GIG DS404 Operation Manual

Congratulations! You decided in favour of a high-technology product from GfG. A good choice! Our detectors are characterised by reliability, safety, best performance and economic efficiency. They comply with national and international directives. This manual will help you to operate the detector quickly and safely. Please take note of the operational hints before putting into operation! For any questions please feel free to contact us. Your GfG Gesellschaft für Gerätebau mbH Klönnestraße 99 44143 Dortmund, Germany Tel.: +49(0)231 – 564 00-0 Fax: +49(0)231 – 564 00-895 E-mail: [email protected] Internet: www.gasmessung.de

Page INTRODUCTION 4 For your Safety 4 Application and Purpose 4 Installing and Connecting the Docking Station 4 Connections and Control Elements of the DS404 5 Detector Adapter 6 CO2 Absorption Filter 6 HANDLING FEHLER! TEXTMARKE NICHT DEFINIERT. Charging 7 Bump Test 7 Sensor Calibration 9 Data Storage/Data Transfer to a PC 11 SOFTWARE 12 Installation 12 Installation of the USB Driver 12 Configuration of the DS404 12 Connection 12 General 12 CO2 Filter 13 Gas Input 1 13 Test Times 13 Clock 14 Intervals 14 ANNEX 15 Care 15 Maintenance and Inspection 15 Troubleshooting 15 Accessories and Spare Parts 16 Technical Data 16

In accordance with § 3 of the German Equipment and Product Safety Act (GPSG), this manual describes the intended use of the product and serves to avoid danger. It must be read and observed by all persons who operate, service, maintain and inspect this product. This detector can serve its intended purpose only if it is operated, serviced, maintained and inspected according to the instructions given by GfG Gesellschaft für Gerätebau. The warranties given by GfG Gesellschaft für Gerätebau mbH will be voided if the product is not operated, serviced, maintained and inspected in accordance with GfG’s instructions. The above does not alter statements regarding warranties and liabilities in the General Conditions of Sale and Delivery of GfG mbH. Repairs may only be carried out by skilled or trained persons. Modifications and changes to the product may only be carried out with the approval of GfG mbH. Unauthorised modifications to the product result in the exclusion of any liability for possible damage. Only genuine GfG accessories may be used together with the product. Only spare parts approved by GfG mbH may be used for repair work. Note: When using the docking station you have to remember that all gas detectors that are calibrated with the station will be influenced. Incorrectly entered test gas concentrations will result in all gas detectors being incorrectly calibrated. Application and Purpose The Docking Station DS404 is an automatic test station with four test gas ports for carrying out function tests ("bump tests") and for calibration of the zero point and sensitivity of the sensors of the Microtector II, Microtector III und Polytector III series gas detectors. Installing and Connecting the Docking Station During commissioning, the hoses and leads for fresh air supply, test gas supply, gas discharge, pressure switch, mains power supply and PC interface or interface to a further docking station must be connected to the test station. The docking station must be installed on a firm and even surface. The gases must be supplied pressure-free. For direct gas tapping from test gas cylinders, use the gas connection fittings listed in section "Accessories and Spare Parts". During operation, the gas is drawn in by the pump of the docking station. Ensure also that the test gas can leave the docking station freely without pressure! If CO2 sensors are also to be tested or calibrated using the docking station, a CO2 absorption filter should be installed in the fresh air supply line (see chapter CO2 absorption filter). Ensure that the plug is installed on the T-piece of the fresh air supply line or that it is connected to a further docking station. Up to two DS404 or three DS400 docking stations can be operated with one DS400-PS1 power supply unit. For this the DS404 or DS400 have to be connected together using a double-sided jack plug. During commissioning, the connections for gas supply, gas discharge, pressure switch, mains power supply and PC interface or interface to a further docking station must be made as shown in the figure in the following chapter.

