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ToxiPro

Single GasDetector

ReferenceManual

Biosystems LLC651 South Main StreetMiddletown, CT 06457(800) 711-6776(860) 344-1079Fax (860) 344-1068Part number 13-264Version 1.3029NOV2004

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THE TOXIPRO PERSONAL PORTABLE GAS DETECTORS HAVE BEEN DESIGNEDFOR THE DETECTION AND MEASUREMENT OF POTENTIALLY HAZARDOUSATMOSPHERIC CONDITIONS.

IN ORDER TO ASSURE THAT THE USER IS PROPERLY WARNED OF POTENTIALLYDANGEROUS ATMOSPHERIC CONDITIONS, IT IS ESSENTIAL THAT THEINSTRUCTIONS IN THIS REFERENCE MANUAL BE READ, FULLY UNDERSTOOD,AND FOLLOWED.

ToxiPro Reference ManualBiosystems Part Number 13-264

Version 1.30Copyright 2004

byBiosystems LLC

Middletown, Connecticut 06457

All rights reserved.

No page or part of this operation manual may be reproduced in anyform without written permission of the copyright owner shown

above.

Biosystems reserves the right to correct typographical errors.

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Table of ContentsCertifications...............................................................................................................3Warnings and Cautions..............................................................................................3

A. Signal Words-----------------------------------------------------------------------------------------------------3B. Warnings----------------------------------------------------------------------------------------------------------4

1. Overview.................................................................................................................51.1 Methods of sampling -------------------------------------------------------------------------------------------51.2 Sensors -----------------------------------------------------------------------------------------------------------5

1.2.1 ToxiPro sensor ranges ...................................................................................................51.2.2 ToxiPro O2 sensor ranges..............................................................................................51.2.3 OxyPro warm-up phase .................................................................................................5

1.3 Alarm logic--------------------------------------------------------------------------------------------------------51.3.1 Gas alarms.....................................................................................................................51.3.2 Calibration due notices...................................................................................................51.3.3 Low battery alarms.........................................................................................................51.3.4 Missing sensor during startup ........................................................................................51.3.5 Corrupt memory .............................................................................................................5

1.4 Functions ---------------------------------------------------------------------------------------------------------61.4.1 Security beep .................................................................................................................61.4.2 Latching alarms..............................................................................................................6

1.5 IQ Compatibility -------------------------------------------------------------------------------------------------61.6 Design components --------------------------------------------------------------------------------------------61.7 Standard accessories ------------------------------------------------------------------------------------------61.8 Value pack kits --------------------------------------------------------------------------------------------------6

2. Field Operation ......................................................................................................62.1 Turning the ToxiPro on ----------------------------------------------------------------------------------------72.2 Backlight ----------------------------------------------------------------------------------------------------------82.3 Functions ---------------------------------------------------------------------------------------------------------82.4 Calibration due notices ----------------------------------------------------------------------------------------82.5 Low battery alarms ---------------------------------------------------------------------------------------------82.6 Turning the ToxiPro off ----------------------------------------------------------------------------------------9

3. Calibration..............................................................................................................93.1 Verification of accuracy----------------------------------------------------------------------------------------9

3.1.1 Verifying accuracy: ToxiPro O2 ......................................................................................93.1.2 Verifying accuracy: ToxiPro with toxic gas sensor .........................................................9

3.2 Effect of contaminants on ToxiPro sensors ---------------------------------------------------------------93.2.1 Effects of contaminants on O2 sensors ........................................................................103.2.2 Effects of contaminants on toxic gas sensors ..............................................................10

3.4 Fresh air/zero calibration ------------------------------------------------------------------------------------ 103.5 Functional (bump) testing (toxic sensor versions)----------------------------------------------------- 103.6 Span Calibration (toxic sensor versions) ---------------------------------------------------------------- 113.7 Failure to calibrate -------------------------------------------------------------------------------------------- 12

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3.7.1 Fresh air/zero calibration failure...................................................................................123.7.1.1 Causes of fresh air/zero calibration failures ..............................................................123.7.1.2 Forced fresh air/zero calibration................................................................................12

3.7.2 Span calibration failure.................................................................................................123.7.2.1 Sensor out of range (no CAL) ...................................................................................123.7.2.2 No gas.......................................................................................................................123.7.2.3 Causes for span cal failure........................................................................................13

3.8 Fresh air/zero calibration in a contaminated atmosphere-------------------------------------------- 134. Maintenance.........................................................................................................13

4.1 Replacing batteries ------------------------------------------------------------------------------------------- 134.2 Replacing sensors -------------------------------------------------------------------------------------------- 14

5. PC-Instrument Communications .......................................................................155.1 Event logging -------------------------------------------------------------------------------------------------- 155.2 Instrument Software Upgrades ---------------------------------------------------------------------------- 155.3 Initiating communications ----------------------------------------------------------------------------------- 15

6. Exploded view and basic parts list....................................................................15Appendices................................................................................................................16

Appendix A: Sensor Cross-Sensitivity Chart ---------------------------------------------------------------- 16Appendix B: Replacement Sensor List------------------------------------------------------------------------ 16Appendix C: Calibration Frequency---------------------------------------------------------------------------- 17

Biosystems Standard Warranty Gas Detection Products....................................18

CertificationsThe ToxiPro carries the following certifications:UL and c-UL, Class I, Division 1, Groups A,B,C,D, Temp Code T4UL Class II, Division 1, Groups E,F,GATEX Certification:II 2 G EEx ia IIC T4UL International DEMKO A/S 04 ATEX 0327520

Warnings and CautionsA. Signal WordsThe following signal words, as defined by ANSI Z535.4-1998, are used in the ToxiProOperator’s Guide.

indicates an imminently hazardous situation which, if not avoided, willresult in death or serious injury.

indicates a potentially hazardous situation which, if not avoided, couldresult in death or serious injury.

indicates a potentially hazardous situation, which if not avoided, mayresult in moderate or minor injury.CAUTION used without the safety alert symbol indicates a potentially hazardoussituation which, if not avoided, may result in property damage.

