TVOC Unrivalled Detection. Instrument User Manual V4.3

TVOC manual
TVOC
Instrument User Manual V4.3
Part number: 849215
Unrivalled
Detection.
www.gastech.com.au
TVOC manual
Part number: 849215
www.gastech.com.au
TVOC manual
www.gastech.com.au
Declaration of conformity
Manufacturer:
Ion Science Ltd, The Way, Fowlmere, Cambridge, SG8 7UJ, UK
Product:
TVOC
Product Description: An intrinsically safe fixed continuous monitor comprising of a photo-ionisation
detector for detecting and measuring volatile organic compounds with a 4-20mA
output
Directive 94/9/EC
ATEX
Identification:
Notified Body:
II 2G Ex ia IIC T4 (-20 C ≤ Ta ≤ +50 C)
Baseefa Ltd, 1180, Buxton, UK
Identification:
II 3G Ex nL IIC T4 (-20 C ≤ Ta ≤ +50 C)
Ion Science Ltd Self certified EC Type Examination Certificate(s)
Baseefa05ATEX0277
latest supplement Baseefa05ATEX0277/2 issued 24 November 2008
o
o
o
o
th
rd
Ionscience09ATEX002 Examination certificate issued 3 September 2009
Ref Ion Science Cert Report 849237, 849242
International Standards
IECEx BAS 06.0057
Standards
BS EN 60079-0:2006
th
latest revision no.1 issued 20 November 2008
Ref Baseefa Cert Report 05(c)0423, 06(c)0614, 08(c)0578
Electrical Apparatus for Potentially Explosive Atmospheres – General Requirement
BS EN 60079-11:2007 Explosive Atmospheres - Equipment Protection by Intrinsic Safety ‘i’
BS EN 60079-15:2007 Explosive Atmospheres - Equipment Protection by other means ‘n’
BS EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control and
laboratory use – General requirements
Directive 2004/108EC Electrical Equipment – Electromagnetic Compatibility (EMC)
EN61000-6-3:2007
EN50270:2006
Class 1 (light industrial and domestic) Electromagnetic Compatibility (EMC) Generic
standards. Emission standard for residential, commercial and light industrial
environments
Electromagnetic compatibility. Electrical apparatus for the detection and
measurement of combustible gases, toxic gases or oxygen.
Other Standards
BS EN ISO 9001:2008 Quality Management Systems – Requirements
BS EN 13980:2002
Potentially Explosive Atmospheres – Application of Quality Systems
On behalf of Ion Science Ltd, I declare that, on the date this product accompanied by this declaration is
placed on the market, the product conforms to all technical and regulatory requirements of the above listed
directives.
Name: Mark Stockdale
Position: Technical Director
Signature:
Date: 20 November 2009
Unrivalled Detection.
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Contents
Declaration of conformity ............................................................................................................................... 3
Statements ....................................................................................................................................................... 5
Responsibility for use ..................................................................................................................................... 5
Quality assurance .......................................................................................................................................... 5
Disposal ......................................................................................................................................................... 5
Legal Notice ................................................................................................................................................... 5
Introduction to TVOC ...................................................................................................................................... 6
Packing list ....................................................................................................................................................... 8
Standard TVOC instrument ............................................................................................................................ 8
TVOC Calibration Tool Kit .............................................................................................................................. 8
TVOC setup ...................................................................................................................................................... 9
Selector Pins .................................................................................................................................................. 9
Duty Cycle .................................................................................................................................................... 10
Installation ...................................................................................................................................................... 11
Location ........................................................................................................................................................ 11
Cable and gland requirements ..................................................................................................................... 11
Dimensions for mounting ............................................................................................................................. 12
Power requirements ..................................................................................................................................... 13
Initial calibration ........................................................................................................................................... 15
Operation ........................................................................................................................................................ 16
Start Up ........................................................................................................................................................ 16
Adjusting the Duty Cycle .............................................................................................................................. 16
LED’s ............................................................................................................................................................ 17
Selector pins ................................................................................................................................................ 17
Calibration mode .......................................................................................................................................... 17
Calibration gases ......................................................................................................................................... 17
Calibration routine ........................................................................................................................................ 18
Setting the ZERO ......................................................................................................................................... 18
Setting the gas concentration (The actual value that the calibration has been supplied at) ....................... 19
Setting the SPAN ......................................................................................................................................... 19
Maintenance ................................................................................................................................................... 21
Cleaning / replacing the lamp ...................................................................................................................... 21
Fuse rupture and replacement ..................................................................................................................... 23
Lamp Warranty Statement ........................................................................................................................... 23
System recommendations ............................................................................................................................ 24
Remote area monitoring............................................................................................................................... 24
Gas sample systems .................................................................................................................................... 24
Instrument warranty and service ................................................................................................................. 26
Warranty ....................................................................................................................................................... 26
Service ......................................................................................................................................................... 26
Contact details ............................................................................................................................................. 26
Diagnostics .................................................................................................................................................... 27
F4 errors ....................................................................................................................................................... 28
Spare parts ..................................................................................................................................................... 29
Technical specifications ............................................................................................................................... 30
Manual log ...................................................................................................................................................... 31
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Statements
Responsibility for use
TVOC detects a large range of gases, which are potentially dangerous from both a poisoning and/or an
explosive perspective. TVOC has a number of selectable features allowing the detector to be used in a
variety of applications. Ion Science Ltd can accept no responsibility for the incorrect adjustment of features
that cause harm or damage to persons or property. It is the users’ responsibility to respond appropriately to
the readings delivered.
Inadequate performance of the gas detection equipment described in this manual may not necessarily be
self-evident and consequently equipment must be regularly inspected and maintained. Ion Science
recommends that personnel responsible for equipment use institute a regime of regular checks to ensure it
performs within calibration limits, and that a record be maintained which logs calibration check data. The
equipment should be used in accordance with this manual, and in compliance with local safety standards.
Warning
1. Substitution of components may impair intrinsic safety and result in unsafe conditions.
2. For reasons of safety, TVOC must only be operated and serviced by qualified personnel.
3. Please read and understand this user manual fully before installing, operating or servicing TVOC.
Quality assurance
TVOC has been manufactured in compliance with ISO9001:2008, which ensures that the equipment
supplied to our customers has been designed and assembled reproducibly, from traceable components, and
leaves Ion Science calibrated to stated standards.
