Operations Manual

Docking Station DS400

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GfG Products for Increased Safety

Congratulations! You have opted for a precision instrument from GfG. A good choice! Our detectors are characterized 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. GfG Gesellschaft für Gerätebau mbH Klönnestraße 99 D-44143 Dortmund Fon: +49 - 231 – 564 00-0 Fax: +49 – 231 – 564 00-895 www.gfg.biz info@gfg.biz

mailto:info@gfg.biz

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Content Page

INTRODUCTION 4

For your Safety 4

Application and Purpose 4

Positioning and Connecting the Docking Station 4

Connections and Control Elements 5

Adapter Cradles 5

CO2-Absorption Filter 6

Operation 6

Charging 6

Bump Test 7

Sensor adjustment 8

Data Storage/Data Transfer to a PC 10

Cleaning 10

Maintenance and Inspection 10

SOFTWARE 11

Installation 11

Installation of USB Driver 11

Configuration of DS400 11 Open Port 11 General 11 CO2 absorption filter 12 Gas 12 Purging Times 12 Gas amount 13 Time - Date 13 Intervalls 13

ANNEX 14

Accessories 14

Technical Data 15

EC-Declaration of Conformity 16

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Introduction

For your Safety According to § 3 of the law about technical working media, this manual points out the proper use of the product and serves to prevent dangers. It must be read and adhered to by all persons who use, service, maintain and check this product. This device can only perform the tasks for which it is intended if it is used, maintained, serviced and inspected in accordance with the specifications of the Gesellschaft für Gerätebau mbH. The warranty given by GfG Gesellschaft für Gerätebau mbH is void if it is not used, used, maintained, serviced and checked in accordance with GfG mbH's specifications. The above does not alter statements regarding warranties and liabilities in GfG’s general conditions of sale and delivery. Repairs must only be done by skilled personnel resp. by trained persons. Modifications and changes of the product require GfG’s permission. Unauthorized modification of the product results in the exclusion of any liability for possible damage. Make sure that only genuine GfG accessories are used with the product. Repairs require the use of spare parts released by GfG. Attention: When using the docking station it must be taken into account that all gas measuring instruments which are adjusted with it will be affected. Due to incorrectly entered test gas concentrations, all gas measuring instruments can subsequently be incorrectly adjusted.

Application and Purpose The docking station DS400 is an automatic test station for performing bump test and for adjusting the zero point and sensitivity of the sensors of the Microtector II, Microtector III and Polytector III gas detectors.

Positioning and Connecting the Docking Station With start-up, the connections for fresh air, test gas, gas outlet, pressure switch, mains supply and to PC resp. to additional docking stations must be piped and wired. The docking station must be placed on a firm and even surface. The gas must be supplied without pressure. During operation, the gas is aspired by the pump of the docking station. Please make sure that the test gas can leave the docking station without any pressure through an obstacle-free outlet! Should you wish to get CO2 sensors bumped or adjusted in the docking station, make sure that a CO2 absorption filter is fit in the fresh air supply (see chapter “CO2 Absorption Filter”). The T-pieces of the fresh air and test gas supply have either to be closed by means of closing plugs or to be connected to another docking station. Up to three docking stations can be operated simultaneously with one DS400-PS1 power supply unit. For this purpose they must be coupled with a double-sided jack plug. When putting into operation, the connections for gas in, gas out, pressure switch, mains supply and PC resp. another docking station must be done as shown in the picture of the next chapter.

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Connections and Control Elements

Adapter Cradles Three device adapters are available for the docking station. A version for devices without screwed on electric pump. A second version for devices with screwed on electric pump (G400-MP2) and a third version for devices Microtector III and Polytector III. The electric pump can remain on the device for all functions. All three device adapters can be used simultaneously by the docking station as charging cradle. To replace the device adapter, the DS400 must be disconnected from the power supply.

