Mini-BA Portable Gas Detector Instruction Manual
PureAire Monitoring Systems, Inc. 557 Capital Drive Lake Zurich, Illinois 60047 Phone: 847-726-6000 Fax: 847-726-6051 Toll-Free: 888-788-8050 Pureairemonitoring.com
PureAire Monitoring Systems, Inc.
12-17-2005
Table of Contents 1: Introduction................................................................................................2 1.1 Instrument Overview...........................................................................2 2: Specifications .............................................................................................6 2.1 Performance Specifications ..................................................................6 2.2 Gas Detection System..........................................................................6 2.3 Sampling System ................................................................................7 2.4 Signal Outputs ....................................................................................7 2.5 Signal Inputs.......................................................................................7 2.6 Electrical Requirements.......................................................................7 2.7 Physical Characteristics .......................................................................7 3: Installation .................................................................................................8 3.1 Mounting............................................................................................8 3.2 Sample and Exhaust Connections .........................................................8 3.3 Power.................................................................................................9 3.4 Output/Input Connections ....................................................................9 3.5 Sensor Installation.............................................................................10 3.6 Initial Startup ....................................................................................12 4: Programming............................................................................................13 4.1 Control Panel Overview ....................................................................13 4.2 System Configuration ........................................................................15 5: Normal Operation .....................................................................................17 5.1 Modes of Operation...........................................................................17 5.2 Changing the Mode of Operation .......................................................18 5.3 Alarm Messages and Indicators..........................................................18 5.4 Output Status Under Various Conditions ............................................19 5.5 Resetting Alarms...............................................................................20 5.6 Changing the Target Gas or Measurement Range ................................21 5.7 Power...............................................................................................21 6: Maintenance and Calibration .....................................................................23 6.1 Routine Maintenance Schedule ..........................................................23 6.2 Sensor Cell Removal and Installation .................................................24 6.3 Electrolyte Replacement....................................................................24 6.4 Sensor Calibration.............................................................................28 6.5 Pyrolyzer Filament Replacement........................................................30 7: Troubleshooting........................................................................................31 7.1 Troubleshooting Guide ......................................................................31 8: Dimensional Drawings ..............................................................................33
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1: Introduction The Model Mini-BA is a portable extractive gas sampling system designed for the continuous detection and measurement of toxic gas leaks. It is capable of sampling over distances of up to 10 meters. The unit may be used as either a stand-alone system or networked into a facility-wide life safety system. Some of the system’s more important features include: § VAC or re-chargeable battery-powered operation § Local digital display § Integral sampling pump § 4-20 mA output § Self-monitoring operation (see “Normal Operation”) § Integral pyrolyzer § Renewable sensor cell (GS-[ ]HS Only) • Integral alarm relays • Programmable dual-level alarms • Multiple gas monitoring capability
1.1 Instrument Overview The Mini-BA is a portable, extractive gas monitor, which utilizes PureAires’ Combined Electrochemical Detection system. In normal operation, an internal electromagnetic diaphragm pump continuously draws sample air through a pyrolyzer, which converts any of the target hazardous gas present in the sample into a more readily detected and measured gas. The sample is then presented to a Bionics’ GS-[ ]HS or GS-[ ]ES type gas sensor which generates an electrical signal proportional to the concentration of this new gas. The resulting signal is translated into a concentration value for the target gas. Gas concentration information is displayed on the instrument’s LCD readout. The name of the gas being measured as well as the concentration reading is displayed. The Mini-BA features two user-settable gas concentration alarms, a system status alarm, and companion LEDs and alarm contacts. The gas concentration alarms are activated whenever the gas concentration exceeds user-set levels. The system status alarm is activated whenever a system fault, such as a missing sensor, is detected. The Mini-BA also incorporates a “Standby” function, which allows the operator to take the instrument offline for maintenance without activating the alarm relays. Another important feature of the Model Mini-BA is the ability to monitor different gases by simply installing a different electrochemical sensor. The unit automatically interrogates the sensor cell and reprograms itself with the appropriate gas identification information.
