GasTech GasCheck 3000 Page 3 User Manual Download

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GasCheck 3000 & 3000is Ion Science Ltd

Page

2 of 23

Declaration of conformity

Manufacturer:

Ion Science Ltd, The Way, Fowlmere, Cambridge, England. SG8 7UJ

Product:

GasCheck 3000 (Grey Case)

Product description:

a handheld micro thermal conductivity sensor used to detect gas leaks. This

has been designed specifically for search and location of non-flammable gases such as helium and

CFC’s.

Directives:

89/336/EC EMC

Standards:

BS EN 61010-1:2001

Safety requirements for measurement, control & lab equipment

BS EN ISO 9001:2000

Quality management systems

BS EN 61326-1:1997

EMC – Equipment for measurement, control and laboratory use

Signed By:

Name: Mark Stockdale,

Position: Technical Director
Date: 23

April 2007

Safety:

GasCheck complies with the requirements of 73/23 EEC low voltage directive and, apart from

a low voltage pump, there are no moving parts within the instrument so that the machinery directives

are not applicable.

Summary of Contents for GasCheck 3000

Page 1: ...GasCheck 3000 3000IS Instrument User Manual part number 28052 ...

Page 2: ...GasCheck 3000 3000is Ion Science Ltd Page 1 of 23 ...

Page 3: ...such as helium and CFC s Directives 89 336 EC EMC Standards BS EN 61010 1 2001 Safety requirements for measurement control lab equipment BS EN ISO 9001 2000 Quality management systems BS EN 61326 1 1997 EMC Equipment for measurement control and laboratory use Signed By Name Mark Stockdale Position Technical Director Date 23rd April 2007 Safety GasCheck complies with the requirements of 73 23 EEC l...

Page 4: ...f quality systems BS EN 50014 1998 ATEX general requirements BS EN 50020 2002 ATEX Intrinsic safety i BS EN 61010 1 2001 Safety requirements for measurement control lab equipment BS EN ISO 9001 2000 Quality management systems BS EN61326 1 1997 EMC Equipment for measurement control and laboratory use Signed By Name Mark Stockdale Position Technical Director Date 23rd April 2007 Safety Rating This i...

Page 5: ...2 Display 13 4 3 Audio Visual outputs 14 4 4 Prepare the GasCheck 14 4 5 Switch on the GasCheck 16 4 6 Recommended leak search 16 4 7 Switch off the GasCheck 17 5 Maintenance 17 5 1 Inspect and Clean the GasCheck 17 5 2 Replace the Batteries 18 5 3 Fault finding 20 6 Storage Disposal 20 6 1 Storage 20 6 2 Disposal 20 7 Spares and Accessories 21 7 1 Introduction 21 7 2 Spares 21 7 3 Accessories 21 ...

Page 6: ... The GasCheck 3000is intrinsically safe and is suitable for leak detection of hydrogen and other flammable gases and for leak detection in hazardous areas of EEx ia IIC T4 rating The GasCheck has a convenient storage and carrying case together with a spare battery holder a long flexible probe for leak detection in areas where access is restricted and a box spanner for probe changing 1 3 Principal ...

Page 7: ...iving rooms from pipeline assemblies the detection of leaks from stored gases and the detection of vapours released from stored chemicals Medical applications such as the detection of leaks from anaesthetic gas bottles and pipelines and leak testing of membrane materials glove boxes and so forth Valve emission evaluation to EPA Environmental Protection Agency method 2 1 Leak testing of pipeline jo...

Page 8: ...onstruction Storage case Polypropylene with polyester foam insert GasCheck Polyurethane casing on 3000 only Conductive polypropylene resin with metal bracket on 3000is only Dimensions Storage case 420 x 320 x 97 mm 16 5 x 12 5 x 3 75 GasCheck see Figure 2 Mass Complete storage case 1 6 kg 3 5 lb GasCheck 0 5 kg 1 0 lb Ingress ratings Minimum IP20 Length of short probe and nozzle Length of long pro...