Disposal
Dispose of TVOC and its components in accordance with all local and national safety and environmental
requirements. This includes the European WEEE (Waste Electrical and Electronic Equipment) directive. Ion
Science Ltd offers a take back service. Please contact us for more information.
Legal Notice
Whilst every attempt is made to ensure the accuracy of the information contained in this manual, Ion Science
accepts no liability for errors or omissions, or any consequences deriving from the use of information
contained herein. It is provided "as is" and without any representation, term, condition or warranty of any
kind, either express or implied. To the extent permitted by law, Ion Science shall not be liable to any person
or entity for any loss or damage which may arise from the use of this manual. We reserve the right at any
time and without any notice to remove, amend or vary any of the content which appears herein.
Unrivalled Detection.
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Introduction to TVOC
TVOC is a fixed continuous monitor for the detection and measurement of total volatile organic compounds,
which can be dangerous from both a poisoning and explosive perspective. Total VOC’s are detected using
PID (Photo ionisation detection) technology.
TVOC has a number of user selectable features which define its operation and will be application dependent.
The user can define the detection ranges or 0.01 - 10ppm, 0.1 – 100 ppm or 1 – 1,000 ppm (Default);
3
detection units, either ppm or mg/m ; and the duty cycle time i.e. the frequency that the instrument takes a
measurement. Duty cycles are explained in more detail under TVOC set up, and Operation.
IMPORTANT: TVOC can be calibrated on alternative gases to Isobutylene however to ensure TVOC
remains within specification, the correct concentration for the alternative gas must be chosen.
Example: Benzene gas has a response factor of 0.5 which means only half as much concentration is
required to produce the equivalent to Isobutylene.
The ideal gas / concentrations used to set the calibration SPAN are shown below:-
10 ppm range
100 ppm range
1,000 ppm range
Lower limit
8 ppm
90 ppm
90 ppm
Upper limit
12 ppm
110 ppm
110 ppm
Isobutylene equivalent
Isobutylene equivalent
Isobutylene equivalent
How to calculate alternative concentration of gases for gases other than Isobutylene:Ideal response
Response factor
Ideal calibration gas
for Isobutylene
concentration
Benzene
100
x
0.5
=
50 ppm
Isoprene
100
x
0.7
=
70 ppm
Isobutylene
100
x
1.0
=
100 ppm
Carbon Disulphide
100
x
1.4
=
140 ppm
Ethyl Acrylate
100
x
2.0
=
200 ppm
For other gas response factors please refer to the Ion Science web site or contact Ion Science Ltd.
http://www.ionscience.com/GasSearch/tabid/87/Default.aspx
WARNING: Ignoring these guide lines may result in calibration failure, loss of resolution or loss of range.
The default settings of TVOC are:
Detection range
–
Units
Signal update
-
1 – 1000 ppm
ppm
1 minute (60 seconds)
TVOC gives a continuous 4 – 20 mA output which can be integrated into a DCS control system to give an
indication of VOC levels in the operating environment. Note the 4-20mA output must be externally powered
with 8-35V.
In addition to the 4 – 20 mA output TVOC has an LCD display showing gas concentration and 4 colour
LED’s. LED functions are as follows:
Green
- is an indicator of TVOC’s working status
Red
- is the fault indicator
Yellow x 2
- are calibration status indicators
Please see Calibration for more information on LED status.
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Introduction to TVOC
For installation requirements please refer to Installation and Technical Specification of this manual. Before
attempting an installation, please fully read and understand this user manual, and for hazardous area (IS)
installations please also refer to the TVOC Intrinsically safe certificate for further details.
The TVOC safety rating permits its deployment in all hazardous areas of the quoted (or less demanding)
st
rating. For detail please refer to the marking on your instrument (found on the front main label). As of 1 of
October units will be manufactured with two protection concepts applied by separate certifications. Intrinsic
safety (ia) and Non sparking (nA). All units manufactured up to that date will only have intrinsic safety.
a) Intrinsic Safety (ia) permits the deployment in areas where explosive gases (of group IIA, IIB and IIC) are
intermittently present (zone 1) with an ambient temp range of -20°C to 50°C. Intrinsically safe installations will
require the use of safety barriers and appropriate wiring.
b) Non sparking (nA) permits deployment in areas where explosive gases (of group IIA, IIB, IIC) are unlikely
but possible (Zone 2) with ambient temp range of -20°C to 50°C. Non sparking installations do not require
safety barriers however the maximum working voltage should be strictly adhered to as a matter of safety. As
no safety barriers are required there is complete flexibility on the implementation of 3 wire system.
TVOC does require regular calibration onsite please see the Calibration section for more information. TVOC
calibration mode is accessed via a magnetic read switch system.
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Packing list
All items of equipment shipped by Ion Science Ltd are packed in suitable containers and enclosed in a shock
absorbing filling which affords a considerable degree of protection against physical damage.
Contents should be carefully removed and checked against the packing list. Any discrepancies between the
contents and the packing list must be reported to Ion Science Ltd within 10 days of receipt of shipment. Ion
Science cannot be held responsible for shortages not reported with in the period.
Standard TVOC instrument
Item
Description
1.
TVOC instrument
2.
Cable gland M20 (Intrinsically Safe Certified)
3.
Blanking plug M20 intrinsically (Intrinsically Safe Certified)
4.
TVOC Manual
Qty
1
2
1
1
TVOC Calibration Tool Kit
Item
Description
1.
Calibration magnet
2.
Calibration adaptor
3.
Calibration connector
4.
Aspirator
5.
Carbon filter
6.
Allen keys
Qty
1
1
1
1
1
1
3. Calibration
Connector
2. Calibration
Adaptor
1. Calibration
Magnet
6. Allen Keys X 2
5. Carbon
Filter
4. Aspirator
Diagram 1
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TVOC setup
Selector Pins
TVOC has a number of settings that can be selected by the
user via a row of 4 selector pins mounted on the reverse side of
the main PCB. Diagram 2 shows the location of the functional
selector pins labelled - A, B, C & D.