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Front Panel
Local Digital Display Alarm LED Flowmeter Function Keys
Status LED
Power Switch
Flow Adjustment Potentiometer
Power/Battery Status LEDs
Local Digital Display — During normal operation, displays the name and concentration of the target gas. Also displays alarm messages and programming/calibration menus and information. Alarm LED — This LED lights when a sensor error or gas concentration alarm is detected. An audible alarm is also activated. Status LED — This green LED flashes at three-second intervals to indicate that instrument is powered and operating normally. If the LED flashes red a loss of flow fault has been detected; .if it lights red continuously, a pyrolyzer fault has been detected. Function Keys — The function keys are used to access the various programming menus and make selections within those menus. They are also used to activate certain functions during normal operation (monitoring). Flow Meter — Indicates the flow rate of the sample gas in liters/minute. Flow Adjustment Potentiometer — Used to adjust the flow rate of the sampling pump. Power/Battery Status LEDs — Indicate whether the instrument is operating from battery or line power, remaining battery power, and the status of the charging system. Power Switch — This switch controls power to the instrument’s sample pump, pyrolyzer, and gas detection electronics. There is also a power switch located on the rear of the instrument, which controls power to the instrument’s battery charging system.
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Rear Panel
Terminal Block
Pump Signal Input
Sample Inlet AC Power Switch
AC Power Cord Receptacle
Sample Exhaust
Sample Inlet — Serves as the connection for the incoming sampling line. Sample Exhaust — Serves as the connection for the sample exhaust line. Terminal Block — Used to make the connections for the instrument’s various signal inputs and outputs. AC Power Switch — Controls power to the instrument’s battery charging system. When in the On position, the internal battery charges and the instrument operates from VAC power. Pump Signal Input — ON/OFF controls internal pump power from remote relay unit. This function may be set disable at standard specification.
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Interior
Sensor Connector Cable
Sample Pump
Sensor Flow Chamber
Pyrolyzer (Mini-BA-4100 to 4900 only)
Gas Sensor (not shown) — An electrolyte-filled electrochemical sensor. Sensor Flow Chamber — The sampled air is introduced to the gas sensor in this chamber. Sample flow into the chamber is continually monitored by a flow sensor; if flow rate drops below a preset rate, an alarm is activated. Sensor Connector Cable — Connects the sensor cell to the electronics circuit board. Pyrolyzer — (Mini-BA -4100 to 4900 only) Converts target gas into a more electrochemically active gas prior to presentation to the gas sensor. Sample Pump — Draws sampled air into instrument, through pyrolyzer and sensor flow chamber, and exhausts it through the sample outlet.
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2: Specifications Æ NOTE: Due to our commitment to continual product improvement, all specifications are subject to change without notice.
2.1 Performance Specifications Detection System:
Combined Electrochemical Detection System. Utilizes Bionics’ type GS-[ ]HS or ES plug-in electrochemical cell (for model Mini-BA-4100 to 4900 in conjunction with a pyrolyzer).
Response Time:
Within 30 seconds to T90.
Repeatability:
±10% of full scale.
Fault Indicators:
Loss of power Loss of sensor signal No sensor installed Loss of flow Low electrolyte Pyrolyzer fault (Mini-BA-4100 to 4900 only)
Operating Temperature:
5° to 40°C
Humidity:
20% to 80% RH, non-condensing.
2.2 Gas Detection System Type:
Mini-BA-4100 to 4900 : Combined Electrochemical Detection System using electrochemical gas sensor and pyrolyzer. Others: Electrochemical cell GS-[ ]HS Renewable; GS-[ ]ES Disposable;
Sensor Life:
GS-[ ]HS GS-[ ]ES
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3 to 5 years under normal conditions. 1 to 2 year under normal conditions.
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2.3 Sampling System Type:
Electromagnetic diaphragm pump.