Page 9: ...ative response among them argon Ar carbon dioxide CO2 and R134a Minimum response time Short probe fitted Less than 1 second Long probe fitted About 9 seconds Recovery time About 1 second Maximum detection level with the short probe and nozzle fitted 20 ml sec The nozzle when fitted provides automatic 10 fold dilution of the gas stream entering the detector cell Smallest leak detection levels see T...

Page 10: ...ection 5 2 WARNING For GasCheck 3000is Do not modify the GasCheck 3000is equipment to allow any recharging For Intrinsic Safety T4 Rating in the Gas Check 3000is rechargeable batteries e g Ni Cad must not be used There is no provision for the recharging of batteries within the GasCheck 3000is For alkaline types MN1500 or LR6 type use only Duracell Standard Procell or Ultra or Ever Ready Energiser ...

Page 11: ...heck if any item is damaged Refer to Figure 3 and check that the storage case contains the items listed in Table 3 If any item is missing notify your supplier in writing within three days Qty Description Check 1 Gas Check with short probe and nozzle fitted 1 Long probe 1 Box spanner 1 Special screwdriver for access to battery compartment Gas Check 3000is only 1 Spare battery holder with 4 batterie...

Page 12: ...to darken or lighten the display There may be little or no need to use this control at normal temperatures NOZZLE PEAK HOLD 5 When the GasCheck is applied to leak location in the presence of large leakage the nozzle is very useful The nozzle symbol when displayed corrects the leak rate range accordingly Calibration is performed without it Press and hold the nozzle key to scroll through the nozzle ...

Page 13: ...1 0 Positive R134a 0 Negative He 1 Positive SF6 1 Negative R22 1 Negative CO2 2 Negative CH4 2 Positive Ar 2 Negative R11 3 Positive O2 4 Positive Table 4 Gas Groups 1 Power 4 Backlight Contrast 2 Zero 5 Nozzle Peak hold 3 Gases 6 Range Figure 4 Control keys layout shown for both Gas Check 3000 and 3000is 1 2 3 4 6 5 ...

Page 14: ...ow on the lower right hand side of the display In response to key presses written text will appear confirming the changes to settings Examples are Zeroing detector Nozzle On Peak hold On Nozzle off Peak hold off He Group 0 Contrast darker Contrast lighter 4 2 2 Leak rate indication Leakage is displayed as a single signed digit x 10 signed range for ease of interpretation and calibration Note that ...

Page 15: ... the leak rate range see Section 4 2 1 They also operate once to confirm a key press 4 4 Prepare the GasCheck 4 4 1 Select which probe to use Note Whenever possible use the Gas Check with the nozzle fitted The nozzle helps to protect the short probe from blockage or damage You cannot use the nozzle with the long probe Open the storage case and remove the Gas Check The Gas Check is supplied with th...

Page 16: ... over the existing probe so the spanner fits over the brass nut unscrew the probe counter clockwise direction Withdraw the spanner and probe assembly To refit the short or the long probe follow the steps above but in reverse order CAUTION When using the box spanner to tighten the probe nut ensure the nut is firmly tightened however do not use additional tools as the tread may become damaged Should...

Page 17: ... or nozzle around the area of a suspected leak and look at the display or listen to the audible clicks or note the visual LED flash rate on the GasCheck to identify the location of a leak Specific procedures for leak detection along seams and around pipe joints are described in the following sections When required Use the peak hold and Auto Ranging modes to continue to check for leaks but to displ...

Page 18: ...k If the case of the GasCheck is cracked or dented we recommend that you do not continue maintenance but return the GasCheck to your supplier for inspection and calibration 5 Wipe the GasCheck with a clean lint free cloth moistened with a weak solution of detergent 6 Carefully wipe the outer faces of the probe nozzle fitting to remove any small particles of dirt or debris 7 Use a suitable tool to ...

Page 19: ...es WARNING Replace the batteries in the Gas Check 3000is in a safe area where there are no flammable gases If you do not there may be a risk of fire or explosion WARNING Use only dry cell non rechargeable batteries in the GasCheck 3000is The internal resistance of rechargeable batteries is too low to maintain a T4 safety rating The recommended batteries are specified in section 2 3 Battery Data Ga...