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B. Warnings1. The ToxiPro personal, portable gas detector has been designed for

the detection of either oxygen deficiencies or specific toxic gas accumulations. Analarm condition indicates the presence of a potentially life-threatening hazard andshould be taken very seriously.

2. In the event of an alarm condition it is important to follow establishedprocedures. The safest course of action is to immediately leave the affected area, and toreturn only after further testing determines that the area is once again safe for entry.Failure to immediately leave the area may result in serious injury or death.

3. Use only Duracell Ultra #CR2, Energizer #1CR2 (EL1CR2), Sanyo#CR2 or Panasonic #CR2 in the ToxiPro.

4. The accuracy of ToxiPro instruments equipped with toxic gassensors should be checked periodically with known concentration calibration gas.Failure to check accuracy can lead to inaccurate and potentially dangerous readings.The ToxiPro O2 should be periodically calibrated in fresh air.

5. A sensor that cannot be calibrated or is found to be out of tolerancemust be replaced immediately. An instrument equipped with a toxic gas sensor that failscalibration may not be used until testing with known concentration test gas determinesthat accuracy has been restored, and the instrument is once again fit for use.Instruments equipped with an oxygen sensor that fail calibration may not be used untiltesting with fresh air determines that accuracy has been restored and the instrument isonce again fit for use.

6. Do not reset the calibration gas concentration setpoints in theToxiPro unless the concentrations of your calibration gas differ from the concentrationsof the calibration gas that is normally supplied by Biosystems for use in calibrating theToxiPro.

7. Use of non-standard calibration gas and/or calibration kitcomponents when calibrating the ToxiPro can lead to dangerously inaccurate readingsand may void the standard Biosystems warranty.Biosystems offers calibration kits and long-lasting cylinders of test gas specificallydeveloped for easy calibration. Customers are strongly urged to use only Biosystemscalibration materials when calibrating the ToxiPro.

8. Substitution of components may impair intrinsic safety.9. For safety reasons the ToxiPro must be operated by qualified

personnel only. Read, understand and follow the directions set forth in this referencemanual before operating the ToxiPro.

10. The ToxiPro has been tested for intrinsic safety in ExplosiveGas/AIR (max. 21.0% O2).

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1. OverviewThe ToxiPro is a single sensor gas detectorthat can be configured to detect either oxygen(O2) or one of a variety of toxic gases. TheToxiPro’s sensor type is shown on the front ofthe instrument and is also shown in the start upscreens. The ToxiPro includes numerousfeatures designed to meet specific userrequirements.Note: Early production runs of the oxygenversion of the ToxiPro were referred to asthe “OxyPro”. The instructions containedin this manual that refer to the ToxiProoxygen (O2) are also valid for the OxyProwith similar instrument software.1.1 Methods of samplingThe ToxiPro is typically used in diffusion mode.The atmosphere reaches the sensor bydiffusing through the sensor port on the front ofthe instrument. Normal air movements areenough to carry the sample to the sensor. Thesensor reacts quickly to changes in theconcentration of the gas being measured.A hand-aspirated sample draw kit is availableseparately for remote sampling. During remotesampling, the gas sample is drawn into thesensor compartment through the probeassembly and a length of tubing.1.2 SensorsAll versions of the ToxiPro except the O2model use an electrochemical toxic gassensor. The ToxiPro O2 uses a galvanicoxygen sensor. Both types of sensor havebeen designed to minimize the effects ofcommon interfering gases. These sensorsprovide accurate, dependable readings forgases commonly encountered in industrialapplications.1.2.1 ToxiPro sensor rangesSpecific toxic sensor ranges and resolutionsare provided in the sensor replacement chart inAppendix B.1.2.2 ToxiPro O2 sensor rangesThe oxygen sensor used in the ToxiPro O2 hasa range of 0-30% by volume.1.2.3 OxyPro warm-up phaseThe OxyPro requires a one-time, 15-minutewarm-up phase prior to initial activation. Seesection 2.1 for further details.

1.3 Alarm logic1.3.1 Gas alarmsToxiPro gas alarms are user-adjustable andmay be set anywhere within the range of thespecific sensor type. When an alarm set pointis exceeded a loud audible alarm sounds, andthe bright red LED alarm light flashes.Two oxygen alarm set points have beenprovided for ToxiPro O2 instruments. Thedanger alarm is sounded for oxygen deficiencyand the warning alarm is sounded for oxygenenrichment.ToxiPro instruments have up to four alarm setpoints: Warning, Danger, TWA (Time WeightedAverage) (if enabled) and STEL (Short TermExposure Limit) (if enabled).Note: In the standard ToxiPro configurationwith toxic gas sensors, the STEL and TWAalarms are not enabled. The STEL and TWAalarms may be enabled at the factory orthrough BioTrak software. Call Biosystemsfor more details.1.3.2 Calibration due noticesThe ToxiPro includes calibration due noticesthat are displayed when it is due for calibration.For more information on the calibration duenotices, see section 2.4 below.1.3.3 Low battery alarmsThe ToxiPro is designed with two batterywarning alarms that are activated when thebattery voltage is reduced to specific levels.For more details on the battery alarm, seesection 2.5 below.1.3.4 Missing sensor during startupIf the ToxiPro fails to detect a sensor duringstartup, it will show “F 1” with the cautionsymbol and then shut itself off. This is coveredin detail in section 2.1.