Flow Rate:
0.15, 0.2 or 0.5 liter/minute (depends on detectable gas)
Sampling Distance:
10 meters maximum.
Sample Line:
6 mm OD, 4 mm ID PTFE standard.
Exhaust Line:
6 mm OD, 4 mm ID PTFE. 10 meters maximum.
2.4 Signal Outputs Local Display:
Digital display calibrated for the specific target gas.
Analog Output:
4-20 mA
Alarm Relays:
Two Form C dry contacts for gas concentration alarms; One Form C dry contact system fault relay (failsafe action).
External Buzzer:
TTL output, +24V/0V, 50 mA maximum.
2.5 Signal Inputs Alarm Reset:
Dry contact relay input; resets alarm on contact closure.
2.6 Electrical Requirements Power:
Rechargeable NP 4-6 battery. Also operates on 100-240 VAC power.
Battery Life:
Approximately 4 hours fully charged.
Power Consumption:
Approximately 10 watts.
2.7 Physical Characteristics Dimensions:
Approximately 150 (W) x 195 (H) x 250 (D) mm. 6” (W) x 8” (H) x 10” (D)
Weight:
Approximately 5 kg. (11 lbs)
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3: Installation 3.1 Mounting The Mini-BA Monitoring System may be used as either a stationary or portable gas detection system.
3.2 Sample and Exhaust Connections The sample and exhaust lines are connected to the 1/4 inch female PT fittings located on the rear of the instrument. 3.2.1
Sample Line The sample line should be no longer than 10 meters in length. PTFE tubing with a 6 mm OD and 4 mm ID should be used. A moisture filter should be installed on the end of the tubing to prevent the entry of moisture. To ensure the unrestricted flow of sample, the sample line should be run without bends or kinks. Likewise, it should not run between any equipment or other objects that may move, pinch, or abrade the tubing.
Æ IMPORTANT: The inlet to the gas sampling line must not be exposed to areas of negative pressure. Negative pressure will affect the flow rate and possibly prevent the target gas reaching the detector. Consult factory for more information. 3.2.2
Exhaust Line The exhaust line should be no longer than 10 meters in length and terminate in a suitable exhaust duct or hood. TFE tubing with a 6 mm OD and 4 mm ID should be used. To ensure the unrestricted flow of air through the exhaust line, it should be run without bends or kinks. Likewise, it should not run between any equipment or other objects that may move, pinch, or abrade the tubing.
Æ IMPORTANT: The outlet of the gas exhaust line must not be exposed to areas of positive pressure. Positive pressure will affect the flow rate and possibly prevent the unit from exhausting properly. Consult factory for more information.
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3.3 Power The Mini-BA is designed to operate from either its internal rechargeable battery or 100-240 VAC power. 3.3.1
Battery Operation The instrument will operate for approximately 4 hours on a fully charged battery. When operating from battery power, the green status LEDs (H....L) on the front panel light/extinguish to approximate remaining power. The red Low Battery LED lights and the audible alarm sounds when approximately 5 to 10 minutes of battery power remain.
3.3.2
VAC Operation The Mini-BA is also capable of operating from standard 100-240 VAC power. An IEC receptacle is provided for the power cord. AC operation is controlled via the power switch on the rear of the instrument. When this switch is placed in the On position, and the unit is plugged into an appropriate electrical outlet, the green AC LED on the front panel of the unit will light; the orange Charging LED will also light to indicate that the internal battery is being recharged.
3.4 Output/Input Connections All input and output connections are made on the terminal blocks on the rear panel of the instrument. Terminal
Symbol
1
RST-IN (+)
2
RST-IN (-)
3
AOUT (+)
4
AOUT (-)
5
NC
6
BZ-OUT (+)
7
BZ-OUT (-)
8
ALM1 NO
9
ALM1 C
10
ALM1 NC
11
ALM2 NO
12
ALM2 C
13
ALM2 NC
14
ERR NC
15
ERR C
16
ERR NO
Function
Alarm Reset Input
DC 4-20 mA Analog Output * No Connect SCI/TTL
Alarm 1 Relay Output
Alarm 2 Relay Output
Error Relay Output (Fail Safe)
* Maximum Impedance is 500 Ù
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Alarm Reset Input (RST-IN) This connection allows the operator to remotely reset latched alarms via a contact closure.
