
Display
Keys
Diffusion
inlet
Alarm LEDs
Contacts for
accessories
Screw
connectors for
pump
Battery pack (accessible from back of unit)
6
Operation
GfG recommends frequent verification of accuracy. The safest course of
action is to verify accuracy with a known concentration of gas prior to
each day’s use. If the readings are less than 90% or greater than 120%
(-10% to +20% accuracy) the detector must be calibrated before use.
In compliance with c-CSA (Canada) the following requirements must
be observed:
CAUTION: Before each use, sensitivity must be tested on a known
concentration of CO, H2S and combustible gas (depending
on which sensors are installed) equivalent to 25 to 50% of
the full scale concentration. Accuracy must be within
-0 to 20% of the actual measurement.
®
Accuracy may be corrected by performing an AutoCal adjustment (see
calibration).
Detection Mode
Turning the Device On
Turn the G450 on in an environment
known to be free from gases and / or
vapors.
Press the right key to turn the G450 on.
After turning the G450 on, the display gives a short message about the
detector, the user, the date and the time (this message can be set in
service mode). Should the date for the next inspection pass, the G450
gives a rhythmic alarm and the display reads “Inspection Overdue.” The
display also shows every gas being measured, its detection range and the
set alarm thresholds.
7
®
After the warm-up period, you can start the AutoCal program by pressing
the right button (ZERO).
8
If you are not in fresh air, or if you do not
wish to zero the sensors, then press the
left button (MONITOR) after the warm-up
period to switch to detection mode. The
G450 is ready for operation if all
measurement values, the unit and the
gas are displayed.
NOTE: GfG recommends that you “bump check” the sensors before
each day’s use to confirm their ability to respond to gas by
exposing the detector to a gas concentration which will exceed
the alarm set point of the sensors.
Turning the Device Off
To turn the G450 off, hold the right key (ZOOM) for approximately 5
seconds.
Display Illumination
Whenever you press a key or any alarm condition is activated, the display
illumination turns on. It turns off automatically after approximately
10 seconds, or when the alarm condition is corrected.
Individual Gas Display / Rotating the Display
The display can be rotated 180° by pressing the right and the left keys
simultaneously.
The G450 allows the user to store and display time-weighted averages
(TWA), short-term exposure levels (STEL), peak values (MAX) and
minimum values (MIN). The stored values have the following meanings:
STEL:
The STEL (short-term exposure level) is the average value of
the gas concentration over a period of time, which is
determined by the short-term period. Short-term exposure
levels are used to evaluate exposure peaks. The short-term
period is set to 15 minutes. If other exposure intervals are
set, you can adjust the short-term period for toxic gases to
between 5 and 60 minutes.
9
TWA:
The time-weighted average (TWA) is the average value of
the gas concentration over an 8 hour working shift. For
calculating the total dose, the G450 uses all gas levels
measured since the detector was turned on.
MIN / MAX: Minimum and peak values measured since the detector was
switched on or since the stored values were reset.
Press ZOOM briefly to view one gas at a time (ZOOM mode). Pressing
ZOOM quickly while in ZOOM mode will cycle to the next detected gas.
To read the stored values, press and hold the right key while in zoom
mode. Press the key repeatedly to display all other measurement values
and the battery capacity one after the other.
Example – Zoom Display for H2S:
Top left:
Top right:
Bottom left:
Maximum value
Actual gas concentration
Short-term exposure level
(STEL)
Bottom right: Time-weighted average
(TWA)
Battery
A fully charged G450 battery pack has a capacity of up to 25 hours of
continuous operation in diffusion mode. The operational time may be
reduced by sampling intervals or alarms. The remaining battery capacity
is indicated by the battery symbol on the left side of the display. The black
area represents the remaining capacity.
When the capacity falls to 4%, the G450 gives both a visual (red alarm
LED and an “empty” battery symbol in the display) and an audible
warning. The display turns orange.
10
Alarms
If the measured gas concentration exceeds a pre-set threshold, the
detector immediately gives audible and visual alarms. The display also
indicates the exceeded alarm threshold which caused the alarm. A loud
acoustic alarm (103 dB at 30 cm) and bright flashing alarm LEDs warn of
dangerous gas concentrations. In case of a gas alarm the whole display
turns orange or red, depending on the gas concentration and the
exceeded alarm threshold.
The G450 provides three instantaneous alarms for oxygen (O2) and
combustible gases (CH4), and two alarms for toxic gases (CO, H2S). The
G450 warns the user of dangerous situations caused by decreasing
concentrations (e.g. for oxygen deficiency) when levels fall below the
pre-set alarm threshold. An over range alarm is given if a gas danger
occurs due to increasing concentrations (e.g. for toxic and combustible
gases). For toxic gases there is an additional alarm for exceeded timeweighted averages and short-term exposure levels (TWA and STEL).