Page 20: ... one battery before you refit the battery holder to the GasCheck You then add the fourth battery into the clip before pushing it into the battery compartment 7 On GasCheck 3000 refit the battery compartment cover 2 and ensure that the catch 1 is engaged On the GasCheck 3000is refit the battery compartment cover and use the special screwdriver to tighten the captive screw and secure the cover in pl...

Page 21: ...d Range keys Gas group is wrong Gas Group not set correctly Press hold Gases until shown OK Nozzle Peak not showing Nozzle Peak is not set correctly Press hold Nozzle until both correct Blocked probe Probe blocked Remove probe and clean Stalled motor Motor failed probe not blocked Return to Ion Science for repair Instrument readings noisy Loose probe Tighten nut slightly Instrument readings noisy ...

Page 22: ... 08045 Short probe A 08043 Replacement battery holder 3000 SPGC8055 Replacement battery holder 3000is A 08139 Nozzle 3000 08024CFC8 Nozzle 3000is 08024CPC0 Box Spanner A 08029 3000is screwdriver 4 TS 01 Case 31164 Instruction Manual 28052 7 3 Accessories Accessory Item Number CalCheck A 21500 specifying gas leak rate and pressure 7 4 Calibration Ion Science offers a calibration service including i...

Page 23: ...ed Warranty Period has been activated and processed Full details along with a copy of our Warranty Statement can be found by visiting www ionscience com instrument registration Service Ion Science is pleased to offer a number of service options on our GasCheck 3000 3000IS product range that allow you to choose the instrument cover that best suits your needs At Ion Science we recommend that all of ...

Page 24: ...00 3000is V1 8 Gas Table updated 16 7 08 3000 V0 48 3000is V4 16 N A GasCheck 3000 3000is V1 9 Log added to back of manual 9 1 09 3000 V0 48 3000is V4 16 N A GasCheck 3000 3000is V2 0 Warranty added to cover Declaration Conformity updated page 2 Contents updated Instrument Warranty and Service added page 22 23 07 10 3000 V0 48 3000is V4 16 N A ...

Page 25: ...GasCheck 5000is User Manual V1 5 GasTech Australia Pty Ltd 24 Baretta Rd Wangara Western Australia 6065 Tel 1800 999 902 Fax 1800 999 903 http www gastech com au ...

Page 26: ......

Page 27: ... standards and specifications EN 50081 1 EMC Emissions light industrial EN 50082 1 EMC Immunity light industrial EN50014 Electrical equipment for use in potentially explosive atmospheres EN50020 Electrical equipment for use in potentially explosive atmospheres Product marking is as follows Gas Check 5000is carries the Intrinsic Safety Marking to class II 2 G Baseefa 02ATEX0093 EEx ia IIC T4 20 C T...

Page 28: ...Clock Set Time Synch RTC 19 Data Control 20 Data Control Clear Data 20 Data Control Data Transfer 20 Data Control Logging Settings 21 Data Control Logging settings Interval 21 Data Control Logging Settings No Samples 21 Data Control Memory Used 22 Data Control Single cont 22 Display Style 22 Display Size 23 Gas Group 24 Language 24 Nozzle 25 Peak Hold 25 Power off 25 Program 26 Range 28 Units 28 4...

Page 29: ...heck 34 4 7 1 Auto shut down 34 5 Maintenance 35 5 1 Inspect and clean the GasCheck 35 5 2 Replace the batteries 36 5 3 Fault finding 38 6 Storage and Disposal 38 6 1 Storage 38 6 2 Disposal 38 7 Spares and Accessories 39 7 1 Introduction 39 7 2 Spares 39 7 3 Accessories 39 7 4 Calibration 39 7 5 Refurbish program 39 The 5000is version of this instrument is manufactured to intrinsically safe stand...

Page 30: ...for leak detection in hazardous areas of EEx ia IIC T4 rating The Gas Check has a convenient storage and carrying case together with a spare battery holder a long flexible probe for leak detection in areas where access is restricted and a box spanner for probe changing 1 3 Principal of operation When the Gas Check is switched on a small internal fan draws gas samples through the probe and into the...