3.4.2
Analog Output (AOUT) The instrument outputs an analog signal proportional to the measured concentration of the target gas.
3.4.3
External Buzzer (BZ-OUT) This connection allows the operator to connect the instrument to an external audible alarm.
3.4.4
Concentration Alarm Relays (ALM1, ALM2) These connections allow the operator to activate a remote alarm devic e when the measured gas concentration exceeds the pre-set alarm concentration. These relays energize when an alarm condition is detected.
3.4.5
Error Alarm Relay (ERR) This connection allows the operator to activate a remote alarm device when an instrument fault, such as low electrolyte, is detected. This relay is designed for failsafe operation, de-energizing when a fault is detected.
3.5 Sensor Installation The Mini-BA uses a GS-[ ]HS or ES type electrochemical sensor to detect and measure hazardous gases. Each sensor is sensitive and specific to a particular gas and/or family of gases. Æ NOTE: If sensor is supplied with a warm-up battery, remove the sensor plug.
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Blank/Pressure Vent Plug (GS-[ ]HS) To prevent electrolyte leakage during shipping, all sensor cells are shipped with a blank plug installed in the electrolyte filler port. Before use, this blank plug must be removed and replaced with the pressure vent plug. The blank plug should be re-installed when transporting the sensor cell.
3.5.2
Shorting Plug (GS-[ ]HS)
Æ IMPORTANT: During storage and transportation, PureAire’s’ sensors are supplied with a shorting plug. This plug must be removed prior to installing the sensor. The system will not respond to gas if the pin in not removed. Remove the shorting plug from the sensor electronics. It is located at JP1A on the PCB mounted on the top of the sensor cell.
Shorting Pins
3.5.3
Sensor Installation Keeping the sensor completely upright, carefully insert the sensor into the flow chamber, without tipping or twisting. Connect the sensor connection plug to the terminal on the top of the sensor.
Æ CAUTION: Do not twist the sensor. This may loosen the cap covering the working electrode.
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3.6 Initial Startup Once installation of the gas detector has been completed, it is ready for startup. The following procedures should be performed before putting the instrument in operation: 1. Check the integrity of all wiring and internal/external sample connections. 2. If the unit is being operated from standard line power, place the power switch on the rear of the instrument in the On position. 3. Place the power switch on the front of the instrument in the On position. 4. Adjust flow rate to 0.15, 0.2 or 0.5 litters per minute. detectable gas.
It depends on
The instrument should now be operating properly.
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4: Programming 4.1 Control Panel Overview All instrument configuration and operational programming is performed from the front panel of the Mini-BA.
Alarm LED
Digital Display
Flow Meter Function Keys
Power/Battery Status LEDs
Status LED
Flow Adjust Potentiometer
Digital Display — Programming and operational information is displayed on the instrument’s LCD. Alarm LED — This LED lights when a gas concentration alarm or sensor fault is detected. Status LED — This LED flashes green at three-second intervals when the system is operating properly. It flashes red when a loss of flow is detected; it lights red continuously when a pyrolyzer fault is detected. Function Keys — The four function keys are used to access the various programming menus and make selections within those menus. They are also used to activate certain functions during normal operation (monitoring).
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Function Key
Function Monitoring Mode
Programming Mode
Æ /F1
None
Toggles through the choices available within the displayed menu item or advances the cursor within a value field.
Ç/F2
Silences/resets alarms
Increases the displayed value or returns to the previous menu once a value has been accepted.