Zero gas/fresh air supply Pressure switch – channel 1 Gas exhaust pipe Pressure switch – channel 4 Test gas supply – channel 4 SD card Red LED (on left side in the card slot) Connection for 12 V DC power supply unit Ports for RS485 Green LED (on the right in the card slot) Connection for 12 V DC power supply unit 1 2 3 4 Display of active input

screwed on electric pump. A second version for devices with screwed on electric pump (G400-MP2) and a third version for the detectors Microtector III and Polytector III. The electric pump can remain on the device for all tests. All three device adapters can be used at the same time by the docking station as charging cradle. To replace the device adapter, the DS400 must be disconnected from the power supply. CO2 Absorption Filter CO2-free zero gas is required particularly for the testing and calibration of the CO2 sensor zero point. As fresh air contains approx. 500 ppm CO2, the disturbing CO2 can be removed using a CO2 absorption filter. The CO2 is thereby absorbed by calcium hydroxide (80 %) / sodium hydroxide (5 %) / H2O (15 %) in the following reaction: CO2 + 2 NaOH  Na2CO3 + H2O Na2CO3 + Ca(OH)2  CaCO3 + 2NaOH The absorber removes 1000 ppm CO2 from approx. 2,500 l of air. This corresponds to a service life of approx. 5,000 minutes of zero gas pump operation with one docking station. The DS404 calculates the service life on the basis of the flow rate and gives a warning to replace the filter in good time. The filter gradually changes colour to pale blue. As water is also produced during the absorption process due to the chemical reaction, depending on the CO2 content of the air, this can have a minor influence on the setting of the sensor zero point. Handling The docking station is operated by means of the control keys of the gas detector. The status and test data are output to the detector display. If a gas detector is inserted into the docking station, the "Information", "Function Test" or "AutoCal adjustment" options can be selected via softkeys on the gas detector. Microtector II devices can remain in the docking station for operation. Devices of the Microtector III and Polytector III series must be briefly removed from the charger to select the displayed operating options, in order to be able to operate the concealed keys. After pressing the keys, the unit is placed back in the charger. Under certain conditions, a "Firmware Update" can also be carried out using the docking station when the gas detector is in the station. For this, there must be a newer version of a corresponding update file on the SD card and the "Update" started by pressing the corresponding key. In order to charge a gas detector, it must be switched off and placed in the docking station. If the detector is placed into the docking station switched on, the necessary test or calibration will be started automatically after 10 seconds. Within the 10 seconds you can override the automatic selection and start a function test or calibration manually. G400-DIC1D for Microtector II without a pump G400-DIC2D for Microtector II with attached pump DIC888/999-B for Microtector III and Polytector III

station. The charging procedure starts automatically. Yellow LED Constantly lit: Normal charging Flashing: Trickle charge Green LED ON: Voltage supply for charging module switched on OFF: Detector is in the docking station and function test or calibration is being performed The charging process of an empty battery takes approx. 6 to 7.5 hours. After the normal charging process, the detector automatically switches to trickle charge. Function Test (Bump Test) During the function (bump) test, the following points are checked:  Check visual alarm  Check audible alarm  Check response time of sensor for alarm 1 and for alarm 2, depending on test gas concentration  Depending on the configuration, check response time of sensor for t50 or t90  Automatic data storage on SD card  Setting of the clock  Setting of the function test interval Turn the G450 or G460 on before placing it into the docking station. If the TEST button is pressed within the first 10 seconds, the function test is started. If no button is pressed, the function test or calibration starts automatically after 10 seconds, depending on which interval has expired. The effective time for the function test is approx. 20 seconds, on the DS404 longer depending on the gas inlets used. During the test, the relevant test gas is supplied to the sensors and then they are adequately purged with fresh air. The function test interval is specified in accordance with T021/T023 and is used during each function test and calibration to calculate the next date for function test or calibration. The test progress and the function test report are shown on the display of the detector. Function test starts after 10 seconds automatically Function test running Purging with fresh air