Zero gas / fresh air supply Test gas supply

Gas discharge

Connection for 12V DC power supply

Connection for manometric switch

Connection for 12V DC power supply

Connection for manometric switch

green LED

SD-card

Connections for RS485 (Bottom)

red LED

Derivative catch and/or gas forwarding to the next docking station

G400-DIC1D for Microtector II without a pumpe

G400-DIC2D for Microtector II with a pump

DIC888/999-B for Microtector III and Polytector III

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CO2-Absorption Filter Particularly for test and adjustment of the CO2–sensor zero-point, CO2-free zero-gas is required. Since fresh air contains approx. 500ppm CO2, a CO2 absorption filter removes interfering CO2. Absorption is done by calcium hydroxide (80%)/sodium hydroxide (5%)/H2O (15%) according to the following reaction:

CO2 + 2 NaOH Na2CO3 + H2O Na2CO3 + Ca(OH)2 CaCO3 + 2NaOH

The absorber removes 500ppm CO2 from approx. 9.000 l air. This is equivalent to a life span of approx. 18,000 minutes zero-gas pumping in a docking station. The DS400 considers the flow, calculates the life span and gives a message in time for the change of the filter. The filter turns its colour to light blue.

Since the chemical reaction during the absorption process, depending on the CO2 content of the air, may generate water, it can come to a slight influence on the zero-point setting of the sensor.

Operation The docking station is operated by means of the control keys of the gas detector. Status indication resp. reading of values is provided in the detector display. The DS400 docking station is switched on by connecting it to the mains adapter. With the configuration software, the docking station can be adjusted to the connected gases and various functions. If a gas meter is inserted into the docking station, the option "Information", "Function Test" or "AutoCal adjustment" can be selected via softkeys on the gas meter. 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, the docking station can also be used to carry out a "Firmware Update" on the gas detector inserted. To do this, there must be a more recent version of a corresponding update file on the SD card and the "update" must be started by pressing a key. To charge a device, it must be inserted into the docking station when it is switched off. When the unit is switched on and placed in the docking station, the required test or adjustment is automatically started after 10 seconds. Within the 10 seconds it is possible to override the automatic selection and start a function test or calibration manually.

Charging Turn the G450 or G460 off before inserting it into the docking station. The charging procedure starts automatically.

yellow LED

Constantly lit: quick charge

Flashing: trickle charge

green LED

ON: Voltage supply for charging module switched on

OFF: Detector is in docking station and bump test or calibration is effected

In trickle charge mode, an empty accumulator is recharged within approx. 3 … 4 hours. When quick charge is completed, the detector automatically turns to trickle charge.

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Bump Test During the bump test the following points are checked: Visual alarm Audible alarm Response time of sensor for alarm 1 and for alarm 2, depending on test gas concentration Response time of sensor for t50 or t90 , depending on configuration Automatic data storage on SD-card Set of time Set of bump test interval For the bump test turn the detector on and insert it into the docking station. The bump test starts after 10 seconds and is completed automatically. The effective time for the bump test is approx. 20 seconds. During the test the relevant test gas is supplied to the sensors, before they are purged with fresh air for sufficient time. The bump test interval is specified in accordance with T021/T023 and is used for calculation of the next date for bump test or calibration.

Attention: The screenshots shown here may differ slightly depending on software version and device type!

The test progress as well as the bump test report is shown in the display of the detector.

Bump test starts after 10 seconds

automatically Bump test in process Rinsing with fresh air

Talm = Response time for alarm 1 and alarm 2 of respective test gas

T50 = t50 Response time of respective test gas

Test of audible and visual alarm o.k.

Error response time alarm 1 / 2 for CO – Response time too long

Error response time t50 for CO – response time too long

Following symbols signalize the test result:

= in process - = Sensor not tested √ = Sensor successfully tested = Sensor faulty

Result of bump test: The result of the bump test is indicated by a red and a green LED at the docking station. The green LED stands for a successful bump test, the detector is ready for use again.