1.3.5 Corrupt memoryThe ToxiPro continuously monitors its onboardmemory. If the instrument determines that thememory is corrupt, it will display “F 4” andproceed to shut itself off.

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If “F 4” is displayed, contact Biosystems forfurther details.1.4 Functions1.4.1 Security beepThe ToxiPro includes a security beep that canbe enabled or disabled according to the needsof the user by using BioTrak software and anIrDA port. If the security beep is enabled, theToxiPro will emit a short beep coupled with anLED flash at a specific interval to remind theuser that the instrument is active.1.4.2 Latching alarmsThe ToxiPro includes latching alarms that canbe enabled or disabled according to the needsof the user using BioTrak software and an IrDAport. With the alarm latch enabled, the audibleand visible alarms will continue to sound evenafter the atmospheric hazard has cleared. Toturn the alarm off once the hazard is no longerpresent, simply press the MODE button.1.5 IQ CompatibilityThe ToxiPro must be equipped with instrumentfirmware version 4.30 or higher to becompatible with Biosystems IQ ExpressDocking Station, which is an automaticcalibration station coupled with a datamanagement system.Instrument software in the ToxiPro may beupgraded at any time. See section 5.2 belowfor further details.1.6 Design componentsCase: The instrument is enclosed in a solid PC(polycarbonate) case with TPE (rubber)overmold.Front face: The front face of the instrumenthouses the LCD display, MODE button, sensorport, LED alarm and audible alarm port.LCD display: The liquid crystal display (LCD)allows display of gas readings, messages andother information. A built-in, manually-activated backlight allows the display to beread even in low light conditions.

Figure 1: Exterior front view.Visual alarm (LED) / IrDA port: A bright redLED (Light-Emitting Diode) alarm light providesa visual indication of the alarm state. The LEDalso functions as the IrDA port.MODE button: The large push-button on thefront of the instrument is called the MODEbutton. The MODE button is used to turn theToxiPro on and off, to turn on the backlight, toview the MAX, STEL (if enabled) and TWA (ifenabled) screens and to access the automaticcalibration sequences.Audible alarm port: A cylindrical resonatingchamber contains the loud audible alarm.Bottom surface: The belt clip attaches to thebottom surface of the instrument.1.7 Standard accessoriesStandard accessories with every ToxiProinclude installed sensor and lithium battery,reference manual, quick reference card andcalibration/sample draw adapter.Optional accessories include manual sampledraw kit (hand-aspirated), vibrating alarm,Datalogger Upgrade and BioTrak software kit.1.8 Value pack kitsToxiPro value packs include all standardaccessories, calibration fittings, 34-liter cylinderof calibration gas, and fixed flow rate regulatorin a foam-lined, hard-shell carrying case.

2. Field OperationField operation of the ToxiPro is controlledentirely through the MODE button, which islocated on the front of the instrument.The MODE button is used to turn the ToxiProon and off, to turn on the backlight, to access

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MAX, STEL (ToxiPro only (if enabled)) andTWA (ToxiPro only (if enabled)) gas readingsfor the current session and to initiate thecalibration functions.2.1 Turning the ToxiPro onThe ToxiPro is effectively disabled when itleaves the Biosystems factory. Upon arrival,the ToxiPro’s display will be blank. TheToxiPro O2 will show the negated horn icon.

or

To initialize the instrument, press the MODEbutton. ToxiPro O2 models will proceed with a15-minute countdown while the oxygen sensorstabilizes.Note: The oxygen sensor warm-up periodis only necessary for initial start-up ofToxiPro O2 models.

→

When the ToxiPro O2 warm-up periodconcludes, the screen will be completely blank.ToxiPro models equipped with a toxic gassensor do not require an initial warm up period.

With the blank screen shown, press and holdthe MODE button for 5 seconds to initiate thestart-up sequence.At start-up, the ToxiPro will automatically gothrough a basic electronic self-test and start-upsequence that will take approximately thirtyseconds. During the self-test sequence, allsections of the display will be lit, the displaybacklight will momentarily turn on and theaudible alarm will “chirp”.

If the instrument fails to detect the sensorduring startup, “F 1” will be displayed with the

caution symbol following the display test screen.

If “F 1” is shown, the instrument willautomatically shut down in approximately 5seconds. See Section 4.2 of this manual forinstructions on accessing the sensorcompartment.Once the ToxiPro recognizes the sensor, it willdisplay the software version.

Datalogging versions will then show the “dL”screen, followed by a screen identifying thesensor type in the instrument.

Once the sensor is recognized, the instrumentwill display the sensor type.

The warning alarm level will then be displayed,followed by the danger alarm level. During thedisplay of the warning alarm level, the LEDalarm light will be flashed twice and the audiblewarning alarm will be sounded twice.

During the display of the danger alarm level, theLED visual alarm will be flashed twice and theaudible danger alarm will be sounded twice.The audible danger alarm is a higher frequencythan the warning alarm.

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For ToxiPro instruments with the STEL andTWA alarms enabled, the ToxiPro will brieflyshow the STEL and TWA alarm levels.

→

The current gas readings screen will then beshown.

2.2 BacklightThe ToxiPro includes a backlight that isautomatically turned on during an alarmcondition. The backlight can also be manuallyactivated while the current gas reading isdisplayed by pressing the MODE button once.When manually activated, the backlight willautomatically turn itself off in about twentyseconds. If activated by an alarm condition,the backlight will remain on until the instrumentis no longer in alarm.2.3 FunctionsFrom the current gas reading screen, press theMODE button once to activate the backlightand then once more to view the MAX gasvalues screen. The MAX figure represents thehighest gas value reading that has beenrecorded by the instrument during the currentoperating session. ToxiPro O2 models willdisplay both the highest and the lowestreadings that have been recorded by theinstrument.