Page 31: ...peline assemblies the detection of leaks from stored gases and the detection of vapours released from stored chemicals Medical applications such as the detection of leaks from anaesthetic gas bottles and pipelines and leak testing of membrane materials glove boxes and so forth Valve emission evaluation to EPA Environmental Protection Agency method 2 1 Leak testing of pipeline joints gaskets chambe...

Page 32: ...on Storage case Polypropylene with polyester foam insert Gas Check Polyurethane casing with a metal bracket Dimensions Storage case 420 x 320 x 97 mm 16 5 x 12 5 x 3 75 Gas Check see Figure 2 Mass Complete storage case 1 6 kg 3 5 lb Gas Check 0 5 kg 1 0 lb Ingress ratings Minimum IP20 Length of short probe and nozzle Length of long probe 300 mm 12 Figure 2 Dimensions mm ...

Page 33: ...th a different thermal conductivity to air Table 1 lists those 12 common tracer gases that have been tested and assigned gas groups If the gas or gas mixture that you seek is not included in these groups select group 0 which is the most sensitive The Gas Check will then still find leaks quickly even though the measured values will not be displayed accurately Some gases give a negative response Min...

Page 34: ...ich you leak test the minimum detection levels may be obscured Note2 An offset of up to 10 times the detection levels given in Table 1 may be experienced in the presence of electromagnetic interference 320 30 MHz at the levels specified in EN 50082 1 Table 1 Smallest Leak Detection Levels Gas Gas Group Positive Negative Smallest Leak Detection Level in ml sec H2 0 Positive 1 5x 10 5 ml sec He 0 Po...

Page 35: ...horten the battery life Battery life hours Battery type Gas Check 5000is LR6 R6 20 MN1500 20 R6S 10 R6PP 10 Recommended battery types Table 2 Average battery life WARNING For Gas Check 5000is Do not modify the Gas Check 5000is equipment to allow any recharging For intrinsic safety T4 rating in the Gas Check 5000is Rechargeable batteries e g Ni Cad must not be used There is no provision for the rec...

Page 36: ...if provided are shipped in the spare battery clip and not inside the GasCheck instrument itself Refer to Figure 3 and check that the storage case contains the items listed in Table 3 If any item is missing notify your supplier in writing within three days Qty Description Check 1 Gas Check with short probe and nozzle fitted 1 Long probe 1 Box spanner 1 Special screwdriver for access to battery comp...

Page 37: ...in each case the lowest line is for status information while the upper line s show s the menu topics or the leak rate values You may like to gain some confidence in the operation by simply using the control keys as in section 4 1 1 although if it has not yet been used you should carefully fit the battery clip in accordance with section 5 2 Please take note of the warnings and cautions when fitting...

Page 38: ...s reset the peak hold memory or after changing a gas group In menus successive presses of this key provides a simple step by step route BACK to the normal display PROCEED Press the proceed key to reach the menus that allow you to control special settings of the Gas Check 5000is DOWN Press or hold the Down key to scroll up through menus or to raise a numerical value Release when desired UP Press or...

Page 39: ...bottom line is blanked Main menu ABC Automatic Background Compensation not normally used Alarm Level Setting for the Audible Visual Alarm Audio Mute the leak rate Audible Visual Backlight Controls for the Back light display Clock Data logging clock functions Data Control Functions for data control including download via IR Link Display Bar graph or numeric display functions Gas Group Choice of Gas...

Page 40: ...setting such that if the Gas Group changes the alarm is not set the status symbol is removed from the display although the last alarm level value is retained for reconfirmation This is to ensure the Gas Check avoids incorrect alarm levels on a Gas Group change Press to jump down into Alarm Level setting Display Alarm Level Back 2 x 10 existing Alarm level setting ü Note When the alarm is set to ma...

Page 41: ...l is placed down onto the third row Backlight The backlight control allows the user to switch on the backlight or select a TIME setting Press to jump down into Backlight setting and then the PROCEED key or the UP and DOWN keys Display Backlight Back On Off ü Status shown üwill put the Backlight ON existing backlight TIME setting If the scroll up or down keys are used from this start point then the...