and alarm 2 of the respective test gas T50 = t50 response time of the respective test gas Test of audible and visual alarm o.k. Response time alarm 1 / 2 for CO error – Response time too long Response time t50 for CO error – Response time too long The following symbols signal the test result: = In process - = Sensor not tested √ = Sensor successfully tested = Sensor faulty Result of the function test: Check the proper performance of the test by inspecting the function test report. The result of the function test is also indicated by a red and a green LED in the SD card slot of the docking station using the traffic light principle. If the green LED is lit, the function test was successful and the detector is ready for use again. If the red LED is lit or the display on the detector is red, however, an error has occurred which has to be remedied before the detector can be used. Function test successful: Display is green + green LED lit in slot Function test failed: Display is red + red LED lit in slot Display of the error which has occurred (here Code 2: Flow error) Possible error messages: Code: 1 No gas defined – DS404 is not configured Code: 2 Flow error – Fault in the zero or test gas supply Code: 3 Aborted by detector – Detector problem / fault Code: 4 Power error – Fault in supply voltage to TS400 power supply unit Code: 5 Time too long for function test of the sensors Code: 6 DS404 service necessary – The DS404 has to be serviced Code: 7 No SD card – No SD card inserted Code: 9 Parameter error – An error has been detected in the parameter memory Code: 12 Firmware prior 3.44 – The firmware version on the detector is too old Code: 13 Gas switch error – The gas switch signals a fault

being aborted. 1 = SD card 2 = Gas pressure 4 = CO2 filter 8 = Gas amount If several errors occur at the same time, the error numbers are added: 3 = 2 + 1 (Gas pressure + SD card) 5 = 4 + 1 (CO2 filter + SD card) 6 = 4 + 2 (CO2 filter + gas pressure) 9 = 8 + 1 (Gas amount + SD card) 10 = 8 + 2 (Gas amount + gas pressure) 12 = 8 + 4 (Gas amount + CO2 filter) Sensor Calibration (Calibration) Turn the G460 on before placing it into the docking station. If the AUTOCAL button is pressed within the first 10 seconds, the calibration is started. If no button is pressed, the function test or calibration starts automatically after 10 seconds, depending on which interval has expired. During sensor calibration, the calibration is first performed with fresh air. On sensors for toxic and inflammable gases, the zero point is set. The oxygen sensor is thereby set to 20.9 % v/v. The IR sensor for carbon dioxide is calibrated to its zero point here using the CO2 absorber. Attention must be paid that uncontaminated air is supplied to the docking station. The AutoCal-Gas function is used to set the sensitivity of the sensors. Always use a suitable test gas or test gas mixture for calibration with gas. The sensors are purged after sensor calibration. The calibration takes approx. 3-4 minutes, on the DS404 longer depending on the gas inlets used. The calibration interval is specified in accordance with T021/T023. The progress of the calibration as well as the zero report (air) and cal report (gas) are shown on the display of the detector. Function test starts after 10 seconds automatically Purging Sensor calibration Purging Sensor calibration Result of sensor calibration with fresh air (CO2-free) Reading before => after Results of sensor calibration with test gas (gas mixture) Reading before => after The following symbols signal the calibration result: - = Sensor not calibrated √ = Sensor successfully calibrated = Error during calibration – not calibrated

Check the proper performance of the calibration by inspecting the zero and cal reports. The result of the calibration is also indicated by a red and a green LED in the SD card slot of the docking station using the traffic light principle. If the green LED is lit, the calibration was successful. The detector is now ready for use again. If the red LED is lit or the display on the detector is red, however, an error has occurred which has to be remedied before the detector can be used. Calibration successful: Display is green + green LED lit in slot Calibration failed: Display is red + red LED lit in slot Display of the error which has occurred (here Code 2: Flow error) Possible error messages: Code: 1 No gas defined – DS404 is not configured Code: 2 Flow error – Fault in the zero or test gas supply Code: 3 Aborted by detector – Detector problem / fault Code: 4 Power error – Fault in supply voltage to TS400 power supply unit Code: 5 Time too long for function test of the sensors Code: 6 DS404 service necessary – The DS404 has to be serviced Code: 7 No SD card – No SD card inserted Code: 8 CO2 filter exhausted – CO2 filter exhausted Code: 9 Parameter error – An error has been detected in the parameter memory Code: 12 Firmware below 3.44 – The firmware version on the detector is too old Code: 13 Gas switch error – The gas switch signals a fault Additional information can be called up with the "Info" key. These messages do not lead to the abort of the calibration. 1 = SD card 2 = Gas pressure 4 = CO2 filter 8 = Gas amount If several errors occur at the same time, the error numbers are added: 3 = 2 + 1 (Gas pressure + SD card) 5 = 4 + 1 (CO2 filter + SD card) 6 = 4 + 2 (CO2 filter + gas pressure) 9 = 8 + 1 (Gas amount + SD card) 10 = 8 + 2 (Gas amount + gas pressure) 12 = 8 + 4 (Gas amount + CO2 filter)