The selector pins absence or presence determines the chosen
setting.
TVOC is shipped with all 4 selector pins fitted as shown in
diagram 3.
Diagram 2
Diagram 3
Diagram 4 shows the removal of 1 selector pin.
Diagram 4
The following table shows the selector pin combinations and the corresponding function.
= Selector pin fitted
 = Selector pin removed
Selector pin
A






B


x


x
C

x


x

D



x
x
x
Range
1000
100
10
2280
228
22.8
Displayed units
ppm
(Default)
ppm
ppm
3
mg/m
3
mg/m
3
mg/m
Selector pin ‘B’ and ‘C’ selects the ranges
10ppm, 100ppm or 1,000ppm
3
Selector pin ‘D’ selects the units
ppm’ or ‘mg/m
Selector pin ‘A’
Fault output range
NOTE: During an Alarm condition (F1 or F2) the output will drop to either 3.5 mA or 2.0 mA.
Jumper ‘A’ fitted = 3.5 mA during an alarm condition
Jumper ‘A’ removed = 2.0 mA during an alarm condition.
As default, the TVOC has a 100 ppm factory calibration
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TVOC setup
NOTE:
* TVOC is shipped with ALL selector pins fitted as standard
* TVOC only reads the selector pin settings when power is connected.
Always ensure power is disconnected from TVOC before changing
setting or carrying out maintenance.
* Never place selector pins on the programming port connector.
* Ensure static build up is discharged before touching components.
* IF the jumper selection is not a recognised option then error F4 will occur. To recover
switch the instrument off perform the correct jumper selection and switch the instrument
back on.
Duty Cycle
The life of a photo ionization lamp is used up when the lamp is illuminated, the lamp window can also
contaminate resulting in a reduced level of detection. The TVOC pulses the lamp on and off which extends
lamp life and reduces lamp contamination. This in turn can increase the time between servicing.
The TVOC switches on the lamp, takes a reading and then
updates the 4-20mA output and display screen. The default Duty
Cycle is the frequency between test cycles, the factory default is
set to 1 minute however this time can be adjusted from 0 to 5
minutes.
Please note: When bump testing after a calibration the response
may be delayed depending on when in the gas is applied during
the test cycle.
Fast response mode
The TVOC can be set to Fast Response Mode, when selected the TVOC will update the output every 1
second. Fast response mode can be selected by setting both the seconds and minutes to 0.
Please note: The warrantee of Ion Science PID lamps is based upon a duty cycle of 1 minute. Lamps used
with Duty Cycle below 1 minute will not be covered under the standard warrantee terms.
Unrivalled Detection.
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Installation
Location
There are many variables involved in defining the optimum location for a gas detector. Obvious though it may
sound, the most important rule is:









A detector will not detect gas unless gas actually reaches the detector
TVOC should be mounted in the location most likely to detect gas.
TVOC must be mounted vertically with the sensor underneath the case. This avoids dust and debris
blocking the access to the detector cell.
Mount TVOC higher if detecting VOC gases that are lighter than air or lower if detecting VOC gases
that are heavier than air (but never on the floor). This should maximise detection.
Mount TVOC in an area that has good air circulation. Restricting natural air current may result in
delayed detection.
Never mount TVOC in direct sunlight or over a heat source such as a radiator. This may cause TVOC
to exceed its certified working range.
Do not mount TVOC in areas likely to flood.
Mount TVOC’s in areas that are easily accessible for servicing.
Percentage variations in the composition of air (78% Nitrogen, 21% Oxygen and 1% Argon) may affect
the detected signal.
Please refer to the technical specifications of the instrument under Technical Specifications of this
manual before beginning a TVOC installation.
Cable and gland requirements
2
The Screw terminal sockets for connecting wires in the TVOC accept wires of 0.5mm to 2.5mm
C.S.A.
2
Screened cables for both power and signal out are necessary to achieve EMC compliance. Cable
screens must be terminated at both ends for them to be effective in achieving electromagnetic
compatibility (EMC). The screens should be terminated to the TVOC enclosure using EMC
compatible cable glands. It is important for an EMC compatible gland to make electrical contact to the
enclosure. This is usually done using a serrated washer or EMC lock nut that bites through the paint
making electrical contact. EMC lock nuts have been provided. These locknuts are orientation specific
the points should be facing against the case in order to cut through the paint during tightening.
Two M20 cable glands and one blanking plug have been supplied as standard to ease installation in
most circumstances. These parts will not be appropriate for all applications so they should be used at
the discretion of the installation engineer. It is recommended that the manufacturer’s instructions are
followed for the gland and blanking plug installation. The M20 blanking plug has been included to
enable installations using a single entry cable (for example a three wire system) to be implemented.
While ion science can not recommend the cable gland suitable for every application the following
information may be useful to the installation engineer for the selection of the appropriate cable gland.
 For intrinsically safe operation using safety barriers, the only requirements on the cable
glands are that they are better than IP20 rated. This may seem extraordinary however
where the power is safely limited to the TVOC it is intrinsically safe so does not rely on the
prevention of dirt or moisture into the enclosure.
 For intrinsically safe operation in Zone 2 without safety barriers, cable glands must be ATEX
or IECX rated (Ex e, Ex n or Ex d) and at least IP54.
Installation of the TVOC depends on preferences of the installer, Intrinsically Safe Operating legislation and
the application.
Ion Science suggests connecting the screens from cables via a gland as shown on the diagrams and under
Installation Section of this manual.
There may however be technical circumstances where connection to the PCB is necessary.
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Installation
Dimensions for mounting
Diagram 5
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Installation
NOTE:
The TVOC case can be used as a template when marking out fixing holes but do not drill
through the fixing holes.
Power requirements
Non Intrinsically Safe Operation applications:
2
2
Input power
5 - 28Vdc. 80mA max. (0.5mm to 2.5mm C.S.A.)
Output power (4-20mA)
2
2
8-35Vdc. 22mA (0.5mm to 2.5mm C.S.A.)