Alarm Type
Sensors
Oxygen
Instantaneous Combustible
gases
Value (AL)
Toxic gases
Short Term
Value (STEL)
Long Term
Value (TWA)
Toxic gases
Toxic gases
Number
Description
of Alarms
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.
1
The short-term value (STEL) is the
average concentration over a short
period of time (e.g. 15 minutes). The
reference time is adjustable. The STEL
alarm is not latching; it resets
automatically as soon as the
concentration falls below the threshold.
1
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.
11
Resetting Latching Alarms
For alarms 2 and 3, when alarms are set to latching you must reset an
activated alarm by pressing the RESET key. Alarm 1 will automatically
reset when the gas danger has passed.
If the detection range of the CH4 sensor is exceeded, the display will read
“OVER RANGE” instead of a value for gas concentrations above 110%
LEL. To protect the sensor from damage, the device turns off the sensor.
However, the audible and visual alarms and the “OVER RANGE”
message remain active. The alarms must be reset by pushing the RESET
key. The display will read: “Fresh air?” If you have made sure that there
is no combustible gas in the vicinity of the CH4 sensor, press yes to
resume detection.
STEL, TWA, Maximum / Minimum Values
When you turn the G450 on, the unit begins to measure continuously in
diffusion mode. All concentrations are shown on the display. In addition,
short term and long-term averages (STEL and TWA) are calculated for
toxic gases; for non-toxic gases peak and minimum values (MAX and
MIN) are stored. The stored values can be read from the display by
accessing the applicable display mode.
WARNING: 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.
Peak – Adjusting Peak Values
During peak mode (activated by
pressing the left key PEAK), peak values
can be monitored and displayed. The
display shows an animated symbol in
the bottom left corner.
Within zoom display the peak value will be displayed instead of the gas
concentration.
12
Pressing RESET during peak mode will reset the peak memory to the
current gas concentration. Pressing RESET during zoom display will reset
the peak memory and the peak value memory to the current gas
concentration.
By pressing PEAK again peak mode is deactivated.
Service Mode
Hold the middle key (RESET) for approximately 5 seconds to activate
service mode. In the service mode the program parameters of the G450
can be adjusted and changed. A menu highlights the different adjustment
possibilities. Several menu points require an access code (0011) to
prevent accidental modification of important functions. In service mode all
alarms are deactivated.
All adjustments in service mode are menu-controlled. The 3 keys stand
for the function which is shown in the bottom line of the display. The main
menu is displayed first when you enter service mode.
Main Menu
The menu points are:
1. Location (the physical location of the G450)
2. User (user identity)
3. Datalogger (adjust datalogger function)
4. Confidence blip (adjust intervals)
5. Service (start service menu)
®
6. AutoCal
7. Options (adjust alarm volume and display contrast)
The keys’ functions are explained in the bottom line of the display. In the
main menu the keys have the following functions:
Left key (↓↓ scroll down)
Middle key (SELECT) select menu point
Right key (DETECT) back to detection
mode
13
Location – Entering a Location
From a deposited table one location out of a hundred possible locations
can be selected. The first two digits stand for the number of the table
entry. With the exception of “00” all other 99 entries can only be edited
with a PC. Within “00” up to 15 letters / figures can be entered, which will
be stored as operational place in the G450. Entry is automatically
completed when the cursor reaches the end mark (>).
When Location is selected by the middle key (SELECT), the following is
displayed, and the keys have the following functions:
First a location number is specified:
EDIT
- Change location name
EXIT
- Back to main menu
↑↑
- Change location number
After selecting a location number (by pressing the right key – ↑↑) the
location entry will be displayed. To change the location, press the left key
(EDIT).
The following is displayed, and the keys have the following functions:
ABC↓↓ - Select symbol – move down
<<>>
- Enter the blinking letter or
figure and move the cursor to
the right
012↑↑ - Select symbol – move up
User – Entering User Name
From a deposited table one entry out of ten possible entries can be
selected. The first two digits stand for the number of the table entry.
Except for “00,” the other 9 entries can only be edited with a PC. Within
“00” up to 15 characters can be entered, which will be stored as
“IDENTIFICATION” in the G450. Entry is automatically completed when
the cursor reaches the end mark (>). The entry process for user name
(ID) is the same as that of the location entry.
14
Datalogger
Within the “datalogger” menu point different settings can be accessed:
Full shows the used percentage of the
datalogger memory.
↓↓
- Jump to the next parameter
ERASE - Deletes data. A security
prompt will appear (delete
data?) Æ confirm with yes
(right key), deny with no (left
key).
EXIT
- Back to main menu
If Mode is selected, the instantaneous
value (Instant), average value (Average)
or peak value (Peak) can be chosen with
the left or right key.
If interval is selected, the data recording
interval can be set between 1 second and
60 minutes by pressing ↓↓ and ↑↑.