Page 42: ...ther topics at this level Date format Set time Set date The following frames show the CLOCK sub menus accessed by the key Clock 12 24hr Display 12 24 Back 12hr X 24hr ü Note X because 12hr not selected but a ü always in the bottom row to show that this is currently selected Clock Date Format Display Date format Back dd mm ü dd mm ü Note Both ü in this example because of the same setting This also ...

Page 43: ...Saving Time changes then once PROCEED has been actioned the Back key can be used to return towards the normal display mode with the required changes stored Display Set hour Back 09a existing Clock setting for Time Clock Set Time Set min As per Set hour Clock Set Time Synch RTC This allows users to confirm that the minutes setting conforms to expectations and allows set to 0 seconds When the synchr...

Page 44: ...s by a press Display Clear Data Back All data X Note An X or ü will be required following usual convention on the 2nd line Use the up or down scroll keys for other end tree selections Last data X Data Control Data Transfer Display Data control Back Data Transfer X display No of files ü Note An X or ü will be required following usual convention on the 2nd line When Data is being transferred the X c...

Page 45: ...Interval Enter this by a press and use the UP and DOWN keys to select a new repeat interval for data logging Press PROCEED key to enter this value in seconds BACK key to move back towards the normal display Display Sample time Back 5s X existing setting ü Data Control Logging settings No Samples As per Interval above This sets up the total number of samples per record for each press of the INFO ke...

Page 46: ...uous mode of data taking using the Logging Settings Display This sub menu has the following topics and are accessed by pressing the Style Display Style Gas Check 5000is allows the user to select a preferred style of presentation either a bar graph with an exponent range indicated or a digital display with a similar exponent range The style applies to both the normal display mode and the menu setti...

Page 47: ... larger or a smaller size for the bar graph or numerals and the exponent range value The size only refers to the normal display settings not to the menu settings for the alarms Enter this by a press Display Size Back Large X existing Inst setting ü The option is given here as per clearing Last data or All data is for information purposes to aid selection The choice is given to toggle the Large at ...

Page 48: ...as Group Back Ar X existing gas setting ü Note Similar X and ü convention is followed Language Enter this by a press Language Back English X existing setting ü The option is given here as per clearing Last data or All data is for information purposes to aid selection The choice is given to toggle the English at this level or to scroll through to see what the other options are which in the instance...

Page 49: ...old symbol If PROCEED key pressed then the X turns to a üand the Peak Hold symbol is displayed in the third row Power off This sub menu has the following topics accessed by pressing the key Manual Automatic Power off Back Manual X existing setting ü Manual will ensure the user has to press the I O key to turn off Gas Check Automatic waits approximately 10 minutes from last key press with signal be...

Page 50: ...ther two selections will also be displayed because of different information content on the third line Program Inst Back Menu X Menu status t ü Menu status will only have a S W test to indicate whether it is in the non programmed normal default settings or has any of these settings changed THUS the bottom line will have one of two messages Factory Menu ü Custom Menu ü Pressing the PROCEED key witho...

Page 51: ...ther it is in the non programmed zone or has the zone option programmed within it THUS the bottom line will have one of two messages Zone Set No zone ü Pressing the PROCEED key without an IR Link communication will result in a timed our rest of the unit Note Similar X and ü convention is followed ...

Page 52: ... are only an example for the units of ppm selected Units Press to jump down into the units topic Display Units Back ppm ü Existing status shown ü existing units status ü This is ppm for ü above If the scroll up or down keys are used from this start point then the following options are shown ml min ml s ft3 yr ppm sccm mm3 s mm3 min Some Gas Check versions have a language selection where the units ...

Page 53: ...tus symbols will also change consistently Examples are Zeroing detector Nozzle On Peak hold On 4 2 1 Leak rate indication Leakage is displayed as a single signed digit x 10 signed range for ease of interpretation and calibration Note that some gases eg CO2 may cause a negative leak indication after Gas Check zeroing in clean air Examples are Leak rate for a positive gas 5 x 10 5 ml s Leak rate for...