Note: 4-20mA loop must be externally powered.
4 Wire System
(Non IS)
Diagram 6
3 Wire System
(Non IS)
Diagram 7
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Installation – Hazardous location
Warning!
The label on the enclosure details the IS and nA certifications. The appropriate section of the Intrinsically
Safe label should be covered up or blocked out to reflect the type of installation. For Non Intrinsically Safe
applications the label should be covered completely. For Intrinsically Safe zone 2 applications with out safety
barriers the ia certification details should be blanked out. For Zone 1 or 2 IS applications with safety barriers
the nA certification details should be covered.
This will prevent safety discrepancies and or mis-use in the future should the equipment be moved or the site
be re-defined as a hazardous area.
Intrinsically Safe nA (Non sparking) applications for Zone 2 areas only: Entry parameters
Input power
5 to 24Vdc 80mA max
Output power (4-20mA) 8-35Vdc. 22mA
For information only please see Intrinsically Safe Operation certificate before installation
The wiring of Intrinsically Safe systems is identical to the wiring showing for non Intrinsically Safe
applications. The only difference is the requirements to ensure that the power supplied used provides 24v or
less in normal operation.
Intrinsically Safe (IS) applications:
Entry parameters
Input power
Ui = 18V
Ii = 800mA
Pi = 1.2W
Ci = 0F
Output power(4-20mA) Ui = 30V
Ii = 200mA
Pi = 1.2W
Ci = 0F
For information only please see Intrinsically Safe certificate before installation
Li = 0mH
Li = 0mH
Ion Science Ltd suggest using the following Zener Barriers for IS approved applications. Use competent
installation engineers and ask them for installation and application advice.
Note



All cable lengths are estimated for zone 1 IIC installation of the equipment
2
Using 1mm C.S.A conductor S.T.P cables with capacitance per meter of 250pF/m, L/R ratio of
25uH/ conductor resistance at 20C of 18.4/km.
Calculation assumes cables are at 50C.
Warning!
Intrinsically Safe (IS) applications
 Units should not be powered using non IS power supplies prior to installation in an IS application.
 If non IS power is supplied the unit will require inspection by Ion Science Ltd or an Ion Science Approved
Service Centre prior to installation in an IS application.
 TVOC fuses may not be replaced in the field.
 If a fuse is blown TVOC will require inspection by Ion Science Ltd or and Ion Science Approved Service
Centre before it is used in an IS application
Unrivalled Detection.
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Installation – Hazardous location
4-wire Control equipment sensing 4 – 20 mA on return line
Diagram 8
Notes:
 For intrinsically safe installations, the enclosure may be opened while the system is live,
provided the work is undertaken by competent personal and suitable safety precautions are
taken. This overrides the warning on the enclosure label.
Initial calibration
TVOC is calibrated at Ion Science before dispatch using 100ppm Isobutylene. However if you wish to
calibrate your TVOC once it is installed Ion Science recommends that the TVOC is left to run on its chosen
settings (see TVOC Setup Section) for 24 hours before an initial calibration is carried out, to allow the
instrument to settle into the working environment.
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Operation
Start Up
After electrical power is connected, TVOC runs through a ‘Start up’ routine, which lasts for approximately 1
minute. During this ‘Start up’ routine TVOC demonstrates the following characteristics:
* The LCD screen displays the software version number
* The GREEN LED flashes
* The 4 – 20 mA output is set to 4 mA (0.0 ppm)
NOTE: If the 0-10ppm range is selected the TVOC will require calibration using 10ppm Isobutylene before
use (See the calibration section of this manual)
During this ‘Start-up’ time the user can adjust the Duty Cycle time as referred to in TVOC Setup under the
Duty Cycle section. This time can be adjusted from 0 to 5 minutes in 10 second increments.
Adjusting the Duty Cycle
NOTE: Please read this entire procedure before attempting to adjust the lamp OFF time.
There are two stages to adjusting the Duty Cycle time. The first stage adjusts the seconds 0 to 59 seconds,
the second stage adjusts from 0 to 5 minutes. Please see the description of the Duty Cycle on page 10.
1. During the 1 minute ‘Start up’ time place the calibration magnet over the top
right hand corner of the Ion Science logo. (See diagram 9) Two numbers on the
right of the LCD screen will flash.
Diagram 9
2. While the magnet is held in this position the number on screen will roll over from 00
through to 50 in 10 second steps. Quickly remove the magnet when the desired time
appears.
3. After 5 seconds the TVOC will move on to the next stage. (Reapply the magnet
within 5 seconds if further adjustment is necessary)
4. The TVOC will move to the next stage indicated by a digit appearing on the left of
the screen. Holding the magnet in place will cause this number to roll over from 0 to 5
minutes. Quickly remove the magnet when the desired time appears.
5. After 5 seconds the TVOC will display both the minutes and seconds selected.
(Reapply the magnet within 5 seconds if further adjustment is necessary)
6. TVOC will restart the start-up sequence and then enter running mode. The Duty
cycle is then saved to memory. The duty cycle will be remembered through a power
cycle.
Fast response mode
If the Duty Cycle time is adjusted lower than 0:10 (10 seconds) the instrument will update the output every
seconds. In this mode of operation the F2 fault condition is disabled. This means that removal of the sensor
may go undetected as ambient light may is detected by the lamp on sensor mounted under the PID sensor.
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Operation
LED’s
The GREEN LED indicates TVOC’s working status
ON
Indicates the PID lamp is OFF
Flashing
Indicates the PID lamp is ON
The RED LED indicates Fault status
ON
Indicates TVOC cannot function correctly. The 4-20mA output drops
to 3.5mA.
URGENT attention is required.
Flashing
Indicates the TVOC cannot function but a reading is being
attempted
The Yellow Zero LED indicates during normal operation
ON
Last calibration zero level was outside expected limits
(The instrument will operate normally with the previous calibration)
The Yellow Span LED indicates during normal operation
ON
Last calibration Span level was outside expected limits
(The instrument will operate normally with the previous calibration)
last calibration carried out was outside expected limits. The instrument will continue
working but service is required.
Please see Section 7 Calibration for YELLOW LED status.