The red LED reminds of an error which must be sorted out before the detector is used.

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Bump test successful: Display colour green + green LED lit

Bump test failed: Display colour red + red LED lit Display of occurred error (here code 2: Flow Error)

Possible error codes: No gas defined – DS400 is not configured Cancelled by detector – Detector problem/-fault Time elapsed – for bump test of sensors Power error – faulty operational voltage of DS400 mains unit

Additional information can be called up with the “Info“ key. These error messages do not lead to a stop of the bump test. 1 = No SD-Card 2 = Gas Pressure 4 = CO2-Filter 8 = Gas-Amount If several errors arise at the same time, the error numbers are added: 3 = 2 + 1 (gas pressure + no SD card) 5 = 4 + 1 (CO2-filter + no SD card) 6 = 4 + 2 (CO2-filter + gas pressure) 9 = 8 + 1 (gas-amount + no SD card) 10 = 8 + 2 (gas amount + gas pressure) 12 = 8 + 4 (gas amount + CO2-filter)

Sensor adjustment Turn the G460 on and insert it into the DS400 docking station. Push key AUTOCAL within the first 10 seconds to start calibration. If no key is hit, the bump test is started automatically after 10 seconds. Calibration starts with fresh air adjustment. With the sensors for toxic and combustible gases the zero-point is set. The oxygen sensor is adjusted to 20.9 Vol.%. The zero-point of the IR sensor for carbon dioxide is adjusted by means of the CO2 absorption filter. Make sure that the docking station is connected to fresh air without any interfering gas. With the function AutoCal-Gas the sensitivity of the sensors is adjusted. Always use a suitable test gas or test gas mixture for calibration. After the sensor adjustment the sensors are rinsed. The adjustment takes approx. 3-4 minutes. The adjusting interval is specified in accordance with T021/T023. The progress of the adjustment as well as the zero-report (Air) and the cal-report (gas) will be presented on the display.

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Bump test starts after 10 seconds automatically

Purging Sensor adjustment

Purging Sensor adjustment

Result of sensor adjustment with fresh air (CO2-free) Reading before => afterwards

Results of sensor adjustment with test gas (gas mixture) Reading before => afterwards

Following symbols signalize the result of adjustment: - = Sensor not adjusted √ = Sensor successful adjusted = Error for adjustment - not adjusted Result of adjustment: The result of the adjustment is indicated according to the traffic light principle by a red and a green LED at the docking station. The green LED shines like that was successful the adjustment, the equipment is now again operational. However if the red LED shines, an error is present, which must be repaired before the employment of the equipment.

Adjustment successful: Display colour green + green LED

Adjustment failed: Display colour red + red LED Display of occurred error (here Code 2: Flow Error)

Possible error messages: NO Gas defined – DS400 not configured Cancel by Device – Device problem/fault Time too long – for bump test / adjustment of sensors (Problem Sensor/Gas) Power error – Power supply DS400 faulty

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Additional information can be called up with „the info. “- key. These messages do not lead to the abort of the adjustment. 1 = No SD-Card 2 = Gas Pressure 4 = CO2-Filter 8 = Gas-Amount If several errors arise at the same time, the error numbers are added: 3 = 2 + 1 (Gas pressure + No SD-card) 5 = 4 + 1 (CO2-Filter + No SD-card) 6 = 4 + 2 (CO2-Filter + Gas pressure) 9 = 8 + 1 (Gas-Amount + No SD-card) 10 = 8 + 2 (Gas-Amount + Gas pressure) 12 = 8 + 4 (Gas-Amount + CO2-Filter)

Data Storage/Data Transfer to a PC All information about bump tests and calibration of the individual sensors are automatically stored on a SD-card (if ordered). The data transfer to a PC is affected automatically when the docking station is connected to the PC. The data on the SD-card, however, can also be evaluated by means of a card reader, without having the docking station connected to a PC. The data transfer is done with the DS400 software. Test data for storage both in the PC-data base and on the SD-card:

Device information: Type of device Serial number Software version Sensor serial number Gas Detection ranges Alarm thresholds: A1, A2, A3, STEL, TWA Battery capacity Confidence beep ON/OFF Docking station: Date and time Mode: Bump test or sensor calibration Test gas and gas concentration Gas bottle number Test result Bump test: Horn (audible alarm) LED (visual alarm) tAlarm1 tAlarm2 t50 or t90 Sensor calibration: Zero-point (ZP) before sensor adjustment Zero-point (ZP) after sensor adjustment Sensitivity (CAL) before sensor adjustment Sensitivity (CAL) after sensor adjustment DS400 serial-no. and name DS400 ID DS400 software version Cleaning Polluted enclosures can be cleaned with a damp cloth. Do not use solvents and detergents!

Maintenance and Inspection Please make sure that the CO2 absorption filter and the hose connectors are checked regularly. An annual examination by an expert is recommended.

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Software

Installation Install the program first with the SETUP program, which is started from the CD. After inserting the CD, the setup program is started automatically. If this does not work, select the relevant CD drive in the explorer, start the program manually by means of double-click on the program icon and follow the instructions of the program. You may either use the suggested directory name and drive or select a different path. The program is then installed on the selected drive and directory. After the installation the program group “GfG DS400” and the icons for starting the program are generated.

Installation of USB Driver Connect the RS485-USB interface cable to your PC. Windows recognizes the new hardware and asks for the driver. The driver is on the CD in directory USB_V200. Make Windows install the driver from this directory or to search for the driver on the CD. Two driver components are installed. The first driver is the USB driver, the second driver is the virtual COM port. With Windows XP, depending on the PC configuration, the message is given that the driver did not pass the Windows logo test. 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 needed for adjustment in the software.

Configuration of DS400 With the configuration program DS400Config.EXE the docking station can be configured. This refers mainly to the adjustment of test gas concentrations. Open Port Click on the button “Open Port“. The screen opens a new window (Select Port). In the selection box you can select the port for the cable and confirm it by pushing the OK button. This opens the communication port for the DS400. In the field on the right side you can select the DS400 you want to communicate with. Select ID “1“ and click on the button connect.

General Here you can enter resp. read some general information of the DS400. DS400 Name: Entry of an alternative name for the docking station. ID: Change of the ID of the connected DS400 - only necessary if several DS400 are connected via patch cable. In the field “last service” you can see when the DS400 has passed its last service. The field “next service” indicates when the DS400 is to be serviced next.

Note: When this date is reached, the information “DS400 service“ shows up in the display of the detector. If the date is exceeded by 21 days, bump tests or calibrations cannot be done any longer. The test is stopped and the message “service DS400 necessary” shows up.

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CO2 absorption filter Here you set the parameters for the CO2-absorption filter. Here you must indicate whether no filter, a new filter, or a used filter is attached. If you select no filter, the zero-point for CO2 is not adjusted during the next calibration of the G460. The DS400 counts automatically the cycle time of the filter. If the filter reaches its warning threshold, the display reads “CO2-Filter“. The filter should be replaced at the next opportunity. If the filter is used up, the CO2 zero-point is not adjusted during the next calibration of the detector. For calculation you need to enter the actual hose length in meters (usually 1 meter).

Gas Here the connected test gas is specified. These entries are obligatory for bump test and calibration.