From the MAX screen, press the MODE buttonagain to access the time screen. A dot belowthe colon between the hours and the minutesdigit indicates afternoon/ evening hours (pm).

10:45 am 10:45 pm

If the STEL (Short Term Exposure Limit) alarmis enabled, press the MODE button once to viewthe STEL reading. The STEL value displayedrepresents the average concentration ofinstrument readings for the target gas for themost recently completed 15 minutes ofoperation.

If the TWA (Time Weighted Average) alarm isenabled, press the MODE button once more toview the current TWA value. TWA values arecalculated by taking the sum of the instrumentreadings for the target gas for the currentoperating session in terms of parts-per-million-hours and dividing by an eight-hour period.

Press the MODE button again to return to thecurrent gas readings screen.2.4 Calibration due noticesWhen the Toxi Pro is due for fresh aircalibration “0-CAL will be displayed at thebottom of the current gas readings screen alongwith the warning symbol.

When the Toxi Pro is due for fresh aircalibration the calibration bottle icon will bedisplayed at the bottom of the current gasreadings screen along with the warning symbol.

2.5 Low battery alarmsWhen the ToxiPro determines that there areless than 7 days of battery life remaining, thelow battery icon will be lit.

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When the ToxiPro determines that there areless than 8 hours of battery life remaining, thetriangular warning symbol on the LCD will alsobe shown.

When the battery reaches a level where it canno longer power the instrument, the ToxiProwill sound the danger alarm while displayingthe danger, caution and battery icons.

Press MODE to turn the instrument off. Thebattery must be replaced before the instrumentcan be used again. If the MODE button is notpressed, the instrument will remain in alarm foras long as it can before shutting itself off.2.6 Turning the ToxiPro offTo turn the ToxiPro off, press and hold theMODE button down until the instrument chirpsthree times and OFF is displayed.

Once OFF is displayed, release the MODEbutton. The instrument has been successfullyturned off when the display goes blank.

3. CalibrationThe ToxiPro features fully automated freshair/zero and span calibration functions. TheMODE button is used to initiate the automaticcalibration sequence. Calibration adjustmentsare made automatically by the instrument.3.1 Verification of accuracy3.1.1 Verifying accuracy: ToxiPro O2Verification of accuracy for ToxiPro O2 is a onestep procedure. Simply take the ToxiPro O2 toan area where the atmosphere is known to befresh and check the readings. If the readingsdiffer from those expected in fresh air (oxygenmonitors should read 20.9% in fresh air), thena fresh air/zero calibration adjustment must bemade as discussed below in section 3.4. Iffresh air is not available, see section 3.8 below

for instructions for calibrating the ToxiPro O2 incontaminated air.3.1.2 Verifying accuracy: ToxiPro with toxicgas sensorVerification is a two-step procedure for theToxiPro instruments with toxic gas sensors:Step one is to take the ToxiPro to an areawhere the atmosphere is known to be fresh andcheck the readings. If the readings differ fromthose expected in fresh air (instrumentsequipped with a toxic sensor should read 0PPM in fresh air), then a fresh air calibrationadjustment must be made as discussed belowin section 3.4.Step two is to test sensor response by exposingthe sensor to a test gas of known concentration.This is known as a functional (bump) test.Readings are considered to be accurate whenthe display is between 90% and 120% of theexpected values as given on the calibration gascylinder. If readings are accurate, there is noneed to adjust your gas detector. See section3.5 for further details concerning thefunctional/bump test.If the readings are inaccurate, the instrumentmust be span calibrated before further use asdiscussed in section 3.6.

Accuracy of the ToxiProinstruments equipped with toxic gassensors should be checked periodically withknown concentration calibration gas.Failure to check accuracy can lead toinaccurate and potentially dangerousreadings.See Appendix D for a discussion ofcalibration frequency recommendations.3.2 Effect of contaminants on ToxiPro

sensorsThe atmosphere in which the ToxiPro is usedcan have lasting effects on the sensors.Sensors may suffer losses in sensitivity leadingto degraded performance if exposed to certainsubstances.The ToxiPro O2 uses a galvanic oxygen sensor,while all other versions of the ToxiPro use anelectrochemical toxic gas sensor. Each type ofsensor uses a slightly different detectionprinciple, so the kinds of conditions that affectthe accuracy of the sensors vary from one typeof sensor to the next.

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3.2.1 Effects of contaminants on O2sensors

Oxygen sensors may be affected by prolongedexposure to "acid" gases such as carbondioxide. The oxygen sensors used inBiosystems instruments are not recommendedfor continuous use in atmospheres containingmore than 25% CO2.3.2.2 Effects of contaminants on toxic gas

sensorsBiosystems “substance-specific”electrochemical sensors have been carefullydesigned to minimize the effects of commoninterfering gases. “Substance-specific”sensors are designed to respond only to thegases that they are supposed to measure. Thehigher the specificity of the sensor, the lesslikely the sensor will react to other gases,which may be incidentally present in theenvironment. For instance, a “substance-specific” carbon monoxide sensor isdeliberately designed not to respond to othergases that may be present at the same time,such as hydrogen sulfide (H2S) and methane(CH4).Although great care has been taken to reducecross-sensitivity, some interfering gases maystill have an effect on toxic sensor readings. Insome cases the interference may be positiveand result in readings that are higher thanactual. In other cases the interference may benegative and produce readings that are lowerthan actual and may even cause theinstrument to display negative readings for thetarget gas.See Appendix A for cross-sensitivitydata.3.4 Fresh air/zero calibrationTo initiate the fresh air/zero calibrationprocedure:1. From the current gas reading screen, press

the MODE button three times within twoseconds to begin the fresh air/zerocalibration sequence. The ToxiPro willbriefly display “CAL” and then begin a 5-second countdown with the 0-CAL icon lit.