È/F3
Lights display back-light
Decreases the displayed value or advances to the next menu once a value has been accepted.
Exits monitoring mode
Accepts the displayed value; places unit back in monitoring from the Operating Mode
ENT/ON/F4
Power/Battery Status LEDs — These LEDs indicate the instrument’s power source, remaining battery power, and the status of the charging system. LED
Color
Description
AC
Green
Lights when instrument is connected to VAC power and the rear panel power switch is on the On position.
CHG
Orange
Lights when the instrument’s internal battery is recharging.
H........L
Green
Light to indicate approximate condition of battery.
LOWBAT
Red
Lights when approximately [AMOUNT OF TIME] minutes of battery life remain.
Power Switch — Controls power to the instrument’s sample pump, pyrolyzer, and gas detection electronics.
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4.2 System Configuration The Mini-BA’s system configuration functions are accessed from the main operational display by pressing the F4 function key for 4 seconds. The following display will appear:
OPERATING MODE MEASURE Press the F3 key to advance to the first programming screen. 4.2.1
Measurement Range
FULL SCALE XX.X PPM The instrument’s measurement range is programmed from this screen. To change the displayed value, press the F1 key to advance to the first digit of the value field and then use the F2 and F3 keys to increase/decrease the value at the cursor position. Press the F1 key to advance to the next digit and repeat. Press the F4 key to accept the displayed value and then press the F3 key to advance to the next programming screen. 4.2.2
Alarm 1 (Low)
ALARM – 1 X.X PPM This is the gas concentration at which the instrument’s low level alarm will be activated. To change the displayed value, press the F1 key to advance to the first digit of the value field and then use the F2 and F3 keys to increase/decrease the value at the cursor position. Press the F1 key to advance to the next digit and repeat. Press the F4 key to accept the displayed value and then press the F3 key to advance to the next programming screen. 4.2.3
Alarm 2 (High)
ALARM – 2 X.X PPM This is the gas concentration at which the instrument’s high-level alarm will be activated. To change the displayed value, press the F1 key to advance to the first digit of the value field and then use the F2 and F3 keys to increase/decrease the value at the cursor position. Press the F1 key to advance to the next digit and repeat. Press the F4 key to accept the displayed value and then press the F3 key to advance to the next programming screen.
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Alarm Delay
ALARM DELAY XX SEC
This is the amount of time an alarm level concentration of gas must be present before the instrument’s gas concentration alarm(s) will be activated. To change the displayed value, press the F1 key to advance to the first digit of the value field and then use the F2 and F3 keys to increase/decrease the value at the cursor position. Press the F1 key to advance to the next digit and repeat. Press the F4 key to accept the displayed value and then press the F3 key to advance to the next programming screen. 4.2.5
Suppress Level
SUPPRESS LEVEL XX %
This setting is used to decrease the sensitivity of selected gas sensors. It essentially programs the instrument to ignore gas measurements that are below the programmed % level (% full scale). Æ EXAMPLE: If the measurement range of the instrument is 0 to 10 ppm, gas measurements below 0.5 ppm will be displayed and output as 0 (zero) when the suppress level is set at 5%. Æ IMPORTANT: PureAire recommends that you consult the factory before changing the factory programmed suppression level. To change the displayed value, press the F1 key to advance to the first digit of the value field and then use the F2 and F3 keys to increase/decrease the value at the cursor position. Press the F1 key to advance to the next digit and repeat. Press the F4 key to accept the displayed value and then press the F3 key to return to the Operating Mode screen.
OPERATING MODE MEASURE Press the F4 key to return to monitoring or press the F1 key to go to the Test, Standby, or Calibration modes (see Section 5.1 for additional information).
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5: Normal Operation The Model Mini-BA Gas Monitor is a single point monitor designed for the continuous detection and measurement of hazardous gas leaks. It may be used as either a stationary or portable gas detection system.