You can enter up to six gases of a test gas mixture. Only %-Vol or ppm can be used as units for methane, the DS400 converts the range automatically from %-Vol to % LEL. Gas bottle no.: Enter the number or a name for the gas bottle. Hose length (m): Enter the length of the hose to the gas bottle

Purging Times In the file purging times you can change the parameters for the bump test and for the adjustment. Changing the times, however, should only be done for special applications, e.g. in case of extreme hose lengths. Bump test time max: Entry of the maximum time (seconds) for the bump test Bump test purging time: Entry of the time (seconds) the sensor is purged with fresh air once the bump test was completed, to avoid false alarm after the bump test Adjustment ZP purging time: Entry of the time (seconds) the sensor is purged with fresh air before the zero-point is adjusted Adjustment CAL purging time: Entry of the time (seconds) the sensor is exposed to test gas before adjustment Gas drain time: Entry of the time the sensor is purged with fresh air once adjustment with test gas is completed

Response time: Selection of the response time, which is tested in addition to alarm 1 and alarm 2: only the time for alarm 1 and alarm 2 is checked T50 check: Check of alarm 1, alarm 2 and response time t50 T90 check: Check of alarm 1, alarm 2 and response time t90

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Gas amount

Here the parameters are specified for the quantity of the gas. On this side you can enter, as much gas is in the bottle: If you have a bottle with 10l and 200bar pressure, have 2000l gas. The DS400 requires 0,5l/min., the maximum flow time amount to necessary thus: 4000 minutes. In the field „Warning Flow Time“ you can specify danger threshold, after which duration a message is to appear on the display of the G450/G460. In the field „Actual Flow Time“ you can read off current flow time, how many minutes the DS400 out of the gas bottle took to gas.

Time - Date

Here time and date are stopped for the DS400. The time is set automatically, if the difference is more than 10 seconds.

Intervalls

Under the menu intervals the intervals are stopped for function test and adjustment. Intervals transfer: The intervals will automatically transfer series to the gas warning device of the G400. It takes place when switching on of the equipment a message on, if these intervals are exceeded. This message can be acknowledged. With the field „intervals transferred“ determination of whether with each function test or adjustment the adjusted intervals will be transferred or not.

Function test interval (days): For the attitude of the function test interval in accordance with T021/023 a work daily examination is recommended. In the field „Bump Cal Interval“ can be deposit function test interval into like much meeting the equipment a function test demand. Will the value on 0 days set is demanded by the equipment no function test. Adjustment interval (days): The time intervals of the adjusting interval should not exceed one period of 4 months in accordance with T021/023. In the field „Bump Cal Interval“ you can deposit adjustment interval into like much meeting the equipment an adjustment demand. Will the value on 0 days set is demanded by the equipment no adjustment. The intervals for the function test and the adjustment replace not the annual examination of gas warning device by experts, see also operating instructions of the gas warning devices Microtector II. With the field „Set Time at Device“ determine you set time in the equipment whether the date and time are to be set by the equipment on the date and time of the docking station. With the field „Turn device OFF after test“ put you switch of firmly whether the equipment 10 minutes after a function test to be switched off are or not.

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Annex

Maintenance Contamination of the device housing can be removed with a damp cloth. Do not use solvents or cleaning agents!

Service and In Regular inspections of the CO2 absorption filter and hose connections are required. An annual inspection by an expert is recommended.

Malfunction, Cause and Remedy

Malfunction/Message Cause Remedy 1. Red and green LED in SD

card slot permanently on Error in the program memory or error in the RAM

- Switching the device off and on again - Contact GfG service, if necessary

2. „Abort by the device!“ Error in gas detector

- Switching the device off and on again Repeat if necessary

3. „CO2 filter consumed!“ The CO2 absorption filter is used up. - Replace CO2 absorption filter and readjust with configuration program

4. „DS400 Parameter Error!“ Parameter Error in the RAM - Switching the device off and on again Reconfigure if necessary - Contact GfG service, if necessary

5. „Flow Rate Error!“ gas supply failure - Open the valve of the test gas cylinder. - Eliminate interruption of test gas supply - Contact GfG service, if necessary

6. „No Gas“ DS400 is not configured or parameter memory is corrupted

- configure DS400 - Contact GfG service, if necessary

7. „No SD-Karte!“ SD card not available or not writable - Insert or replace SD card 8. „Power Error!“ Supply voltage of DS400 faulty - Replace power supply unit