All information on the function tests and calibrations of the individual sensors are automatically stored on an SD card (if inserted). The data transfer to a PC is effected automatically when the docking station is connected to the PC. The data on the SD card can also be evaluated by means of a card reader, however, without having the docking station connected to a PC. The data is transferred using the DS400 software. Test data for storage both in the PC database and on the SD card: Detector information:  Type of detector  Serial number  Software version  Sensor serial number  Gas type  Detection ranges  Alarm thresholds: A1, A2, A3, STEL, TWA  Battery capacity  Confidence beep ON/OFF Docking station:  Date and time  Mode: Function test or sensor calibration  Test gas and gas concentration  Gas cylinder number  Test result  Function test: Horn (audible alarm) LED (visual alarm) tAlarm1 tAlarm2 t50 or t90  Sensor calibration: Zero point (ZP) before sensor calibration Zero point (ZP) after sensor calibration Sensitivity (CAL) before sensor calibration Sensitivity (CAL) after sensor calibration  DS400 Serial No. and name  DS400 ID  DS404 firmware version

the setup program starts automatically. If this does not work, select the relevant CD drive in the Explorer, start the program manually by means of a double-click on the program icon and follow the instructions of the program. You may either use the suggested directory name and drive designation or select a different path. The program is then installed on the selected drive and directory. After installation, the program group “GfG\DS(TS)400” and the icons for starting the program are created. Installation of the USB Driver Connect the RS485 USB interface cable to your PC. Windows recognises the new hardware and asks for the driver. The driver is on the CD in directory USB_V206. Make Windows install the driver from this directory or search for the driver on the CD. Two driver components are installed. The first driver is the USB driver, the second driver the virtual COM port. Depending on the PC configuration, a message will be displayed that the driver did not pass the Windows logo test under Windows XP or Windows 7. This message can be ignored. After successful installation you can see in the device manager (Start->System control->System->Device manager) which COM port was reserved for the USB adapter. The designation of the COM port, e.g.: COM4, is required for the setting in the software. Configuration of the DS404 The docking station can be configured with the configuration program TS400Config.EXE from Version 3.5.3. This includes in particular the setting of the test gas concentrations. Connection Click on the arrow in the port selection box to select the correct COM port. Normally the software suggests the correct port automatically. In field DS400/4 ID, select the DS404 with which you wish to communicate. This is normally the ID "1". Now click button "Connect". The connection to DS404 is now established and the page "General" is displayed. General General information of the DS400 is entered and displayed here. DS400/4 alias name: Input of an alternative name for the docking station. ID: Change the ID of the connected DS404 – only necessary if several DS404 are connected via patch cable. In the field "Last service" you can see the date on which the DS404 was last serviced. The field "Next service" indicates when the DS404 is to be serviced next. Note: When this date is reached, the message "DS404 service necessary" appears on the display of the detector. If the date is exceeded by 21 days, no further function tests or calibrations can be carried out. The tests are aborted with the message “DS404 service necessary”.