→

2. Press the MODE button before the end ofthe 5-second countdown to begin the freshair/zero calibration. The fresh air/zerocalibration has been successfully initiatedwhen the ToxiPro alternates between thefollowing two screens:

↔

3. For ToxiPro instruments, the fresh air/zero

calibration is complete when the instrumentbegins another 5-second countdown for thespan calibration. If span calibration is notrequired, allow the countdown to reach 0without pressing the MODE button. Forfurther instructions concerning the spancalibration of ToxiPro models see section3.6.For ToxiPro O2 models, calibration iscomplete when the instrument returns to thecurrent gas readings screen.

Fresh air/zero calibrationsmay only be performed in an atmospherethat is known to contain 20.9% oxygen and 0PPM toxic gas. Performing the fresh air/zerocalibration in an atmosphere that is notcomprised of 20.9% oxygen and 0 PPM toxicgas may lead to inaccurate and potentiallydangerous readings.3.5 Functional (bump) testing (toxic

sensor versions)The accuracy of ToxiPro instruments may beverified at any time by a simple functional(bump) test. To perform a functional (bump)test, do the following:1. Turn the ToxiPro on and wait at least three

minutes to allow the readings to fullystabilize. If the sensor has just beenreplaced, allow the instrument to stabilize for15 minutes prior to performing the functional(bump) test.

2. Make sure the instrument is located in freshair.

3. Verify that the current gas readings matchthe concentrations present in fresh air. Thereading for toxic gases should be 0 parts-per-million (PPM) in fresh air. If the readingis anything other than 0 PPM proceed to

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section 3.4 and perform a fresh air/zerocalibration before continuing.

Figure 3.5 Proper bump-test/spancalibration set-up for toxic sensor-equipped instruments.

4. Apply the calibration gas as shown in figure3.5.

5. Wait for the readings to stabilize. (Forty-five seconds to one minute is usuallysufficient.)

6. Note the readings. Readings areconsidered sufficiently accurate if thereadings are between 90% and 120% of theexpected value. If the readings areaccurate, then the instrument may be usedwithout further adjustment. If readings areinaccurate, the instrument must be adjustedusing the “span” calibration proceduresdiscussed in section 3.6 before further use.

3.6 Span Calibration (toxic sensorversions)

Span calibration should be performed when afunctional (bump) test has shown that theinstrument’s gas readings are not between90% and 120% of the expected values asgiven on the calibration gas cylinder (asdiscussed in section 3.5).Prior to performing a span calibration, performa fresh air/zero calibration as discussed insection 3.4. After successful completion of thefresh air/zero calibration, the instrument willbegin a second five-second countdown withthe calibration gas bottle icon highlighted.

1. Press the MODE button before thecountdown is complete to initiate the spancalibration. The display will alternatebetween “GAS” and the expectedconcentration of calibration gas.

↔

2. Apply calibration gas as shown above infigure 3.5. Once calibration gas is detected,the readout will change to show the gasreading. Note that the negated horn symbolis shown at lower left to indicate that thealarms are not operating because theinstrument is in calibration mode.

3. The calibration is fully automatic from thispoint on. Once the instrument successfullycompletes the span calibration, it will emitthree short beeps and display the maximumspan calibration adjustment value for twoseconds.

Note: The maximum span calibrationadjustment value shown is an indication ofthe relative health of the sensor. As asensor loses sensitivity, the maximumadjustment level will approach thecalibration gas concentration, letting youknow when the sensor is losing sensitivity.Once the maximum span adjustment iswithin 10% of the calibration gasconcentration, it is time to order a newsensor.

4. The instrument will then return to normaloperation.

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Note: Once the calibration cycle iscompleted, the ToxiPro automaticallyreturns to normal operation and the gasalarms may be activated. Disconnect thecalibration assembly immediately aftercalibration.

Use of non-standardcalibration gas and/or calibration kitcomponents when calibrating the ToxiProcan lead to inaccurate and potentiallydangerous readings, and may void thestandard Biosystems warranty.3.7 Failure to calibrate3.7.1 Fresh air/zero calibration failureIn the event of fresh air/zero calibration failure,the “no” and “CAL” screens will be alternatelydisplayed as shown below with the “0-CAL”segment lit. The instrument will then return tothe gas reading screen.

↔

Following a fresh air/zero calibration failure, thetriangular warning symbol will be lit and the “0-CAL” indicator will flash until a successful freshair/zero calibration is performed.

3.7.1.1 Causes of fresh air/zerocalibration failures

Fresh air/zero calibration failures often resultfrom the attempt to calibrate the instrument in acontaminated atmosphere.Fresh air/zero calibration failures in the ToxiProO2 can also result from a dead or dying oxygensensor.3.7.1.2 Forced fresh air/zero calibrationIf a fresh air/zero calibration fails in anatmosphere known to be fresh, the ToxiProcan be forced to fresh air calibrate as follows.1. Follow instructions 1 and 2 in section 3.4 to

begin the fresh air/zero calibrationsequence.

2. As soon as the alternating right and left 0’sare shown on the screen, press and holdthe MODE button.

↔

3. The forced fresh air/zero calibration iscomplete when the instrument emits threeshort beeps and then moves on the spancalibration procedure.