15
Datalogger (sample screen shots)
16
Confidence Blip
Within the Confidence blip menu point, the interval between confidence
blips can be chosen.
The confidence blip can be heard in
intervals of 15 to 90 seconds or be
deactivated (- -).
↑↑
- Scroll up
EXIT - Confirm interval and return to
main menu
↓↓
- Scroll down
17
®
AutoCal
®
The AutoCal menu point can be selected in the main menu or occurs
automatically when the calibration adapter (Smart Cap) is connected.
®
Within the AutoCal menu point the device can be calibrated with fresh
air (ZERO) or test gas (CAL).
®
ZERO - AutoCal with fresh air
®
CAL - AutoCal with test gas
EXIT - Back to main menu
Options
Within Options you can adjust
• The buzzer volume (90 dB or 103 dB)
• The screen contrast: 1 (very low) up to 15 (very high)
↓↓
- Scroll down
CHANGE - Change selected parameter
EXIT
- Back to main menu
Service Menu
Enter the service menu by selecting Service. Within the service menu the
G450 program parameters can be adjusted.
This menu point is only accessible with the code “0011.” The code
prevents important functions from being changed by mistake or by
unauthorized persons. In service mode all alarms are suppressed.
18
ABC↓↓
<<>>
012↑↑
- Previous digit
- Enter (cursor moves
automatically to the next
position). By holding the key
the last entry will be deleted
and the cursor will move
one position back.
- Next digit
After entering code “0011,” you enter the system menu (see System
Menu) and can perform general adjustments. Within the System menu
the sensors can be deactivated or calibrated. Information can be viewed
and alarm thresholds can be adjusted.
Select Sensors to adjust sensor-specific
functions.
DETECT
- Back to detection mode
System Menu
Within the System menu the following adjustments are possible:
Time
- Date and time
Inspection
- Date of next inspection
Information
- System information
Options
- Change language,
vibration alarm,
latching and auto save
settings
Sensor– Enable - Turn sensors on or off
®
®
AutoCal – Air - Enable AutoCal to
zero specific sensors
®
®
AutoCal – Gas - Enable AutoCal to
adjust the sensitivity
of specific sensors
19
Time
The blinking parameter is selected by
pressing SELECT.
>> moves to the next parameter.
EXIT returns to the system menu.
To change a parameter, the following
options are available:
↓↓
- Decreases value
EXIT - Confirms value
↑↑
- Increases value
Inspection
The date of the next maintenance or inspection can be entered under the
Inspection menu. When the date arrives, the G450 will automatically
sound an alarm. If the inspection date passes, the G450 will give a
reminder every time it is switched on.
Within the system menu, select Inspection.
EXIT
- Back to system menu
SELECT - Selects the blinking
parameter
>>
- Moves to the next
parameter
To change a parameter:
↓↓
- Decreases value
EXIT
- Confirms value
↑↑
- Increases value
Information
The unit type (G450), software version, serial number and battery type
can be viewed in the system menu point Information.
20
Options
In the Options menu point, the language can be changed, the vibrating
alarm can be activated or deactivated and the latching and auto save
features can be turned on or off.
↓↓
- Scroll down
CHANGE - Change setting for the
selected option
EXIT
- Return to system menu
Latching Alarm Function
The detector is shipped with the latching alarm function disabled. If the
alarms are set to latch, the audible and visual alarms will persist until the
alarm is acknowledged by pressing the center key (RESET). To enable
latching alarms, press the left key (↓↓) until Latching is highlighted. Press
the center key (CHANGE) to enable latching alarms.
Sensor – Enable
Each individual sensor can be activated or deactivated for each
measurement. This function is necessary for applications in which a gas
does not need to be measured or if the G450 will be upgraded with
different sensors.
ON or OFF indicates the status of the sensor (active or inactive). An
indicator in parenthesis – (ON) or (OFF) – means that the sensor is not
®
available. These indicators have the same meaning in the AutoCal – Air
®
and AutoCal – Gas menus.
ON
OFF
(ON) / (OFF)
↓↓
On / Off
EXIT
21
-
Sensor active
Sensor inactive
Sensor not available
Scroll down
Activate/deactivate sensor
Return to system menu
®
AutoCal – Air
®
This menu point is to enable AutoCal for sensors, using fresh air (zero
calibration). Generally all sensors will be zero calibrated and show “ON.”
↓↓
- Scroll down to next sensor
On / Off - Calibration / non-calibration
®
of sensor in AutoCal program
EXIT
- Return to service menu
®
AutoCal – Gas
®
This menu point is to enable AutoCal for sensors, using a test gas (gas
calibration). Generally all sensors (except O2) will be calibrated and show
”ON.”
↓↓
- Scroll down to next sensor
On / Off - Calibration / non-calibration
®
of sensor in AutoCal –
program
EXIT
- Return to service menu
Sensor Menu
The following functions refer to individual sensors in the G450. In the
service menu each individual sensor can be selected. The adjustments
are only valid for the selected sensor.