5.1 Modes of Operation The Mini-BA features four different modes of operation: Measure — This is the standard operating mode. When the unit is in the “Measure” mode, all local and remote signal outputs are active. This includes the local audio/visual alarm indicators, concentration alarm and system fault relays, and 4-20 mA analog output signal).
NAME OF GAS 0.0 PPM
Standby — This mode is used to take the instrument completely off-line for maintenance, service, etc. When in the “Stand-by” mode, all local and remote signal outputs are inactive.
NAME OF GAS /STBY 0.0 PPM
Test — This mode is used when testing the instrument. When in the “Test” mode, the instrument’s local alarm indicators are active. The gas concentration and system fault relays as well as the 4-20 mA analog output are also active.
NAME OF GAS /TEST 0.0 PPM
Calibration — This mode is used when calibrating the instrument. When in the “Calibrate” mode, all local and remote signal outputs and zero suppression are inactive.
NAME OF GAS /CAL 0.0 PPM
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5.2 Changing the Mode of Operation The mode of operation is selected from the Operation Mode menu screen. This screen is accessed by pressing the F4 key when the instrument is in any of the four modes of operation.
OPERATING MODE MEASURE Once the Operating Mode Menu Screen is displayed, pressing the F1 key toggles the display through the available choices.
OPERATING MODE TEST OPERATING MODE STAND-BY OPERATING MODE CALIBRATION Pressing the F4 places the Mini-BA in the mode of operation that is shown on the display.
5.3 Alarm Messages and Indicators The Mini-BA incorporates both gas concentration and system fault alarms. When an alarm condition is detected, an alarm message is displayed and the instrument’s audio alarm and appropriate alarm relay(s) activated. 5.3.1
Gas Concentration Alarms In the event that a gas concentration that exceeds the user-programmed alarm setpoint(s) is detected, the alarm level, which has been exceeded, will be indicated on the LCD display.
NAME OF GAS A1
4.2 PPM
The display shown above indicates that the low level (Alarm 1) setpoint has been exceeded. The audio alarm and Alarm 1 relay will both activate and stay in that state until the alarm condit ion is acknowledged and the measured concentration drops below the Alarm 1 setpoint. The audio alarm may be silenced by pressing the F2 key.
NAME OF GAS A1 A2 8.5 PPM
This display shown above indicates that the high level (Alarm 2) setpoint has been exceeded. The audio alarm and both Alarm 1 and Alarm 2 relays will activate. The Alarm 2 relay will stay in that state until the measured gas concentration falls below the Alarm 2 setpoint. The Alarm 1 relay will stay in that state until the alarm condition is acknowledged and the measured
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concentration drops below the Alarm 1 setpoint. The audio alarm may be silenced by pressing the F2 key. 5.3.2
System Fault Alarms In the event a system fault is detected, the condition will be indicated on the LCD readout. The audio alarm will also sound and the error relay will be activated. A sensor fault, such as low electrolyte, is indicated as follows:
NAME OF GAS *SENSOR ERROR* If the sensor is removed, the following message will appear:
NAME OF GAS *NO SENSOR* Pressing the F2 key silences the audio alarm and acknowledges the alarm condition. The system fault relay will remain active until the condition causing the alarm is corrected.
5.4 Output Status Under Various Conditions Alarm 1 Relay
Alarm 2 Relay
Alarm LED
Error Relay
Alarm Message
Status LED
Audio Alarm
4-20 mA
Gas concentration below Alarm 1 and 2 setpoints.
De-energized
De-energized
Off
Energized
—
Flashing Green
Off
Gas value
Gas concentration above Alarm 1 setpoint, below Alarm 2 setpoint.
Energized (latching)
De-energized
On
Energized
A1
Flashing Green
On
Gas value
Gas concentration above Alarm 1 and 2 setpoints.
Energized (latching)
Energized (non-latching)
On
Energized
A1, A2
Flashing Green
On
Gas value
Low Electrolyte
De-energized
De-energized
On
De-energized
Sensor Error
Flashing Green
On