Selector pins
TVOC has a range of options that are selected via the selector pins on the back of the main PCB (please see
the TVOC Set up Section).
The options are shown below with the defaults highlighted in bold:
1-1000ppm
or
0.01 – 10 ppm or 0.1 – 100 ppm
ppm units
or
mg/m units
3
Calibration mode
TVOC calibration mode can be accessed using the calibration
magnet supplied in the TVOC calibration tool kit (Part number: A845214).
To enter calibration place the magnet over the top right of the Ion
Science Logo until the state changes (i.e. an LED illuminates and/or
the display changes).
Ensure the magnet is withdrawn away from the magnetic switch by
at least 1 cm once a change has occurred.
Calibration gases
TVOC has three (3) ranges that can be selected however the 010ppm range requires the instrument is calibrated by the user before
use. The 0-100ppm and the 0-1000ppm ranges can initially run
using the Factory calibration carried out during the instruments
manufacture, however because the 0-10 ppm range is more
sensitive and more susceptible to environmental and system
tolerances the instrument must be calibrated before use.
Diagram 10
If the 0-10 ppm range is selected TVOC will display the following
screen to indicate that a calibration is required before it can be used.
Follow the calibration instructions before use.
Diagram 11
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Calibration
Calibration routine
Ion Science recommends calibrating TVOC after any maintenance or lamp cleaning is carried out and on a 3
monthly basis to ensure TVOC is working to specification.
NOTE: Please read this entire calibration procedure before attempting a calibration.
TVOC calibration has 4 stages:
1. Setting the ZERO
2. Setting the gas tolerance
3. Setting the SPAN
(Using clean gas via carbon filter)
(1 – 200 ppm Isobutylene on 0-100 ppm and 0-1000 ppm ranges)
(0.1 – 20.0 ppm Isobutylene on the 0-10ppm range)
(Using the SPAN gas)
GREEN
STATUS LED
ZERO LED
SPAN LED
FAULT LED
Diagram 12
Setting the ZERO
1–
2–
3–
4–
Place the calibration magnet over the top right hand corner of the Ion Science logo to enter
calibration mode. The ZERO LED will illuminate and the GREEN STATUS LED will extinguish.
Remove the calibration magnet
Insert the calibration adaptor into the sensor cap, attach the carbon filter to the calibration adaptor.
The carbon filter should be attached to the hand aspirator.
Again place the calibration magnet over the logo. The ZERO LED will flash, during this stage TVOC
displays a direct millivolt (mV) output from the PID sensor.
Diagram 13
Calibration adaptor
Unrivalled Detection.
Carbon filter
Page 18 of 32
Hand
aspirator
TVOC manual
www.gastech.com.au
Calibration
56–
Slowly and repeatedly squeeze the hand aspirator to push clean air through the carbon filter and past
the PID sensor. The ZERO LED will stop flashing after approximately 2 minutes.
Now remove the equipment except for the calibration adaptor.
NB during the Zeroing process the mV reading on the display must reduce to below 30 mV to pass the ZERO
calibration stage.
An acceptable ZERO calibration level will result in the illumination of the GREEN LED.
An unacceptable ZERO calibration level will result in the illumination of the RED LED. Should this occur the
TVOC will not proceed to the gas tolerance setting and return to normal operation the previous calibration
levels will be used. The Yellow zero LED will be illuminated to indicate the failure to set a zero calibration
level.
Setting the gas concentration (The actual value that the calibration has been supplied at)
1
Now, again place the calibration magnet over the corner of the logo –
The GREEN or RED LED will be extinguished and the numeric display
will start to flash.
2
If the 0-10ppm range is selected you will be able to adjust between 1.0 ppm and 100ppm, for both
the 100 ppm and 1000 ppm ranges a concentration of between 1 and 200 ppm can be selected.
Leaving the magnet in position will cause the displayed number to cycle through the concentration,
remove the magnet when the displayed value matches that stated on the Calibration gas bottle.
Should you miss the desired reading quickly reapply the magnet to continue scrolling through the
numbers and remove the magnet at the desired figure.
The selected number will be recorded 5 seconds after the removal of the magnet when the display
stops flashing. The display will initially show 90, should this be the desired figure remove the magnet
straight away.
Setting the SPAN
1
Connect the SPAN gas to the calibration connector then the connector to the adaptor. Do not over
tighten the Luer fitting; only a ¼ turn is required.
Switch on the gas supply and then place the magnet over the logo.
The SPAN LED will flash and TVOC will display the direct millivolt (mV) output from the PID sensor.
Now remove the magnet.
Diagram 14
Calibration adaptor
SPAN gas
Calibration connector
2
3
The SPAN LED will stop flashing after approximately 2 minutes.
Turn off the gas and disconnect the equipment
Unrivalled Detection.
Page 19 of 32
TVOC manual
www.gastech.com.au
Calibration
NB during the span measurement process the mV reading of the span must be greater than the zero level to
pass the ZERO calibration stage.
An acceptable SPAN calibration level will result in the illumination of the GREEN LED.
An unacceptable SPAN calibration level will result in the illumination of the RED LED. Should this occur the
previous calibration levels will be used when the instrument returns to normal operation. The Yellow span
LED will be illuminated to indicate the failure to calibrate the span.
Now place the magnet over the logo corner to return to normal monitoring routine.
The GREEN LED will start flashing as TVOC starts its cycle with a lamp ON cycle.
If either the ZERO and/or SPAN levels were outside acceptable levels the RED LED will flash until an
acceptable calibration has been carried out.
Unacceptable calibration levels will NOT be used, TVOC will default to the previously stored acceptable
calibration factor.
NOTE:
*
Always check the accuracy of your calibration by checking readings from TVOC when it is running
normally using the ZERO filter and SPAN gas.
*
Accuracy of calibration is the responsibility of the person carrying out the calibration. If in doubt seek
advice.
*
TVOC must be calibrated after lamp/cell cleaning or general maintenance.
NOTE: Causes of contamination and error in signal:
*
Changes in air pressure when detecting ppm concentration
*
Variation in Oxygen and / or Argon beyond ambient levels.
*
Variation in ambiant moisture content.