For a description of sensor-specific adjustments, the O2 sensor is being
used as an example. The adjustment options are the same for all
sensors.
↓↓
- Move to next sensor
SELECT
- Select sensor
EXIT
- Return to service menu
22
For each sensor, the following
adjustments can be made:
ZERO
- Adjust the zero point
Calibrate
- Sensitivity calibration with
test gas
Alarms
- Adjust alarm thresholds
Calibration - View the date and
dates
status of the last
calibration and zero
Information - View sensor information
↓↓
SELECT
EXIT
- Move to next menu point
- Select menu point
- Return to service menu
Zeroing – Adjust Zero Point
To adjust the zero point, the sensor menu point Zero must be selected.
START - Start zero point adjustment
GAS
- Enter zero gas concentration
EXIT
- Back to “O2 menu”
NOTE:
After entering GAS the display reads:
↓↓
- Zero gas value decreases by
one unit
EXIT
- Enter value and return to the
O2 menu
↑↑
- Zero gas value increases by
one unit
To set the zero point for oxygen, supply the unit with 100%
nitrogen through a calibration adapter.
23
Calibration
During calibration, the sensitivity of the G450 is adjusted. Before starting
calibration, make sure that the zero point adjustment has been done.
For calibration you need a suitable test gas, e.g.:
Detection Range Test Gas
Carbon monoxide (CO), hydrogen sulfide (H2S)
TOX
Fresh air or test gas with 20.9% volume oxygen (O2)
OX
in nitrogen (N2)
Methane (CH4)
EX
NOTE:
Please call GfG for the correct calibration gas for your
instrument.
To adjust sensitivity, the sensor menu point Calibrate has to be selected.
START - Start calibration
GAS
- Enter calibration gas
concentration
EXIT
- Return to O2 menu
After entering GAS the display reads:
↓↓
- Decreases calibration gas
value by one unit
↑↑
- Increases calibration gas
value by one unit
EXIT
- Saves value and returns to O2
menu
24
Alarms – Adjust Alarm Thresholds
The G450 provides 3 alarm thresholds for each non-toxic gas (O2, CH4).
For each toxic gas (H2S, CO) the G450 provides 2 alarm thresholds. The
alarms are triggered when the gas concentration exceeds or falls below
the threshold. For toxic gases an additional alarm for exceeded long-term
and short-term averages can be set.
After selecting the sensor menu point
Alarms the following reading is displayed
(here, for an O2 sensor):
↓↓
- Scroll down
EDIT
- Change alarm threshold
EXIT
- Back to O2 menu
After selecting the alarm thresholds by pressing EDIT (e.g.: Alarm 1), the
value can be entered:
↓↓
- Decreases alarm value by
one unit
EXIT
- Back to Alarm menu
↑↑
- Increases alarm value by one
unit
WARNING: If alarm points are set to off (--), the user will not be notified
of an alarm condition. This could result in injury or death.
Calibration Dates
Within the sensor menu point Calibration
dates, the date of the last calibration can
be displayed, as well as if the calibration
was successful (√) or not (a).
25
Information
In this menu point, specific information for the sensor can be displayed:
Type of sensor (ID)
- Type of
sensor
Serial number (SN)
- Serial number
Detection range (NR)
- Detection
range
Temperature range (TR) - Temperature
range
CH4 Unit
A unit equipped with a CH4 unit has an additional CH4 Unit menu point in
which you can set the CH4 sensor to detect in % LEL or % volume.
Activate Lights
The G450 provides an optional battery pack with lights. The lights can be
switched on or off by holding down the left key for approximately 5
seconds. The lights are useful when the device is tied to a cord and
lowered down into a sewer system. Using the lights can prevent the
device from being dunked under water.
Replacing the Batteries and the Rechargeable Battery Pack Module
NOTE: 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 the supply module, unscrew the two screws on the front of the
detector and pull the whole module backwards or insert the allen wrench
through one of the screw holes to push the module backwards.
When the alkaline batteries have to be replaced, use a thin object 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.
26
Charging the Optional NiMH Battery Pack
WARNING: The detector must not be charged in a hazardous location.
o
o
Only charge in non-hazardous atmospheres of 4 to 122 F (-20 to 50 C).
Charge the detector using only the
recommended charging adapter. Do
not use any other charging adapter, as
a fire or an explosion may result. Do
not connect the charging adapter to
voltages other than those used in North
America, or an explosion may result.
The rechargeable G450 battery pack
module can be charged with the GfG
Drop-in Charger. The Drop-in Charger
is available as a plug-in unit that can
be mounted to a wall or as a vehicle charging unit. For both versions,
make sure that the maximum connected voltage does not exceed 30 V.