Here you have to indicate whether no filter, a new filter, or a used filter is connected. If you select No filter, the zero point for CO2 will not be calibrated at the next G460 calibration. The DS404 automatically counts the current cycle time of the filter. When the filter reaches its warning threshold, the message "CO2 filter" is displayed. The filter should be replaced at the next opportunity. If the filter reaches the status Filter exhausted, no further AutoCal adjustments will be carried out and the message "CO2 filter exhausted!" appears on the display of the gas detector. Gas Input 1 The connected test gas is specified here. Function tests and calibration are not possible without these inputs. Up to six different gases of a test gas mixture can be entered here. Only % vol. or ppm can be selected as units. For combustible gases, the DS404 converts the test gas concentration automatically from % vol. or ppm to % LEL. Gas cylinder No.: Enter the number or a name for the gas cylinder. Gas hose length (m): Input of the hose length to the gas cylinder necessary This configuration program and the docking stations accept a wide range of test gas values. The gas detectors require test gases with gas concentrations between 10 and 105 % of the respective measuring range for calibration. Outside this range, no calibration is performed with test gas. The use of test gases with gas concentrations between 30 and 70 % of the respective measuring range is recommended. After selecting and setting new test gases and test gas concentrations, the connection to the docking station must be interrupted by clicking the button "Disconnect". The connection must then be established again by clicking the button "Connect". Now check in the file "Gas" whether the transmitted test gas concentrations correspond to those of the connected test gas cylinder. Test Times The parameters for the function test and calibration can be changed in the file Test times. The times should only be changed, however, for special applications, e.g. in the case of extreme hose lengths. Under certain circumstances, setting the times too short may hinder the function test or the sensor calibration. Setting CAL purging times too long consumes test gas unnecessarily. Function test time max. (sec): Input of the maximum time (seconds) for the function test Function test purging time (sec): Input of the sensor purging time (seconds) with fresh air after the function test to avoid false alarms after the function test

the zero point Calibration preparation (sec): Input of the sensor purging time (seconds) before calibration with test gas Calibration purging time (sec): Input of the sensor purging time with fresh air after calibration with test gas Only Alarm1 and Alarm2: Only the time for Alarm 1 and Alarm 2 is tested Additional T50 test: Test of Alarm1, 2 and the response time t50 Additional T90 test: Test of Alarm1, 2 and the response time t90 Clock The time and date for the DS404 are set here. Note: Date and time are saved in the log file on the SD card during the function test and during sensor calibration. Ensure that the PC clock, and hence the clock of the DS404, is set correctly. If the internal clock of the DS400/4 outputs a wrong date, the calibration of function test will be aborted with the error: Code 6 DS404 service necessary. Intervals The intervals for function test and calibration are set under the tab Intervals. Transfer intervals: The intervals are automatically transferred to the gas detectors of the G400 Series. If these intervals are exceeded, a message is displayed when the detector is switched on. This message can be acknowledged. With the field "Transfer intervals" you can determine whether or not the set intervals are to be transferred at each function test or calibration. Function test interval (days): A check of the setting of the function test interval every working day is recommended. In the field "Function test interval" you can set the number of days after which the detector demands a function test. If the value is set to 0 days, the detector does not demand a function test. Calibration interval (days): The lengths of the calibration intervals should not exceed a period of 6 months. In the field "Calibration interval" you can set the number of days after which the detector demands calibration. If the value is set to 0 days, the detector does not demand calibration. The intervals for the function test and calibration are not a substitute for the annual inspection of the gas detector by an expert, see also operating manual of the Microtector II gas detectors. With the field "Set time in detector" you determine whether the date and time in the detector is to be set to the date and time of the docking station. With the field "Switch OFF detector after test" you determine whether or not the detector is to be switched off 10 minutes after a function test.