Unrivalled Detection.
Page 20 of 32
TVOC manual
www.gastech.com.au
Maintenance
Cleaning / replacing the lamp
TVOC has been designed to ensure servicing is quick and easy:
1. Before servicing TVOC,
disconnect the electrical
power supply.
2. Remove the Locking Screw
from the Metal Sensor Cap
using the Allen Key
supplied within the
Calibration tool kit.
(Calibration tool kit part number A849214)
Warning:
Failing to remove the locking
screw before unscrewing the
Sensor Cap will damage the
sensor holder.
3. Unscrew the sensor Cap
to access the PID sensor.
Locking Screw
Diagram 15
Sensor Cap
4. Remove the PID Sensor
by withdrawing it from
the Sensor Housing. Only
light force is required
Warning:
Do not twist the PID Sensor while
it is within the Sensor Housing
PID Sensor
Diagram 16
Sensor Housing
Unrivalled Detection.
Page 21 of 32
TVOC manual
www.gastech.com.au
Maintenance
5. The PID Cell’s Metal Spring
Cover can be pulled off
using moderate force. The
Electrode Stack and PID
Lamp can then be removed
by holding the PID Cell
upside down.
Electrode
Stack
Warning:
Ensure the Electrode Stack and
PID Lamp fall onto a soft surface
such as a piece of tissue. This will
avoid damaging the parts as they
fall out and avoids finger contact
with the PID Lamp window.
PID Lamp
6. Clean the PID Lamp using
Alumina Powder loaded
onto a cotton bud.
Rub the Cotton Bud /
Alumina power on the
PID Lamp Window using
a circular motion until a
light audible squeak can
be heard.
Diagram 17
Metal Spring
Cover
Cotton Bud / Alumina
Powder
Alumina Powder
NOTE:
Contamination of the Lamp
Window can considerably reduce
the detection capability of the PID
Cell, even when the contamination
is not visible.
Cleaning of the lamp should be carried out on
a regular basis depending on the duty cycle of
the PID Lamp and the environment.
Diagram 18
Pellet
Unrivalled Detection.
Page 22 of 32
TVOC manual
www.gastech.com.au
Maintenance
The amount of humidity and quality of the ambient air will directly affect the time between servicing.
Warning:
Leaving contamination on the lamp window can cause irrecoverable damage to the PID Lamp.
7.
The Electrode Stack should be inspected for visible signs of contamination, if contamination can be
seen the Stack it must be replaced. (The Electrode Stack part number 1/EA-02)
Reassembly:
8.
Place the clean PID Lamp into the PID Cell avoiding finger contact with the Window.
9.
Refit the Electrode Stack with the electrical pin holes and electrode contacts facing down.
10.
Refit the Metal Spring Cover.
11.
Ensure the Electronic
Pins of the PID Cell are at
the 12 o’clock position
before inserting the PID
Cell.
The PID Cell should insert
into the connectors easily,
if significant resistance is
felt, remove the cell and
check alignment before
reinserting.
Electronic Pins
Diagram 19
Warning:
Irreparable damage will be caused by forcing the PID into the Sensor Holder if not correctly aligned.
NOTE: Always calibrate TVOC after servicing is carried out.
Fuse rupture and replacement
TVOC has a 125 mA BASEEFA certified fuse to provide intrinsically safe protection when the unit is installed
in hazardous areas.
This fuse may ruptures for example due to over voltage or a current surge, if this is the case replacement is
different depending upon the application being Intrinsically Safe or not.
For Intrinsically Safe (IS) applications the unit must be inspected and have the fuse replaced by Ion Science
Ltd or an Ion Science Approved Service Centre. The intrinsically safe rating is not maintained if the fuse is
simply replaced.
For Non Intrinsically Safe (Non IS) applications the fuse may be replaced by an equivalent rated fuse and
operation tested by qualified engineering personnel.
Lamp Warranty Statement
Please note: The standard warranty period for a 10.6 PID lamp is one year, providing that the default duty
cycle for lamp is set to 1 minute of greater.
Unrivalled Detection.
Page 23 of 32
TVOC manual
www.gastech.com.au
System recommendations
TVOC is generally used to measure gas concentrations in the ambient atmosphere. The sensor is open to
the atmosphere and any gas that diffuses or moves under convection into the locality of the TVOC sensor
will be detected. This is ideal for area monitoring however there are applications (listed below) that need
adaption of the TVOC for operation.
Diagram 20
Remote area monitoring
This is where TVOC is monitoring the atmosphere in a roof or other space that is hard to access but where
the TVOC still needs regular bump tests. In order to avoid the difficulty of accessing the TVOC such as
scaffolding, ladders, enclosed area breathing apparatus etc. and permits for accessing. Here the TVOC can
be fitted with a “Fixed Cal adaptor”. This will enable calibration gas to be piped to, and flood the sensor so
that the instrument / system can be tested or calibrated remotely. See diagram 3 above.
Fixed Cal Adaptor
Diagram 21
Diagram 22
Gas sample systems
It is sometimes necessary to pump or draw a gas sample past the TVOC. For this a “Flow Adaptor " can be
fitted. The flow adaptor has an inlet and an outlet port so that gas may be pushed or drawn across the
sensor. See diagram 2 above.
TVOC Flow Adaptor
5/JHS-01
Diagram 23
Unrivalled Detection.
Diagram 24
Page 24 of 32
TVOC manual
www.gastech.com.au
System recommendations
For a gas sample system we have the following recommendations:
1. Where possible use the Flow Adaptor (as described above) that is sold by ISL. This has an integral oring to seal the sensor housing and ports for connection of inlet and out let sample tubes. Refer to Spare
parts section for part number.
2. The pressure difference of a pumped system relative to atmosphere should be minimised. This is
because any pressure difference will have an effect on gas concentration readings. As pressure
difference increases/decrease the mass of gas in the sensing chamber will increase/decrease and affect
the response to any concentration of sensed gas. This can be explained using the ideal gas equation
PV=nRT and cannot be avoided so should be calibrated out or compensated for. Also please note when
the system is under pressure any gas will be more searching so clear down is like to be slightly
extended.
