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GMI Oxygas P-500 User Handbook Manual

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Oxygas P-500
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  • Page 1 Oxygas P-500 User Handbook...
  • Page 2 OXYGAS P-500 USER HANDBOOK Issue 2 11/06/13 Part Number: 42645 GMI welcomes comments on all our publications. Your comments can be of great value in helping us to improve our customer publications. Please send any comments that you have to our Customer Support...

  • Page 3: Copyright

    COPYRIGHT This User Handbook is copyright of Gas Measurement Instruments Ltd (GMI) and the information contained within, is for use only with the Oxygas P-500 instrument. Reproduction, in whole or in part, including utilisation in machines capable of reproduction or retrieval without written permission of Gas Measurement Instruments Ltd is prohibited.

  • Page 4: Safety

    Directive 94/9/EC Any right of claim relating to product liability or consequential damage to any third party against GMI is removed if the warnings are not observed. AREAS OF USE Exposure to certain chemicals can result in a loss of sensitivity of the flammable sensor.

  • Page 5: Declaration Of Conformity

    DECLARATION OF CONFORMITY Refer to current Declaration of Conformity document Part No. 42907 (supplied with product)
  • Page 6 OXYGAS P-500 USER HANDBOOK...

  • Page 7: Revision Record

    REVISION RECORD Date Issue Description Of Change 29/07/04 New Handbook 11/06/13 Revised to include effect of CN 6257.
  • Page 8 OXYGAS P-500 USER HANDBOOK...

  • Page 9: Table Of Contents

    CONTENTS COPYRIGHT ..............i LIABILITY ............... i MODIFICATION NOTICES ..........i SOFTWARE ..............i DISPOSAL ADVICE ............i SAFETY ................. ii AREAS OF USE ............. ii STORAGE, HANDLING AND TRANSIT ......ii DECLARATION OF CONFORMITY ....iii REVISION RECORD ........v INTRODUCTION ..........
  • Page 10 OXYGAS P-500 USER HANDBOOK Volume Gas, 0 to 100 % .......... 14 Oxygen, 0 – 25% ............. 14 PPM Flammable 0 – 1000 ppm ........15 Construction ............... 15 Batteries ..............16 Disposable Alkaline (LR20) Dry Cell Batteries ..16 Rechargeable Battery Pack ........
  • Page 11 CONTENTS Standard Charger ............. 27 Flatbed Charger ............28 Smart Charger ............28 Replacing the Battery Pack ........29 Recharging the Battery Pack ........30 Replacing Alkaline (LR20) Dry Cell Batteries ..... 30 Filter Replacement ............32 ..................33 CALIBRATION ..........35 Calibration Validity ............
  • Page 12 OXYGAS P-500 USER HANDBOOK Display ..............A-2 Sampling System ............ A-2 Response Time (O2) ..........A-2 Power Source ............A-3 FIELD CALIBRATION ........B-1 Selectable Ranges in FCM ........B-3 Entering FCM ............. B-3 Zeroing the Instrument ..........B-4 Field Calibration Procedure ........B-5 Quitting FCM ..............

  • Page 13: Introduction

    INTRODUCTION The Oxygas P-500 is a two button instrument designed to measure Parts Per Million, Lower Explosive Level, Volume flammable gas and Oxygen for (CGI) leak detection and purge operations. The instrument is designed to the latest standards and is certified for use in Hazardous Areas.

  • Page 14: Overview

    OXYGAS P-500 USER HANDBOOK Overview This chapter provides a brief overview of the principles of operation of the instrument in its two modes of operation. 1) Combustible Gas Indicator - Leak Detection 2) Purging This is not intended as operating instruction in the application of finding leaks, monitoring atmospheres or practical purging operations.
  • Page 15 INTRODUCTION In some applications, all three sources are available, e.g. a boiler burner. In other applications, where gas may be liable to escape or present, ignition sources controlled, e.g. hazardous or zoned areas. In applications, such as purging, the Air or Oxygen source is controlled or excluded.