cleaning agents! Maintenance and Inspection Regular inspection of the CO2 absorption filter and hose connections. An annual inspection by an expert is recommended. Troubleshooting Code Fault / message Cause Remedy Red and green LED in SD card slot lit continuously Error in program memory or error in main memory Switch detector off and on again Contact GfG Service, if necessary 1 "No gas defined" DS404 is not configured or error in parameter memory Configure DS404 Contact GfG Service, if necessary 2 "Flow error!" Fault in the gas supply Open valve of the test gas cylinder Remedy interruption in the test gas supply Contact GfG Service, if necessary 3 "Aborted by detector!" Fault in gas detector Switch DS404 and detector off and on again Repeat procedure 4 "Power error!" Fault in operating voltage of the DS404 Replace plug-in power supply unit Contact GfG Service, if necessary 5 "Time too long!" Function test of the sensors taking too long Check gas supply 6 "DS404 service necessary!" Service date has been exceeded by max. 21 days Contact GfG Service 7 "No SD card!" SD card not inserted or cannot be written Insert or replace SD card 8 "CO2 filter exhausted!" The CO2 absorption filter is exhausted Replace CO2 absorption filter and reset in the configuration program 9 "DS404 parameter error!" Error in parameter main memory Switch detector off and on again Reconfigure, if necessary Contact GfG Service, if necessary 12 "Firmware below 3.44" Detector software version too old Carry out detector update Contact GfG Service, if necessary 13 "Gas switch error" The gas switch is faulty Contact GfG Service I 1 "DS404 service due" Service date exceeded or clock incorrect or not set Contact GfG Service I 2 INFO "Gas pressure!" Gas pressure too low if external gas pressure switch is installed Check test gas cylinder and replace, if necessary I 8 INFO "Gas amount!" Test gas cylinder almost empty Replace test gas cylinder and reset with the configuration program

Description Order No. CO2 absorption filter for zero gas filtration for CO2 sensors 1000220 Gas connection fitting, Type 2001, 2-stage pressure reducer for calibration gas supply by pump for test gas cylinders of Type 2 AL, 8 AL or 6D, maximum inlet pressure: 0-1000 psi/70bar 1319216 Gas connection fitting, Type 2003, 2-stage pressure reducer for calibration gas supply by pump for high-pressure cylinders; incl. fitting for high-pressure cylinders (M19x1.5LH) maximum inlet pressure: 0-3000 psi/207bar 1319217 Pressure switch for high-pressure cylinders incl. T-piece for installation on the gas connection fitting, Type 2003, pressure setting range: 65-300 psi/4.5-20.7 bar 1319218 USB-RS485 interface cable for data transmission PC<->DS400/DS404 1319221 Patch cable for data transmission and connection of several docking stations, in various lengths: 1m / 3m 5m / 8m 10m 1319222 / 23 1319224 / 25 1319226 Plug-in power supply unit DS400-PS1 (European plug) 1450403 Jack plug 6.3 mm for connection of a pressure switch 1450404 Double-sided jack plug 6.3 mm for cascading of the DS400/DS404 1450405 Test and charging cradle G400-DIC1D (for detector without pump) 1450406 Test and charging cradle G400-DIC2D (for detector with pump) 1450407 Test and charging cradle DIC888/999 (for Microtector III and Polytector III) 1990223 SD memory card for archiving instrument-specific test data and test routines, different storage capacities 1450408 Database software for automatic storage of instrument data, tests, test dates and test routines. 1319203 Technical Data Type designation: DS404 Display and control elements: Display and 3 buttons on G450 or G460 Power supply: 12 V DC / 1.25 A (2 input/output jacks) Gas Connections: 1 zero gas inlet, 4 test gas inlets, 1 gas outlet (for hose di≈5 mm) Delivery rate: Flow rate: 0.5 to 0.6 l/min; drawn in by internal pump (pressure-free) Pressure monitoring: 4 electric inputs for floating contacts (2 input/output jacks) Time Function test: 20 - 60 sec. (depending on setting and test gas concentration) Calibration: 2 - 10 minutes (depending on sensor type and number of test gases) Data Storage medium: 2 GB SD card (formatted with FAT or FAT16 file system) Communication: RS-485 (2x RJ45 modular jacks) Housing Protection class: IP20 Material: Plastic Dimensions: 125x169x225 mm (WxHxD) Weight: 1500 g including G400-DIC1D GfG Gesellschaft für Gerätebau mbH Klönnestraße 99 – D-44143 Dortmund Telefon: +49 (0)231 – 564 00-0 Telefax: +49 (0)231 – 564 00-895 Internet: www.gasmessung.de E-Mail: [email protected] Firmware Version 3.04 211-100.24_BA_DS404.doc Last edited: 16. February 2018 Subject to change