Performing the forcedfresh air calibration in a contaminatedatmosphere will lead to inaccurate andpotentially dangerous readings.3.7.2 Span calibration failureThe ToxiPro is designed to recognize twodistinct types of span calibration failure: failuresthat occur due to sensor response outside thesensor’s normal range for calibration andfailures that occur when the instrument fails torecognize any calibration gas whatsoever.3.7.2.1 Sensor out of range (no CAL)If the instrument recognizes calibration gas, butthe sensor response is not within the range tocalibrate the instrument, span calibration will failand the “no” and “CAL” screens will bealternately displayed.

↔

After displaying “no” and “CAL” three times, theinstrument will return to the current gasreadings screen and the warning symbol andthe calibration bottle icon will be shown, whichsignifies that the instrument failed the lastattempt to span calibrate.

3.7.2.2 No gasIn the case of a span calibration failure in whichcalibration gas is not detected, the “no” and“GAS” screens will be alternately displayed asshown below with the calibration bottle iconhighlighted.

↔

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When the instrument returns to the current gasreadings screen, the warning symbol and thecalibration bottle icon will be shown, whichsignifies that the last attempt to span calibratethe instrument failed.

3.7.2.3 Causes for span cal failureSpan calibration failures can be caused by thefollowing:1. Expired calibration gas.2. Calibration gas whose concentration fails to

match the concentration expected by theinstrument.

3. Inappropriate regulator. The ToxiPro mustbe calibrated using a 1.0 liter/minute fixedflow regulator.

4. Sensor failure.3.8 Fresh air/zero calibration in a

contaminated atmosphereTo calibrate in a contaminated atmosphere, itis necessary to use special calibration gas,whose composition is identical to that of freshair. Biosystems offers the “Zero Air” calibrationgas cylinder as part number 54-9039, whichcontains 0 PPM toxic gas and 20.9% oxygen.1. Apply “Zero Air” calibration gas to the

instrument as shown above in figure 3.5 forat least 15 seconds or until the readingsfully stabilize.

2. Perform the fresh air/zero calibrationprocedure as described in section 3.4 whilecontinuing to flow gas to the oxygen sensor.

3. Once the fresh air/zero calibration iscomplete, disconnect the calibrationassembly and move on to the spancalibration if necessary as described insection 3.6.

4. Maintenance4.1 Replacing batteries

Removal or replacementof the lithium battery in potentiallycombustible atmospheres may compromiseintrinsic safety. The lithium battery used in

the ToxiPro may only be removed orreplaced in an atmosphere that is known tobe free of combustible gas.To replace the batteries:1. Remove the two screws from the back of the

ToxiPro.2. Remove the front housing. The main board

will stay attached to the rear instrumenthousing. The battery is located directlyabove the display.

Figure 4.1: Interior view with battery andsensor removed.

CAUTION The IRDA module is located onthe main board directly above the batteryand below the LED alarm light. Take specialcare not to damage it or bend theconnection pins during replacement of thebattery. If the pins are inadvertently bentduring battery replacement, gently return theIRDA module to a 45-degree angle relative tothe main board pointing away from thebattery.

3. Remove the old lithium battery. Ifnecessary, use a small screwdriver andgently pry the battery out.

4. Install the new battery. Be sure to align thepolarity of the battery in accordance with thediagram on the face of the batterycompartment.

Use only Duracell Ultra#CR2, Energizer #1CR2 (EL1CR2), Sanyo#CR2 or Panasonic #CR2 in the ToxiPro.

5. Once the new battery is installed, theinstrument will automatically restart with thehours digits blinking. The next five stepsinvolve programming the current time anddate into the instrument.

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6. Press and release the MODE button toadvance the setting by one. Hold theMODE button down to scroll rapidly. Whenthe hours setting moves over from am topm, a dot will be added below the colon onthe display.

The image above is 10 a.m.The image below is 10 p.m.

7. Once the appropriate hour setting is shown,wait 5 seconds and the minutes setting willstart to blink.

8. Adjust the minute setting with the MODEbutton, then wait 5 seconds and the monthssetting will be shown.

9. Adjust the months setting with the MODEbutton, then wait 5 seconds and the dayssetting will be shown.

10.Adjust the days setting with the MODEbutton, then wait 5 seconds and the yearsetting will be shown. The display for theyear is given in two digit format.

11.Enter the last two digits of the year with theMODE button, then wait 5 seconds and theinstrument will continue to the normal startup sequence as discussed in section 2.1.

12.Replace the front cover plate.13.Reinstall the screws that were removed in

step 1.14.The ToxiPro must be calibrated following

replacement of the battery. Once the sensorhas stabilized, calibrate the detector. ForToxiPro O2 units, perform the Fresh Air/ZeroCalibration as described in section 3.4. ForToxiPro units, perform both the FreshAir/Zero calibration (section 3.4) and theSpan calibration (section 3.6).

4.2 Replacing sensors Removal or replacement

of the lithium battery or sensor in potentiallycombustible atmospheres may compromiseintrinsic safety. The lithium battery orsensor used in the ToxiPro may only beremoved or replaced in an atmosphere thatis known to be free of combustible gas.The sensor in the ToxiPro may requireperiodic replacement. To replace thesensor:1. Follow the directions in section 4.1 steps 1-3

to remove the battery.2. The sensor is located to the left of the LED

alarm light on the main board. Gentlyremove the old sensor and install a newsensor of the same type.

3. Reinstall the battery and follow theremaining steps in section 4.1 to reset theinstrument’s time and date settings.

4. New sensors must be allowed to stabilizeprior to use according to the followingschedule. The detector must be powered offand functional batteries must be installed forthe sensors to stabilize.