  • Page 16: Purging

    OXYGAS P-500 USER HANDBOOK Figure 1.3 Flammability The Oxygas P-500 uses a catalytic sensor to measure LEL, which requires air to be present, and a thermal conductivity sensor to measure the % Volume range. Purging The opening of a pipeline or vessel causes a mixing of flammable products, such as gas with air, creating potentially flammable mixtures.
  • Page 17 INTRODUCTION Figure 1.4 Principle of Purging When the pipe has been open to atmosphere for maintenance or when first being put into service, there is a requirement to introduce flammable gas into the pipe in a controlled way to avoid large flammable mixtures being created and to avoid air being introduced into the network.
  • Page 18 OXYGAS P-500 USER HANDBOOK The following diagram illustrates a typical direct purging operation and is not intended to demonstrate the purge technique, but illustrate the effect on the instrument reading. Figure 1.5 Direct Purging - Commissioning Commissioning In the direct purge mode for commissioning, the pipe would contain air and the pipe would be purged with Natural Gas.
  • Page 19 INTRODUCTION De-commissioning In purging down to air the typical figure would be 2% Methane or around 40% LEL to end the purge. In the Purge mode only the % Gas and the 02 ranges are available and normally the % Vol range can be used. A reading can be taken from the 02 range for confirmation but care should be taken that the pressure applied to the cell is the same or similar to the zero point, ie atmospheric pressure.
  • Page 20 OXYGAS P-500 USER HANDBOOK When commissioning, the instrument will start in the LEL range and autorange up automatically to % Gas when the LEL reaches around 110% or the %Gas is greater than about 5.5%. Thus above these values of gas in air the instrument will be in the %Gas range and the reading increase up to the final purge reading of >95% gas (85 - 95% depending on...
  • Page 21 INTRODUCTION Indirect Purging The following diagram shows a typical indirect purging operation using a Nitrogen cylinder. Figure 1.7 Indirect Purging - De-commissioning In this situation Nitrogen or an inert gas is used to purge the vessel of flammable gas; the above illustration does not fully describe purging, only its influence on the instrument.
  • Page 22 OXYGAS P-500 USER HANDBOOK Since 100% air is used to set zero at switch-on, it is the zero that is affected by the difference between air and Nitrogen. There is a typical difference in reading between these two conditions of around 5% on the % Volume scale when calibrated in Methane on an Oxygas.
  • Page 23 These numbers still fall within the 30% safety factor normally used. As the Oxygas P-500 has a wide variety of available user selected options, it is not possible to provide an operator handbook specific to each possible variation, therefore, what...
  • Page 24 OXYGAS P-500 USER HANDBOOK...

  • Page 25: General Information

    GENERAL INFORMATION Ranges of Operation LEL, 0 to 100% The LEL range indicates the explosivity of the flammable gas in the sample. This is displayed as a percentage of the lower explosive limit (LEL) of the gas. For methane 100% LEL corresponds to 5% Volume methane in Air.

  • Page 26: Volume Gas, 0 To 100

    OXYGAS P-500 USER HANDBOOK Volume Gas, 0 to 100 % This range displays the total volume of a specific flammable gas with respect to air. The calibration gas is shown on the service label and for the purpose of this handbook is assumed to be methane.

  • Page 27: Ppm Flammable 0 - 1000 Ppm

    GENERAL INFORMATION PPM Flammable 0 – 1000 ppm This range is used to measure very low levels of gas and indicates the parts per million concentration of the gas in air (1000 ppm is equivalent to 0.1% Volume Gas). The digital display reading resolves to 5 ppm with the analogue bargraph following in steps of 40 ppm.

  • Page 28: Batteries

    30 minutes operating time is left at normal temperatures. The instrument will then turn off. There are three GMI Battery Chargers: a Standard Charger, a Flatbed Charger and a Smart Charger. The Smart Charger has both slow and fast charge options as well as a serial link for communications with the instrument.

  • Page 29: Filters

    GENERAL INFORMATION Filters A number of different filter types are available from GMI. The minimum requirement is a cotton particulate filter and a hydrophobic filter which are incorporated in the probe handle assembly supplied with the instrument. Filters must be checked at frequent intervals and where appropriate changed to ensure a clean sample path.
  • Page 30 OXYGAS P-500 USER HANDBOOK...

  • Page 31: Operating Instructions

    Button Two . See Figure 3.1 below. INST. PUMP ZERO PURGE OXYGAS P-500 RANGE Figure 3.1 Instrument Front Plate Mode 1 (CGI): Switching ON with Button One provides four gas ranges LEL autoranging to Volume Gas, and Oxygen Range 0-25%.

  • Page 32: Switching On

    OXYGAS P-500 USER HANDBOOK Mode 2 (Purge): Switching ON with Button Two provides access to only 0-100% Vol Gas and 0-25% Oxygen for purge applications. Switching On Press and hold Button One to turn the instrument on. This initiates the instruments warm up cycle and switches on the pump.