To charge the G450, simply slide the device into the charging unit. The
G450 will beep and then display either “quick charge” or “trickle-charge.”
These two modes indicate the charge status of the G450. When the
rechargeable battery pack is completely depleted, it will take approximately
3 hours to recharge in quick-charge mode. Then the Drop-in Charger will
automatically switch to trickle-charge mode so that it is impossible to
overcharge the battery pack. Both charging modes are indicated on the
G450’s display. When the charger changes to trickle-charge mode, the
battery pack has reached at least 80% of its capacity. An additional 2-3 hours
of trickle-charge will fully charge the detector. The G450 will keep charging as
long as it is plugged into the charger. Charging can be stopped by removing
the G450 from the Drop-in Charger or by unplugging the charger.
Cleaning
The casing can be cleaned with a damp cloth. Never use solvents or
detergents!
27
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.
Service – Repair
WARNING: To avoid personal injury or damage to the detector, use only
the specified replacement parts.
A function test must be executed before the first operation and at least
once a year. This test comprises (depending on use and sensor exposure
to poisons and contamination):
• Check zero point
• Charge battery (optional)
• Check pump (optional) and diffusion inlets
• Test display with standard test gas (bump test) and adjust, if necessary
• Check alarm signals
• Test response time
NOTE:
GfG recommends that you “bump check” the sensors before
each day’s use to confirm their ability to respond to gas by
exposing the detector to a gas concentration which will exceed
the alarm set point of the sensor.
Any G450 repair must be done according to the manufacturer’s
instructions and with genuine spare parts. Return to GfG for proper
service.
28
Accessories and Replacement Parts
Part Number
7711-450
4002-001
4003-450
1450-202
1450-211
1450-212
1650231
7771-450
1450225
Aspirator, hand (with wand)
Batteries, alkaline (AA)
Battery hardware kit (includes 6 screws and hex key)
Battery pack, alkaline (without batteries) with vibrator
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
Calibration connector
Charger, plug-in (110 VAC) wall pack
4001-650
(for use with drop-in charger)
Charger, vehicle
4001-650V
Crocodile clip
943450
Datalogging kit – alkaline
1450235
(cable, software and drop-in cradle charger)
Datalogging kit – rechargeable (cable and software)
1450235R
Drop-in cradle charger (charge and data transfer)
1450220
Regulator, (for aluminum calibration gas cylinders) 0.5
2603-025
lpm fixed flow rate with pressure gauge and on / off knob
Regulator, (for steel calibration gas cylinders) 0.5 lpm
2603-020
fixed flow rate with pressure gauge and on / off knob
Sensor - carbon monoxide, (CO)
0-300 ppm
1450004
CO - 0-300 ppm
Sensor - COSH – dual channel sensor
1450002
H2S - 0-100 ppm
Sensor - hydrogen sulfide, (H2S)
0-100 ppm
1450003
Sensor - methane, (CH4)
0-100% LEL
1450005
(combustible gases)
Sensor - oxygen, (O2)
0 -25% volume
1450001
Software, datalogging (CD only)
1450233
Training DVD
3005-450
Spare parts and accessories should be stored at ambient temperatures of 32 to 86°F (0 to 30°C). Storage time
should not be longer than 5 years. Electrochemical sensors should not be stored for more than 6 months.
When you store oxygen sensors, be aware that storage reduces the expected lifetime of the sensor. When
storing spare sensors, make sure that the ambient atmosphere is free from corrosive substances and sensor
poisons.
29
Sensor Types and Detection Ranges
Warning: To avoid personal injury, use only sensors specifically
designed for this detector.
Plug
Sensor Part
Number
Detection
Range
Gas
Resolution
T-Band *
EC1
1450003
0-100 ppm
Hydrogen sulfide (H2S)
1 ppm
±1 ppm
EC2
1450004
0-300 ppm
Carbon monoxide (CO)
1 ppm
±3 ppm
EC3
1450001
0-25% volume
Oxygen (O2)
0.1% volume
±0.2% volume
PL
1450005
0-100% LEL
Methane (CH4)
0.5 %LEL
±2.5 %LEL
* T-Band = Tolerance band
30
Sensor Specifications
MK221 Catalytic combustion sensor for combustible gases and vapors (GfG part number
1450005)
Response time:
t50: <10 seconds t90: <30 seconds
Pressure
950 to 1,100
Maximum ±5% of detection range or ±15% of display (1,013 hPa)
hPa:
Humidity 5% to 90% r.h.: Maximum ±5% of detection range or ±15% of display (55% r.h.)
Temperature -4 to 122°F
Maximum ±3% of detection range or ±10% of display (68°F or 20°C)
(-20 to +50°C):
Expected lifetime:
3 years
MK429 Electrochemical sensor for hydrogen sulfide H2S (GfG part number 1450003)
Response time
t20: <5 seconds
t90: <45 seconds
Pressure
800 to 1,200
Maximum ±3 ppm or ±10% of display (1,000 hPa)
hPa:
Humidity 20% to 90% r.h.: Maximum ±3 ppm or ±10% of display (50% r.h.)