Instrument Stabilization PeriodToxiPro O2 1 hour

ToxiPro withtoxic gas sensor 15 minutes

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5. Once the sensor has stabilized, calibratethe detector. For ToxiPro O2 units, performthe Fresh Air/Zero Calibration as describedin section 3.4. For ToxiPro units with toxicgas sensors, perform both the FreshAir/Zero calibration (section 3.4) and theSpan calibration (section 3.6).

Note: The ToxiPro must be calibrated afterany sensor change. See section 3.4 and 3.6above for details on the fresh air/zero andspan calibration sequences.

5. PC-Instrument Communications5.1 Event loggingEach ToxiPro includes a built-in event loggerthat stores instrument readings during alarmconditions, calibration values and other data.BioTrak software and an IrDA port arenecessary to download the collected data to aPC. See section 5.3 for instructions oninitiating communications.5.2 Instrument Software UpgradesThe ToxiPro’s instrument software may beupgraded at any time with a PC through theinstrument’s IrDA port. See section 5.3 forinstructions on initiating communications.See the Biosystems website athttp://www.biosystems.com for the latestversion of the software.

5.3 Initiating communicationsTo initiate communications, simply hold theMODE button as if you are turning theinstrument off. Once OFF is shown, continue tohold MODE until the “IrdA” screen is shown andthe LED/IrDA port turns on.

Once “IrdA” is shown release the MODE button.Then align the infrared port at the top front ofthe ToxiPro with the PC’s infrared port toproceed with the download. The LED/IrDA portwill blink during communication with the PC.The ToxiPro should be located 1-2” (2.5-5cm)from the IrDA Port.

Proper Positioning of IrDA Module

6. Exploded view and basic parts list

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AppendicesAppendix A: Sensor Cross-Sensitivity ChartThe table below provides the cross-sensitivity response of the ToxiPro toxic gas sensors tocommon interference gases. The values are ToxiPro as a percentage of the primarysensitivity, or the reading of the sensor when exposed to 100ppm of the interfering gas at20ºC. These values are approximate. The actual values depend on the age and conditionof the sensor. Sensors should always be calibrated to the primary gas type. Cross-sensitive gases should not be used as sensor calibration surrogates without the writtenconsent of Biosystems.

SENSORCO H2S SO2 NO NO2 Cl2 ClO2 H2 HCN HCl NH3 C2H4 C2H2

CarbonMonoxide (CO)

100 10 5 10 -15 -5 -15 50 15 3 0 75 250

CarbonMonoxide (CO+)

100 350 50 30 -60 -60 -120 50 n/d n/d 0 75 250

CarbonMonoxide (CO-H)

100 10 5 n/d (-) (-) (-) 5 n/d n/d n/d (+) (+)

Hydrogen Sulfide(H2S)

0.5 100 20 2 -20 -20 -60 0.2 0 0 0 n/d n/d

Sulfur Dioxide(SO2)

1 1 100 1 -100 -50 -150 0.2 n/d n/d 0 (+) (+)

Nitrogen Dioxide(NO2)

-5 -8 -1 0 100 90 270 0 n/d n/d 0 n/d n/d

Chlorine (Cl2)(nonspecific)

0 -3 -1 0 110 100 310 0 n/d n/d 0 n/d n/d

Chlorine (Cl2)(specific)

0 -3 0 n/d 12 100 0 0 0 2 n/d 0 0

Ammonia (NH3)(54-47-21)

0 <5 0 n/d 0 0 n/d 0 0 0 100 0 0

Phosphine (PH3) 0.5 25 20 n/d (-) (-) (-) 0.1 n/d n/d n/d 1 0.5HydrogenCyanide(HCN)

0.5 350 160 -5 -100 -20 -60 0.1 100 65 -5 50 n/d

n/d = no data, (+) undetermined positive, (-) undetermined negative

Appendix B: Replacement Sensor ListPart No. Sensor Description Range Resolution

54-47-90 O2 Oxygen (2 years) (for ToxiPro O2) 0 – 30%/Vol. 0.1%/Vol.54-47-01 CO Carbon monoxide 0 – 1000 PPM 1 PPM54-47-02 H2S Hydrogen sulfide 0 – 200 PPM 1 PPM54-47-03 SO2 Sulfur dioxide 0 – 25 PPM 0.1 PPM54-47-05 CO+ Carbon monoxide plus 0 – 1000 PPM 1 PPM54-47-09 NO2 Nitrogen Dioxide 0 – 20 PPM 0.1 PPM54-47-10 HCN Hydrogen cyanide 0 – 100 PPM 0.1 PPM54-47-13 PH3 Phosphene 0 – 20 PPM 0.01 PPM54-47-15 SO2 Hi Sulfur dioxide extended range 0 – 100 PPM 0.1 PPM54-47-18 Cl2 Chlorine 0 – 20 PPM 0.1 PPM54-47-19 CO-H Carbon monoxide minus 0 – 800 PPM 1 PPM54-47-21 NH3 Ammonia 0 – 100 PPM 1 PPM

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Appendix C: CalibrationFrequency

One of the most common questionsthat we are asked at Biosystems is:“How often should I calibrate mygas detector?”

Sensor Reliability andAccuracy

Today’s sensors are designed toprovide years of reliable service. Infact, many sensors are designed sothat with normal use they will only lose5% of their sensitivity per year or 10%over a two-year period. Given this, itshould be possible to use a sensor forup to two full years without anysignificant loss of sensitivity.A lot of sensors indeed do last that longwith only minimal loss of sensitivity.However, there are a number ofreasons why a sensor mayunexpectedly lose additional sensitivityor even fail to respond to gas. Suchreasons include desiccation, poisoning,physical restriction of airflow,overexposure, leakage, andmechanical damage due to dropping orimmersion.