  • Page 33: Calibration Date Features

    OPERATION Calibration Date Features At the end of warm-up and before the Oxygas P-500 instrument is ready for measuring, the instrument will indicate on the display when the next calibration is due. This will be displayed as month and year, as shown in Figure 3.3:...

  • Page 34: Switching On In Purge Mode

    Switching On in Purge Mode To switch on in Purge mode, press and hold Button Two The Oxygas P-500 will initiate the warm-up sequence as explained previously. This mode uses the Volume Gas and Oxygen ranges only. When in purge mode, the PURGE flag is activated on the display, as shown in Figure 3.4.

  • Page 35: Zeroing The Ppm Range

    OPERATION Zeroing the PPM Range A double press of Button Two zeroes the current range. This should be carried out in fresh air and may take a few minutes to reach the optimum zero stability. The display in Figure 3.5 occurs if a large adjustment is needed to reach the zero point.

  • Page 36: Summary Of Button Operation

    OXYGAS P-500 USER HANDBOOK Summary of Button Operation Double Press and Mode Single Press Hold Press Button 1 Toggles Pump Switches Switches ON / OFF Instrument Instrument (during operation) ON (CGI) Switches Button 2 Zero Instrument LEL/VOL - O - PPM (CGI)
  • Page 37 OPERATION blockage and Button One should then be pressed to restart the pump. ‘CHECK ZERO’ This indicates that there may have been a zero shift due to the presence of gas. Switch off the instrument and switch on again in fresh air. ‘ZERO FAULT’...
  • Page 38 OXYGAS P-500 USER HANDBOOK...

  • Page 39: Operator Maintenance

    OPERATOR MAINTENANCE Rechargeable Battery Pack Three battery chargers are available from GMI, a Standard Charger, a Flatbed Charger and a Smart Charger. Standard Charger The GMI Standard Charger takes approximately 14 hours to charge a flat battery. Note: The 4-button instrument is for illustration purposes only.

  • Page 40: Flatbed Charger

    Note: The 4-button instrument is for illustration purposes only. Smart Charger The GMI Smart Charger provides both fast and standard charging facilities and can charge an instrument and spare...

  • Page 41: Replacing The Battery Pack

    OPERATOR MAINTENANCE battery pack simultaneously. Using the standard charging option, a battery pack can be recharged in 12 hours from a fully discharged state. Using the fast charge option a battery pack can be 90% recharged in approximately 60 minutes and fully recharged in 120 minutes.

  • Page 42: Recharging The Battery Pack

    Replacing Alkaline (LR20) Dry Cell Batteries All four batteries should be replaced at any one time and in a safe area. GMI only recommend the use of Energiser or Duracell cells. 1) Loosen the two instrument base screws (4mm hex)
  • Page 43 OPERATOR MAINTENANCE 2) Remove battery cover. 3) Remove the old batteries. 4) Check battery compartment for damage to spring contacts or corrosion on springs. Caution: Under no circumstances should rechargeable batteries be fitted in place of Alkaline batteries. 5) Insert four new batteries observing correct polarity indication in battery compartment base.

  • Page 44: Filter Replacement

    OXYGAS P-500 USER HANDBOOK Filter Replacement Hydrophobic and cotton particulate filters in the probe handle minimise the danger of water and dust ingress. Caution: The instrument should never be switched on without suitable filters installed. If a blockage occurs the ‘SAMPLE FAULT’ indicator is displayed.
  • Page 45 OPERATOR MAINTENANCE 2) Remove the cotton particulate filter and discard. 3) Remove the hydrophobic filter. 4) Clean the probe handle to make sure that it is free from dirt and water. 5) Fit a new cotton particulate filter. 6) Fit the hydrophobic filter. The yellow label on the f i l - ter fits against the yellow label on the probe handle.
  • Page 46 OXYGAS P-500 USER HANDBOOK...

  • Page 47: Calibration

    CALIBRATION The instrument has been calibrated for a particular flammable gas mixture. Where any doubt exists the instrument should be returned to GMI or an authorised distributor for calibration. Calibration Validity Calibration validity is the responsibility of the user. Under normal operating conditions a 12 month period can be expected.
  • Page 48 OXYGAS P-500 USER HANDBOOK...