Temperature 50 to 104°F
Maximum ±3 ppm or ±10% of display (68°F or 20°C)
(10 to +40°C):
Temperature -4 to 122°F
Maximum ±3 ppm or ±20% of display (68°F or 20°C)
(-20 to +50°C):
Cross sensitivity:
SO2: 20% , NO2: 35% , NO: <2% , CO: <0.5% , H2 <0.1% (*1)
Expected lifetime:
3 years
MK369 Electrochemical sensor for carbon monoxide CO (GfG part number 1450002)
Response time
t90: <45 seconds
(<90 seconds without diffusion acceleration)
Pressure
800 to 1,200
Maximum ±3 ppm or ±10% of display (1,000 hPa)
hPa:
Humidity 15% to 90% r.h.: Maximum ±3 ppm or ±10% of display (50% r.h.)
Temperature -4 to 122°F
Maximum ±3 ppm or ±15% of display (68°F or 20°C)
(-20 to +50°C):
Cross sensitivity:
H2: <10% , NO: <9% , H2S: 0% , SO2: 0% (*1)
Expected lifetime:
3 years
MK376 Electrochemical sensor for oxygen O2 (GfG part number 1450001)
Response time:
t20: <5 seconds
t90: <10 seconds
Pressure
800 to 1,200
Maximum ±0.2% volume or ±2.5% of display (1,000 hPa)
hPa:
Humidity 10% to 90% r.h.: Maximum ±0.2% volume or ±2.5% of detection range (50% r.h.)
Temperature -4 to 122°F
Maximum ±0.5% volume or ±2.5% of display (68°F or 20°C)
(-20 to +50°C):
Expected lifetime:
3 years
MK380 Electrochemical sensor for CO and H2S (COSH) (GfG part number 1450002)
Response time:
<45 seconds
(<90 seconds without diffusion acceleration)
Pressure
800 to 1,200
Maximum ±3 ppm or ±10% of display (1,000 hPa)
hPa:
Humidity 15% to 90% r.h.: Maximum ±3 ppm or ±10% of display (50% r.h.)
Temperature -4 to 122°F
Maximum ±3 ppm or ±20% of display (68°F or 20°C)
(-20 to +50°C):
Expected lifetime:
3 years
(*1) Displayed value with reference to the supplied gas concentration
31
Technical Data
Type:
G450
Detection principle:
Electrochemical (EC): toxic gases and oxygen
Catalytic combustion (CC): combustible gases and vapors
(up to 100% LEL)
Detection range:
See Sensor Type and Detection Range
Response time t90:
See Sensor Specifications
Expected sensor life:
3 years
Gas supply:
Diffusion
Display:
Illuminated full-graphic LCD, automatic size adjustment for optimal
read out, battery capacity display, gas concentration as
instantaneous and peak value
Alarm:
Depending on gas type; 2 or 3 instantaneous and 2 dosimeter
alarms, low battery alarm
Visual and audible warning and display indication, coloring of
display depending on alarm status (orange/red)
Buzzer: 103 dB (can be restricted to 90 dB)
Climate conditions:
for operation: -4 to 122°F (-20 to +50°C) / 5 to 95% r. F. / 70 to 130 kPa
for storage: -13 to 122°F (-25 to +50°C) / 5 to 95% r. F. / 70 to 130 kPa
(recommended 32 to 86°F (0 to +30°C))
Zero point and
sensitivity calibration:
Manual or automatic with calibration program
Operational time:
Up to 25 hours
Power supply:
1. NiMH battery module, rechargeable
Im=1 A (maximum charging current)
Um=30 VDC (maximum voltage) or
2. Alkaline battery module, non-rechargeable with 2x size AA
Duracell MN1500 LR6
Casing:
Material:
Dimensions:
Weight:
Protection:
Rubberized plastic
4.3x3.0x2.2 inches (110x75x55 mm) (HxWxD)
10.23 oz. (290 g)
IP 67
cCSAus Class I, Division 1, Group A, B, C and D Hazardous locations
Approvals:
CSA Approval: Temp code T3
CSA C22.2 No. 152
ANSI / ISA-12.13.01-2000
Firmware Version 3.07
32
Caution
¾ Substituting components may hinder intrinsic safety.
¾ For safety reasons, this equipment must be operated and serviced by
qualified personnel only. Read and understand the user manual
completely before operating or servicing this device.
¾ Do not use the detector if it is damaged. Before you use the detector,
inspect the case. Look for cracks or missing parts.
¾ If the detector is damaged or something is missing, contact
GfG Instrumentation, Inc. immediately.