3. The maximum pressure that can be applied to the TVOC sensor housing is 300mbar. However this is not
a recommended working pressure for the reasons stated above. Ideally working pressure should be +/30mBar of ambient pressure.
4. In line flow restrictions must be minimized. Flow restrictions cause differential pressures which can
directly affect the TVOC ready. If flow restrictions are unavoidable the flow rate should be lowered to
minimize the pressure effects, this however will increase the response time.
5. A flow between 250and 500 ml/min is recommended for calibration. This will ensure a full response to
applied gas in a sensible time.
6. The working flow should be very similar to that use to calibrate the instrument or errors in output will
occur (see point 2).
7. The response time of the system is defined by the sensor response rate and sample flow rate will in
combination with the tube length and diameter as well as any dead volumes.
Unrivalled Detection.
Page 25 of 32
TVOC manual
www.gastech.com.au
Instrument warranty and service
Warranty
Standard Warranty can be extended to up to 2 years on the TVOC when registering your
instrument via our website:
To receive your Extended Warranty, you need to register within one month of purchase (Terms
and Conditions apply). You will then receive a confirmation email that your Extended Warranty
Period has been activated and processed.
Service
Ion Science is pleased to offer a number of service options on our TVOC product range that
allow you to choose the instrument cover that best suits your needs.
At Ion Science we recommend that all of our gas detection instruments be returned for service
and factory calibration once every 12 months.
Contact Ion Science or your local distributor for service options in your area.
Unrivalled Detection.
Page 26 of 32
TVOC manual
www.gastech.com.au
Diagnostics
Below are two conditions your TVOC can be in when it is working correctly:
Diagram 25
Diagram 26
The two conditions shown below are of the instrument in an error state with potential checks/cures
for these faults:
Diagram 27
If an F1 error occurs when the instrument is first switched on there may not be an issue. The instrument
needs to be left on for a few cycles to see if the lamp strikes on its own. If ‘F1’ is still on screen after 5
minutes then look at the information below
The first thing to check is to make sure the red cable between the sensor PCB and the main PCB is securely
plugged in. If the red cable is gripped inside the case it can be pushed into the sensor housing using the
rigidity of the cable to make sure the connector is fully plugged in. Then the connector on the main PCB
should also be checked. The build standard has been improved to pot the senor cable into the sensor
housing (so that it cannot come loose) and provide improved strain relief at the Main PCB connection. Where
this has been done a an F3 diagnostic has been added to the software (see F3 section below) that indicates
if the sensor cable has become disconnected at any point. All instruments built with serial numbers newer
than 10-01790 will have this improvement.
Unrivalled Detection.
Page 27 of 32
TVOC manual
www.gastech.com.au
Diagnostics
The notes below will require some TVOC spares:
Next thing to try is to replace the pellet with another one if available and switch the instrument on to check
(remembering that the instrument should be left on for a few minutes if F1 appears straight away).
If the instrument still shows this error then the lamp should be replaced if available and then the PID cell
should be replaced after if it is still not cured.
If you do not have any spare electrode stacks, lamps or PID cells then you will need to contact Ion Science
for some assistance if the problem remains after the instrument has completed a few minutes of run cycles
and the cable has been checked. Or alternatively if the problem remains after you have tried replacement
parts.
Diagram 28
The F2 error occurs when the lamp appears to be illuminated yet power is removed from the PID sensor,
TVOC checks the PID lamp status using a light sensor. Running TVOC with the sensor or the sensor cap
removed will result in an F2 error.
Please note: The F2 error is disabled when the duty cycle is set below 10 seconds.
A light guard is fitted within the PID sensor housing. This ensures the light sensor is unaffected by ambient
light.
Diagram 29
IMPORTANT:
Diagram 30
The F3 error occurs in current build standard instruments when the cable is disconnected. Instruments with
serial numbers earlier than 10-01790 will not indicate an F3 error if the cable is disconnected an F1 error will
be displayed instead and the diagnostics associated with F1 errors above should be performed.
If an F3 error occurs then check the cable is properly connected to the main PCB. If not push it fully home.
F4 errors
The F4 error occurs when the wrong selection on the jumper is used and it does not have any function.
Review the jumper selection in conjunction with section 4 TVOC set up.
Unrivalled Detection.
Page 28 of 32
TVOC manual
www.gastech.com.au
Spare parts
Part
Calibration tool kit
Flow adaptor
Description
Calibration magnet, Calibration adaptor,
Calibration connector, Zero gas aspirator,
Carbon filter, 2 x Allen keys.
Part number
A-849214
Replaces the standard Sensor Cap
(Allows an external pump to be fitted as
Shown in diagram below)
A-849246
Replaces the standard Sensor Cap
(Allows an external pip connection as
Shown in diagram below)
849217
PID Lamp cleaning kit
Alumina powder and cotton buds
A-31063
Span Gas kit (100ppm)
100ppm Isobutylene (103Liters) and Flow
Regulator in a carry case
A-845213
10ppm Isobutylene (103Liters) and flow
Regulator in a carry case
849230
PID Cell
Replacement PID Sensor
1/EO-2
Carbon filter
User for ZERO span
A-31057
Calibration magnet
User to step through calibration
A-849219
Fixed Cal Adaptor
Span Gas kit (10ppm)
Electrode stack
1/EA-02
PID lamp
A-833227
Sensor Light Guard
Prevents bright light conditions causing
False F2 alarms.
849245
O Ring for Sensor Light
Guard
Fits to outside of Sensor Light Guard
5/OV-11
Calibration Adaptor
(Part of the Calibration toolkit)
For connecting to the standard cap for calibration.
A-849209
Unrivalled Detection.