  • Page 49: Accessories

    ACCESSORIES Accessories Supplied with Oxygas P-500 Instrument Part Number 42501P / 42501PR Part Number Description 42119 Carrying Case 12370/2 Shoulder Harness 12451 4mm Hex. Driver 12712 Clear Sample Line x 1.5 metres. (4ft.10ins.) approx. 12480 Plastic Probe - Solid End 35cm.
  • Page 50 OXYGAS P-500 USER HANDBOOK 12888 Standard Charger / 220V Power Supply (Australian Plug) 13179 Standard Charger w/o Power Supply 42121 Flatbed Charger / 240V Power Supply (UK PLug) 42122 Flatbed Charger / 220V Power Supply (Euro Plug) 42123 Flatbed Charger / 110V Power Supply...
  • Page 51 Carrying Case (Large) ; Probe Handle Assembly ; Probe Handle Adaptor ; Bellows Probe. Note: Large carrying case has space for special probes, e.g. Swan Neck Note: For other sampling probes and accessories, and for calibration gases, contact GMI Ltd.
  • Page 52 OXYGAS P-500 USER HANDBOOK...

  • Page 53: Additional Information

    ADDITIONAL INFORMATION Training Training courses are available on all our products. Contact our Marketing Department for further details: Tel: +44 (0) 141 812 3211 Fax: +44 (0) 141 812 7820 e-mail: sales@gmiuk.com World Wide Web Visit our web site at www.gmiuk.com...
  • Page 54 OXYGAS P-500 USER HANDBOOK...

  • Page 55: Typical Operating Parameters

    TYPICAL OPERATING PARAMETERS Typical operating parameters are as follows: Range Resolution Zero Accuracy Range Stability 0 to 10% 0.1% +/- 0.5% 10 to 100% 2% +/- 1% LEL Volume 0 to 100% +/- 2% 1% +/- 1% Gas Oxygen 0 to 21% 0.1% +/- 0.5% +/- 0.5% + 3% reading...

  • Page 56: Size

    OXYGAS P-500 USER HANDBOOK Size 180mm (7.08”) x 95mm (3.74”) x 105mm (4.13”) Weight 1.7kg (3.75lbs.) with alkaline batteries Operating Temperature C to 50 C (-4 F to 122 Humidity 0 – 95% RH Construction Moulded polypropylene case protected to IP54...

  • Page 57: Power Source

    Power Source 4 ‘D’ size alkaline cells providing approximately 15 hours runtime at 20 C (68 F).. Rechargeble (NiCd) battery pack providing approximately 9 hours runtime at 20 C (68...
  • Page 58 OXYGAS P-500 USER HANDBOOK...

  • Page 59: Field Calibration

    Field calibration allows simple calibration to be carried out in the field without the use of additional test equipment. Other calibration procedures require the use of the GMI Manual Calibration software or the Workshop System. There are fundementals, in terms of instrument calibration, that should be noted: •...
  • Page 60 OXYGAS P-500 USER HANDBOOK INST. PUMP ZERO PURGE RANGE Figure B-1 Button Functions To simplify button operation when calibrating the instrument, an overlay card, shown in Figure B-2, is available and can be placed over the top face of the instrument to identify calibration button functions.

  • Page 61: Selectable Ranges In Fcm

    FIELD CALIBRATION Selectable Ranges in FCM When in FCM the following ranges are manually selectable by pressing Button Two : LEL, Volume GAS, Oxygen. Entering FCM 1) Switch the instrument on and allow it to complete its warm-up checks. 2) Double press Button One to initiate instrument switch off.

  • Page 62: Zeroing The Instrument

    OXYGAS P-500 USER HANDBOOK In CAL mode, the instrument buttons have the functions shown in Figure B-4. Press and Single Press Double Press Hold Button 1 Button 2 Figure B-4 CAL Mode Button Functions Zeroing the Instrument 1) Enter FCM. See the previous section ENTERING FCM.

  • Page 63: Field Calibration Procedure

    FIELD CALIBRATION Field Calibration Procedure 1) Zero gas ranges before attempting calibration. See previous section ZEROING THE INSTRUMENT for details. 2) Make sure that the instrument pump is running and the gas range selected is compatible with the calibration gas. Note: A single press of Button One toggles the pump Off / On.
  • Page 64 OXYGAS P-500 USER HANDBOOK 4) Turn the regulator valve counter clockwise to open the valve slightly. Make sure that the gas is flowing before connecting the sample tubing to the instrument, otherwise an instrument sample fault may occur. 5) Connect tubing from regulator to instrument inlet...
  • Page 65 FIELD CALIBRATION In SPAN mode, the instrument buttons have the functions shown in Figure B-7. Press and Single Press Double Press Hold Button 1 Button 2 Figure B-7 SPAN Mode Button Functions 8a) In SPAN mode, a single press of Button One will produce small incremental changes to increase display reading, or a single press of Button Two will produce small decremental changes to...
  • Page 66 OXYGAS P-500 USER HANDBOOK 9) The calibrated instrument display will now return to CAL mode display as shown in Figure B-8. Figure B-8 50% LEL Display 10) Make sure that correct reading is displayed before disconnecting the calibration gas then disconnect...