Page 54: ...e Alarm bell This symbol shows that the alarm level has been set up for use ABC This symbol shows that the Automatic Background Compensation is applied Auto Range This symbol shows when the Gas Check leak rate is not in a fixed range Data Logging This symbol shows continuous Data Logging is in progress Data Logged This symbol shows continuous Data Logging was completed each dash 10 Audio This show...

Page 55: ...or refer to Section 4 1 If the area you want to leak check has restricted access remove the nozzle and the short probe and fit the long probe The long probe is flexible and can be bent in a gentle arc so that it can reach areas that would otherwise be difficult to reach Press the nozzle button to tell the Gas Check that the nozzle is not fitted when you fit the long probe refer to Section 4 1 Note...

Page 56: ...be 4 5 Switch on the Gas Check Press I O key and wait for Gas Check to bleep flash the LCD to light up and show Ion Science Ltd Cambridge England Then show Gascheck 5000is SW Version 1 49 Text Version 1 00 Then show Zeroing Detector After a short while the LCD display will then revert to the display format previously set up for the leak rate which can be either the bar graph or the digital display...

Page 57: ...t is different from normal air Move the end of the probe or nozzle around the area of a suspected leak and look at the display or listen to the audible clicks or note the visual LED flash rate on the Gas Check to identify the location of a leak Specific procedures for leak detection along seams and around pipe joints are described in the following sections When required Use the peak hold and Auto ...

Page 58: ...ver move the probe or nozzle around the joint at approximately half the speed specified in Section 4 6 2 Light gases such as hydrogen and helium diffuse quickly into air so an apparent leak on the side or top of a joint may actually be a leak at the bottom of the joint 4 6 4 Data logging interruption for menu access Gas Check 5000is settings are protected during data logging Press the INFO key to ...

Page 59: ... tool to push any blockage out of the end of the nozzle then wipe the outside of and the inner face of the wide part of the nozzle 8 Inspect the probe The hole in the short probe is approximately 0 47mm 0 0185inches in diameter We recommend that you push stiff wire of 0 25mm 0 01inches diameter or less into the hole in the probe to remove any blockage The long probe is too long to be effectively c...

Page 60: ... non rechargeable batteries in the Gas Check 5000is Recommended batteries are specified in Section 2 3 Battery Data CAUTION The Gas Check 5000is will blow a factory fitted internal protection fuse if the battery clip is reverse connected The complete instrument will have to be returned to the supplier for fuse replacement Ensure that the rubber sleeve on the female part of the battery holder is co...

Page 61: ...batteries in the correct orientation Refit the battery holder to the Gas Check 7 On the Gas Check 5000is refit the battery compartment cover and use the special screwdriver to tighten the captive screw and secure the cover in place 8 Switch on the Gas Check to ensure that the batteries are correctly fitted If the display remains blank when you switch on the Gas Check refer to section 5 3 CAUTION T...

Page 62: ...ak is not set correctly Press hold Nozzle until both correct Calibration due message Unit has exceeded 1 year on cal Return to Ion Science for recalibration Unit will not zero correctly Sensor contaminated Leave to stabilise Blocked probe Probe blocked by solid or liquid Remove probe clean check now OK Stalled motor Motor failed probe not blocked Return to supplier for repair Instrument readings n...

Page 63: ... Replacement battery holder A 08139 Nozzle 5000is 08024CPC0 Box spanner A 08029 5000is screwdriver 4 TS 01 Case 31164 Manual 28053 7 3 Accessories Accessories Item Number CalCheck A 21500 Specifying Gas Leak rate and pressure IR Data Link A 28170 Specifying voltage A USA K UK E Euro U Universal and C Car 7 4 Calibration Ion Science offer a calibration service including issue of traceable certifica...

Page 64: ...ate Log Manual Version Amendment Date updated Instrument Firmware PC Software GasCheck 5000 V1 4 Gas Table updated 16 7 08 V4 16 V3 26 GasCheck 5000 V1 5 Update log added to back of manual 9 1 09 V4 16 V3 26 ...

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