¾ Calibrate the detector before first-time use and then on a regular
schedule, depending on use and sensor exposure to poisons and
contaminants.
¾ 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.
¾ 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).
¾ 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.
¾ High off-scale readings may indicate an explosive concentration.
¾ Only the combustible gas detection portion of this instrument has been
assessed for performance by CSA International.
¾ 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.
¾ For use only in hazardous locations where oxygen concentrations do
not exceed 20.9% volume (v/v).
¾ 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.
33
¾ 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.
¾ Do not test the combustible sensor’s response with a butane cigarette
lighter; doing so can damage the sensor.
¾ Do not expose the detector to electrical shock and/or severe
continuous mechanical shock.
¾ 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.
¾ Electromagnetic interference (EMI) signals may cause incorrect
operation of this detector.
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 any such defect or to furnish a new part (at the option of
GfG Instrumentation) in exchange for any part of any product that 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
examination 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. No
agent or reseller of GfG Instrumentation may alter the above statements.
34
G450/460 Motorized Pump
Application and Use
The G450/460 motorized pump ensures
personal safety in atmospheric conditions in
combination with the portable gas detectors
of the G400 series.
The G450/460 pump is designed for use in
explosion endangered areas and is
designed for conformity with ATEX II2G Ex
ia IIC T4 or T3.
Special Conditions for Safe Use
In hazardous locations the G450/460 pump must be used properly; i.e.,
the pump (with a G400 series gas detector) must be carried with you and
must not be laid down unattended (to prevent electrostatic charge).
The pump must be attached to the G400 gas detector before entering a
hazardous location. It must not be disconnected from the detector in the
hazardous location.
Always pay attention to the ignition protection and the temperature class
of the gas detector.
35
General Description and Design
The G450/460 pump is a very small and convenient supplemental module
for the G400 series gas detector. It allows gas sampling from a safe
distance, without exposing the user to hazardous locations. The pump
has its own power supply, which works independently from that of
the G400 series monitor.
Sampling Inlet
The sampling inlet is on the
bottom of the pump body.
Here you can attach
accessories for taking gas
samples (hose adapter with
sampling line, probe, GfG
telescopic probe).
Sampling inlet
36
Connection for
gas sampling
accessories
Connecting the Pump
Attach the G450/460 pump to the G400 series gas detector and secure it
with the thumbscrews.
For permanent attachment to the G400 series gas detector you can attach
the pump with 2 additional screws (included). You will find the mounting
holes for the additional screws under the red sensor cover. To access the
holes, slide the sensor cover upwards – push the lock smoothly with a
screw driver – and remove it. Once the screws are in place, replace the
sensor cover and slide it downwards.
To remove the pump from the G400 series monitor, remove all attached
screws.
Operational Hints
NOTE!
If the red sensor cover is slid upwards forcefully, it may slip over
its lock and the diffusion inlets will not be properly covered. This
may result in false detection, since ambient air could dilute the
concentration of the gas sample. Make sure, therefore, that the
diffusion inlets are closed properly.
For sampling gases from sewers, rooms or drains, a hose (with or without
a telescopic probe) that is plugged into the intake can be used. As the
response time heavily depends on the internal volume of the intake hose,
the length should be as short as possible. For the minimum pump time
(Tmin in seconds) please adhere to the following calculation:
Tmin = 20s + 3s / m*Lhose + TTele
Lhose = length of hose (inner diameter 5 mm) in meters
TTele = 10 s with telescopic probe, 0 s without
Turning the Pump On
Slide the red sensor cover upwards to turn the pump on. With sufficient
battery capacity the pump motor starts after a short delay (approximately
1 second). The battery capacity is indicated by flashing signals (see Test
Battery Capacity).
The proper operation of the pump is indicated by a continuously lit green
LED (see Test Battery Capacity).
37
Turning the Pump Off
Slide the red sensor cover downwards to turn the pump off. The pump
should be turned off after detection to prevent unnecessary use of the
batteries.
Confidence Signal
During sampling, a green LED remains continuously lit to indicate
trouble-free operation.
Low Flow Alarm
If the sampled gas amount is too low (<0.25 lpm) or if the power supply to
the pump motor is interrupted, the unit’s red LED flashes as an alarm.
Low flow alarm signal
Approximately 5 LED-pulses per second
REASON:
Gas flow is blocked or sampling line is bent. For proper
operation, make sure that the gas passageway is free.
ATTENTION: During a low flow alarm, proper detection in connection with
the G400 series monitor cannot be assured.
Power Supply
The G450/460 pump is powered by an alkaline battery module. The power
supply module allows continuous operation for up to 10 hours. The
operational time may be reduced, however, by a high load on the pump
motor (e.g. bent sampling line/blocked filter).
The G450/460 pump turns off automatically if the battery voltage falls
below the minimum level needed for proper functioning. At least 15
minutes before automatic deactivation, the green LED flashes once per
second to indicate insufficient battery voltage.