- Contact GfG service, if necessary 9. „Service DS400 due“ Service date exceeded or clock faulty or

not set - Contact GfG service, if necessary

10. „Time Out!“ Bumb test of the sensors takes too long

- Check gas supply

11. INFO „Gas Preasure!“ Gas pressure too low if external gas pressure switch is fitted

- Check test gas cylinder and replace if necessary

12. INFO „Gas Amount!“ Test gas bottle almost empty - Replace the test gas cylinder and reset it with the configuration program.

13. INFO „Service DS400 due!“ Service date exceeded in max. 21 days - Contact GfG service, if necessary

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Accessories Description Order-No. CO2 absorption filter for zero gas processing for CO2 sensors 1000220 Gas sampling fitting, type 2001, 2-stage pressure reducer for calibration gas supply by pump for test gas cylinders type 2 AL, 8 AL or 6D, maximum inlet pressure: 0-1000 psi/70bar

1319216

Gas sampling fitting, type 2003, 2-stage pressure reducer for calibration gas supply via pump for high pressure cylinders; incl. connection for high pressure cylinders (M19x1,5LH) maximum inlet pressure: 0-3000 psi/207bar

1319217

Pressure switch for high pressure bottles incl. T-piece for mounting to the fitting type 2003, pressure range: 65-300 psi/4,5-20,7 bar

1319218

USB-RS485 interface cable for data transmission PCDS400 1319221 Patch cabel for data transfer and interconnection of docking stations, in different lengths: 1m / 3m 5m / 8m 10m

1319222 / 23 1319224 / 25 1319226

Power supply DS400-PS1 (Euro plug) 1450403 Jack plug 6,3mm for connection of a pressure switch 1450404 Double-sided jack plug 6.3mm for cascading the DS400 1450405 Test and charging cradle G400-DIC1D (for device without pump) 1450406 Test and charging cradle G400-DIC2D (for device with pump 1450407 Test and charging cradle DIC888/999-B (for Microtector III and Polytector III) 1990223 SD memory card, for archiving device-specific test data and test sequences, various memory capacities

1450408

Database software for automatic archiving of instrument data, instrument tests, test data and test sequences

1319203

Technical Data Type: DS400

Display and control elements: Display and 3 keys at gas detectors

Power supply: 12V DC / 1,25A (2 input/output sockets)

Gas Connections: 1 zero gas supply, 1 test gas supply, 1 gas discharge (for hose di≈5mm)

Flow rate: Flow rate: 0,5...0,6 l/min; suction by internal pump (pressure free) Pressure control: electrical Input for potential free contact (2 input/output socket)

Time Function test: 20...60sec. (depending on setting and test gas concentration)

Adjustment: 2...4 minutes (depending on sensor type)

Data Storage medium: 1GB SD-Card (FAT16 formatting)

Communication: RS-485 (2 Modular Jacks RJ45) Housing

Protection class: IP20 Material: Plastic

Dimensions: 125x143x225mm (WxHxD) Weight: 880g incl. 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: info@gfg-mbh.com Firmware Version 2.99 211-000.34_OM_DS400.doc Last edited: 18. February 2020 Subject to change

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EC-Declaration of Conformity

PageIntroductionFor your SafetyApplication and PurposePositioning and Connecting the Docking StationConnections and Control ElementsAdapter CradlesCO2-Absorption FilterOperationChargingBump TestSensor adjustmentData Storage/Data Transfer to a PCCleaningMaintenance and Inspection

SoftwareInstallationInstallation of USB DriverConfiguration of DS400Open PortGeneralCO2 absorption filterGasPurging TimesGas amountTime - DateIntervalls

AnnexMaintenanceService and InMalfunction, Cause and RemedyAccessoriesTechnical DataEC-Declaration of Conformity

DS400