  • Page 67: Quitting Fcm

    CAL DUE date will be set to 12 months from now. (This can be altered to a different frequency, via the set-up program, e.g. 6 months from now. Contact GMI for details). Quit Without Saving Changes 1) Double press Button One to exit FCM.
  • Page 68 OXYGAS P-500 USER HANDBOOK B-10...

  • Page 69: Operating Instructions

    OPERATING INSTRUCTIONS The following instructions provide the user with a quick guide to the operation of the . . . Oxygas P-500 instrument.
  • Page 70 1.2.7 of Annex II of the ATEX Directive 94/9/EC Any right of claim relating to product liability or consequential damage to any third party against GMI is removed if the warnings are not observed. AREAS OF USE Exposure to certain chemicals can result in a loss of sensitivity of the flammable sensor.
  • Page 71 Oxygas P-500 - Operating Instructions The enclosure material is polypropylene and must not be exposed to environments which are liable to result in mechanical or thermal degradation or to damage caused by contact with aggressive substances. Additional protection may be required in environments where the instrument enclosure is liable to damage.
  • Page 72 INST. BUTTON 1 PUMP ZERO PURGE BUTTON 2 OXYGAS P-500 RANGE Switch ON (CGI Mode) LEL autoranging to Volume Gas ; Oxygen ; PPM. Press and Hold Button One to switch instrument and pump On. This initiates the instrument’s warm-up cycle.
  • Page 73 Oxygas P-500 - Operating Instructions Next, i n s t r u m e n t indicates, as month Alternate and year, when the flash next calibration is due. (February 2005 in example) The CAL DUE display screen is followed by the current gas detection reading.
  • Page 74 GAS MEASUREMENT INSTRUMENTS LTD.

  • Page 75: Index

    Index Symbols 1 25 CALIBRATION VALIDITY 33 Calibration Validity 35 CGI 19 Changing Range 22 ACCESSORIES 37 Charger, Flatbed 28 Accuracy A-1 Charger, Smart 28 ADVICE, DISPOSAL i Charger, Standard 27 Alarms 15 CHECK ZERO 25 alkaline A-3 Combustible Gas Indicator - Alkaline (LR20) Dry Cell Leak Detection 2 Batteries 16, 30...

  • Page 76: Italiano (Italian)

    OXYGAS P-500 USER HANDBOOK INSTRUCTIONS, OPERATING C-1 EN 50104 A-2 INTRODUCTION 1 English x Issue 1 2 Entering FCM B-3 LCD 17, A-2 FAULT, BAT 25 LEL 13 Fault Flags 24 LIABILITY i FAULT, SAMPLE 24 Liquid Crystal Display 17...

  • Page 77: Svensk (Swedish)

    Operator Messages 24 Replacing the Battery Pack Overview 2 Oxygen 14 Resolution A-1 Response Time (O2) A-2 REVISION RECORD v PARAMETERS, OPERATING Power Source A-3 SAFETY ii PPM Flammable 15 SAMPLE 24 Purge 20 SAMPLE FAULT 24, 32 Purge Mode 22 Sampling System A-2 Purging 4 Save Changes B-9...
  • Page 78 OXYGAS P-500 USER HANDBOOK Time, Response A-2 Training 41 TRANSIT ii Validity, Calibration 35 Volume Gas 14 Weight A-2 World Wide Web 41 Zero A-1 ZERO, CHECK 25 ZERO FAULT 25 Zeroing the Instrument B-4 Zeroing the PPM Range 23...
  • Page 80 Thank you for reading this data sheet. For pricing or for further information, please contact us at our UK Office, using the details below. UK Office Keison Products, P.O. Box 2124, Chelmsford, Essex, CM1 3UP, England. Tel: +44 (0)330 088 0560 Fax: +44 (0)1245 808399 Email: sales@keison.co.uk...

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Oxygas 500

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