38
Battery Replacement
NOTE: The pump must not be opened in hazardous locations. Do not
replace the alkaline battery module in hazardous locations.
Always turn the pump off before replacing the alkaline battery module.
Check for the correct polarity of the new 1.5 V AA alkaline batteries (see
Battery Holder).
The correct battery type is: DURACELL PROCELL MN1500 LR6 AA.
NOTE: The batteries may only be replaced in safe areas. Check for
correct polarity when inserting the batteries (see the picture
inside the battery tray). With incorrect polarity the pump will
not turn on.
Battery tray
To replace the batteries, separate the battery tray from the pump:
unscrew the screws on the front and pull the battery tray out of the unit.
Please adhere to disposal requirements!
39
NOTE:
• Batteries must not be replaced in hazardous locations
• Check for the correct polarity of the new batteries (see the picture on
inner side of battery tray)!
• Check for correct insertion of the battery tray (characters on front must
be right side up)!
Tighten all screws after inserting the battery tray.
Test Battery Capacity
Once the pump is turned on, the battery capacity is automatically
indicated by means of the number of flashes of the green LED. To
activate the battery test, turn the pump on (slide the red sensor cover
upwards).
1
2
3
Empty
4
5
Full
Number of pulse-signals
Battery capacity
After indicating the battery capacity, the LED stays dark for 2 seconds
before the confidence signal appears.
System Fault
System fault 1
System fault 2
Approximately 10 red LED pulses per
second
1 red LED pulse every 2 seconds
The circuitry of the G450/460 pump is continuously monitored. If a fault is
recognized, a visual alarm is triggered. To correct this problem, replace
the batteries. If the fault still exists, return the unit to the manufacturer.
40
Appendix
Cleaning
Give the G450/460 pump a short visual check after use.
Use a damp cloth to remove stains or dirt from the
casing. Never use solvents or cleaning agents!
Changing the Filter
To change the filter, separate the pump from the G400
series monitor and slide the red cover down. Use
tweezers to remove the filter and replace it with a new
Filter
one.
Inspection
In addition to regular maintenance, the user has to do the following checks at
least before every shift:
• Visual check for damage
• Check battery capacity
• Check sampling performance
Maintenance and Regular Function Check
Depending on application conditions and technical requirements,
maintenance should be done in intervals required by the application.
Maintenance includes measures which retain the operational status of the
G450/460 pump.
• Visual check for damages
• Check filter condition
• Check pump battery capacity
• Check confidence signal
• Check sampling performance
• Check low flow alarm
In addition to the above, we recommend getting the pump checked for proper
functioning by an expert in combination with the (at least) annual maintenance
of the G400 series monitor.
Service
Service should be done by the manufacturer. Only genuine spare parts
must be used for service and repair.
41
Replacement Parts and Accessories
Description
Alkaline battery (each)
Battery tray without alkaline batteries
Float probe
Sampling probe (without tubing)
Special dust / water filter (pack of 3)
Special sampling line 10 feet, anti-static,
with dust / water filter
Special sampling line 10 feet, anti-static,
with dust / water filter and flow indicator
Special sampling line for exotic gases (one foot)
Telescopic probe CrNi 1.36 m
42
Part Number
4002-001
1450-200
On request
1000214
1000207
1000208
1000209
2806-011
1000205
Technical Data
G450/460 Motorized Pump
0.50 lpm for 0 mm water column
0.35 lpm for 300 mm water column
Maximum 100 m hose length (depending on gas and hose)
Sampling inlet during pump mode or diffusion inlet
Gas supply:
Indication and Green LED: Indication of battery capacity and confidence signal
Battery alarm
Alarm:
Red LED: Low flow alarm and system fault
Power supply: Alkaline battery module (grey casing), non-rechargeable with 2x
Mignon 1.5 V type DURACELL PROCELL MN1500 LR6 AA
Operational
Approximately 10 hours
time:
Climate Condition:
For operation: -4 to 131°F (-20 to +55°C) / 5 to 95% r. h.
-13 to 131°F (-25 to +55°C) / 5 to 95% r. h.
For storage:
(recommended: 32 to 86°F (0 to +30°C))
Casing:
Material: Rubberized compound
Dimensions: 4.29x2.68x.83 inches (109x68x21 mm) (HxWxD)
Weight: 6.35 ounces (180 g) with alkaline battery module
Protection: IP 40
Type:
Pump
performance:
Firmware Version 2.00
43
1194 Oak Valley Drive, Suite 20
Ann Arbor, Michigan 48108 USA
Phone: (800) 959-0329 or (734) 769-0573
Fax: (734) 769-1888
E-mail: [email protected]
Web: www.gfg-inc.com
GfG reserves the right to change part numbers, prices,
and/or technical information without notice.
7004-450 102407
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