Page 29 of 32
TVOC manual
www.gastech.com.au
Technical specifications
PID Sensor
Lamp type
With fence electrode technology
10.6eV (Krypton)
TVOC enclosure ingress protection
Sensor ingress protection
IP65
IP54
3
Range
0 – 10 ppm / 0 – 22.8 mg/m (0.01 resolution)
3
0 – 100 ppm / 0 – 228 mg/m (0.1 resolution)
3
0- 1,000 ppm / 0 – 2280 mg/m (1.0 resolution)
Non IS applications
Input power
4 – 20 mA power
2
ATEX approval
II 3 G Ex nA IIC T4 (-20°C ≤Ta ≤50°C)
IECEx approval
II 2 G Ex ia IIC T4 (-20°C ≤Ta ≤50°C)
Certificate number
Baseefa05ATEX0277
IS applications
Entry parameters
Input power
Ui = 18V
Ii = 800mA
Pi = 1.2W
4-20mA power
Ui = 30V
Ii = 200mA
Pi = 1.2W
For information only please see ATEX certificate before installation
Zener Barriers:
Display
Response
Accuracy
Linearity
Calibration
Temperature
Humidity
Ci = 0F
Ci = 0F
Li = 0mH
Li = 0mH
Required Ask your installation engineers for installation/application advice.
ATEX (Non sparking) approval
Dimensions
Height
Width
Depth
2
5 – 28 Vdc. 65 mA (0.5mm to 2.5mm C.S.A.)
2
2
8 – 35 Vdc. 22 mA (0.5mm to 2.5mm C.S.A.)
4-20mA loop must be externally powered
181mm
124mm
72.6mm
(7.11”)
(4.882”)
(2.859”)
II 3 G Eex nA IIC T4 (-40 C  Ta  50 C) (nA for zone 2 only)
o
Weight
Instrument
Packed
o
1.3kg
1.47kg
(2.9 lb)
(3.2lb)
7 Segment, 4 Digit LCD. 4 Colour LED’s
Sensor T90 < 5sec
TVOC output update: Variable 1 second to 10 minutes
0 to 100 ppm: +/- 1 ppm (whichever is greater)
100 to 1000 ppm: +/- 10% or +/- 10 ppm (whichever is greater)
0 – 1000 ppm >75%
Magnetically accessed
ZERO = Carbon canister
SPAN = 100 ppm Isobutylene +/- 10%
o
o
o
o
Operation: -20 C to +50 C (-4 F to 122 F)
0 – 95% RH (non-condensing)
EMC: Screened cables are required to archive the light industrial immunity levels.
NB: All specifications are against an isobutylene calibration at 20 °C, 90% RH and up to 100 ppm.
Unrivalled Detection.
Page 30 of 32
TVOC manual
www.gastech.com.au
Manual log
Manual Version
Amendment
Date updated
Instrument
Firmware
PC
Software
TVOC Manual
V2.1
TVOC Manual
V2.2
TVOC Manual
V2.3
TVOC Manual
V2.4
TVOC Manual
V2.5
TVOC Manual
V2.6
Diagram 5.2.1 updated on
page 11
Diagram updated on page
15
Declaration on conformity
change only
Log added to back of manual
31/3/08
V3.09
N/A
21/4/08
V3.09
N/A
27/11/08
V3.09
N/A
09/01/09
V3.09
N/A
Diagnostics added and P&F
barrier changed
TVOC firmware modified to
allow customers to calibrate
using an alternative
concentration. Aldo
improved the description of
the F2 fault condition. (P6,
P17, P24)
TVOC ATEX certification to
allow zone 2 installation
without safety barriers. (P12,
P13, P26)
Inclusion of Cable gland in
kit, so addition of details
regarding cable gland
selection and use
20/02/09
V3.09
NA
22/07/09
V3.10
N/A
1.09.09
V3.10
N/A
23.3.10
V3.10
N/A
22/07/10
V3.10
N/A
07/08/10
V3.25
N/A
08/09/10
V3.25
N/A
06/10/10
V3.25
N/A
06/11/10
V3.25
N/A
20/12/10
V3.25
N/A
TVOC Manual
V2.7
TVOC Manual
V2.9
TVOC Manual
V3.0
TVOC Manual
V3.1
TVOC Manual
V3.1
TVOC Manual
V3.1
TVOC Manual
V3.2
TVOC Manual
V3.4
Change to EMC details as
result of testing
Warranty Cover updated
Declaration of Conformity
updated
Contents page updated
Instrument Warranty and
Service updated
Addition of fault output level
on page 9, Calibration fault
LED indication changed on
Page 20, 22 ,23
Addition of F3 and F4 fault to
diagnostics section pages
27, 28, & 29. Additional
notes in TVOC setup,
selector pin section page 11
Addition wire C.S.A areas
accepted on pages 14 & 30
Mounting diagram 5.2.1 on
page changed to general
assembly drawing
Page 9. Text amended to
emphasise when TVOC is
un-calibrated.
Page 14. Barrier part
numbers removed
Unrivalled Detection.
Page 31 of 32
TVOC manual
www.gastech.com.au
Manual log
TVOC Manual
V3.5
TVOC Manual
V3.6
TVOC Manual
V3.7
TVOC Manual
V3.8
TVOC Manual
V3.9
TVOC Manual
V4.0
TVOC Manual
V4.1
TVOC Manual
V4.2
V4.3
Barrier details removed for
technical specification, notes
added that 4-20mA requires
external power
Pages 3&4 updated to
correct Quality Management
System
Page 5 Responsibility of use
updated an legal notice
added
Page 18 Setting the gas
tolerance changed to ‘0.1 –
20.0’ to reflect instrument
function.
Page 24 & 25 System
Recommendations added.
Page 26 contact details
moved here
Page 28 details of Sensor
Light Guard added.
Page 29 Parts notes
updated.
Pages 7,11,13 & 14 ATEX
comments changed.
14/01/2011
V3.25
N/A
23/03/11
V3.27
N/A
Page 30 – Accuracy and
Linearity specifications
updated
IS wiring diagrams and
photos updated.
Slight modification to
installation instructions.
Page 11, Point 7
Page 30, IP clarification
Page 30, Accuracy
specification only
Manual format and layout
updated
Change to duty cycle. Pages
9, 10, 16 and 28
Firmware now suitable for
old and new product
15/03/12
V3.27
N/A
24/05/12
V.3.27
N/A
26/05/12
V3.27
N/A
29/10/2012
V3.27
N/A
07/01/2013
V3.27
N/A
28/02/2013
V4.09
N/A
09/07/2013
V4.11
N/A
Unrivalled Detection.
Page 32 of 32
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