Verification of AccuracyWith so many reasons why a sensorcan lose sensitivity and given the factthat dependable sensors can be key tosurvival in a hazardous environment,frequent verification of sensorperformance is paramount.There is only one sure way to verifythat a sensor can respond to the gasfor which it is designed. That is toexpose it to a known concentration oftarget gas and compare the readingwith the concentration of the gas. Thisis referred to as a “bump” test. This testis very simple and takes only a fewseconds to accomplish. The safestcourse of action is to do a “bump”test prior to each day’s use. It is notnecessary to make a calibrationadjustment if the readings are between90% and 120% of the expected value.As an example, if a CO sensor ischecked using a gas concentration of50 PPM it is not necessary to perform acalibration unless the readings areeither below 45 PPM or above 60 PPM.

Lengthening the Intervalsbetween Verification of

AccuracyWe are often asked whether thereare any circumstances in which theperiod between accuracy checksmay be lengthened.Biosystems is not the onlymanufacturer to be asked thisquestion! One of the professionalorganizations to which Biosystemsbelongs is the Industrial SafetyEquipment Association (ISEA). The“Instrument Products” group of thisorganization has been very active indeveloping a protocol to clarify theminimum conditions under which theinterval between accuracy checksmay be lengthened.A number of leading gas detectionequipment manufacturers haveparticipated in the development ofthe ISEA guidelines concerningcalibration frequency. Biosystemsprocedures closely follow theseguidelines.If your operating procedures do notpermit daily checking of the sensors,Biosystems recommends thefollowing procedure to establish asafe and prudent accuracy checkschedule for your Biosystemsinstruments:1. During a period of initial use of at

least 10 days in the intendedatmosphere, check the sensorresponse daily to be sure thereis nothing in the atmosphere thatis poisoning the sensor(s). Theperiod of initial use must be ofsufficient duration to ensure thatthe sensors are exposed to allconditions that might have anadverse effect on the sensors.

2. If these tests demonstrate that itis not necessary to makeadjustments, the time betweenchecks may be lengthened. Theinterval between accuracychecking should not exceed 30days.

3. When the interval has beenextended the toxic andcombustible gas sensors shouldbe replaced immediately uponwarranty expiration. This willminimize the risk of failure duringthe interval between sensorchecks.

4. The history of the instrumentresponse between verificationsshould be kept. Any conditions,incidents, experiences, or exposureto contaminants that might have anadverse effect on the calibrationstate of the sensors should triggerimmediate re-verification ofaccuracy before further use.

5. Any changes in the environment inwhich the instrument is being used,or changes in the work that is beingperformed, should trigger aresumption of daily checking.

6. If there is any doubt at any time asto the accuracy of the sensors,verify the accuracy of the sensorsby exposing them to knownconcentration test gas before furtheruse.

Gas detectors used for the detection ofoxygen deficiencies, flammable gasesand vapors, or toxic contaminants mustbe maintained and operated properly todo the job they were designed to do.Always follow the guidelines provided bythe manufacturer for any gas detectionequipment you use!If there is any doubt regarding your gasdetector's accuracy, do an accuracycheck! All it takes is a few moments toverify whether or not your instrumentsare safe to use.

One Button Auto CalibrationWhile it is only necessary to do a“bump” test to ensure that the sensorsare working properly, all currentBiosystems gas detectors offer a onebutton auto calibration feature. Thisfeature allows you to calibrate aBiosystems gas detector in about thesame time as it takes to complete a“bump” test. The use of automatic bumptest and calibration stations can furthersimplify the tasks, while automaticallymaintaining records.

Don't take a chancewith your life.

Verify accuracyfrequently!

Please read also Biosystems’application note: AN20010808 “Use of‘equivalent’ calibration gas mixtures”.This application note providesprocedures to ensure safe calibration ofLEL sensors that are subject to siliconepoisoning.

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Biosystems Standard Warranty Gas Detection ProductsGeneralBiosystems LLC (hereafter Biosystems) warrants gas detectors, sensors and accessories manufactured and soldby Biosystems, to be free from defects in materials and workmanship for the periods listed in the tables below.Damages to any Biosystems products that result from abuse, alteration, power fluctuations including surges andlightning strikes, incorrect voltage settings, incorrect batteries, or repair procedures not made in accordance withthe Instrument’s Reference Manual are not covered by the Biosystems standard warranty.The obligation of Biosystems under this warranty is limited to the repair or replacement of components deemed bythe Biosystems Instrument Service Department to have been defective under the scope of this standard warranty.To receive consideration for warranty repair or replacement procedures, products must be returned withtransportation and shipping charges prepaid to Biosystems at its manufacturing location in Middletown,Connecticut, or to a Biosystems Authorized Warranty Service Center. It is necessary to obtain a returnauthorization number from Biosystems prior to shipment.THIS WARRANTY IS EXPRESSLY IN LIEU OF ANY AND ALL OTHER WARRANTIES ANDREPRESENTATIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE WARRANTY OFFITNESS FOR A PARTICULAR PURPOSE. BIOSYSTEMS WILL NOT BE LIABLE FOR LOSS OR DAMAGE OFANY KIND CONNECTED TO THE USE OF ITS PRODUCTS OR FAILURE OF ITS PRODUCTS TO FUNCTIONOR OPERATE PROPERLY.

Instrument & Accessory Warranty PeriodsProduct(s) Warranty PeriodPhD5, PhD Lite, PhD Plus, PhD Ultra, Cannonball3,MultiVision, Toxi, Toxi/Oxy Plus, Toxi/Oxy Ultra, ToxiVision,Ex Chek

As long as the instrument is inservice

ToxiPro, MultiPro 2 years from date of purchase

ToxiLtd2 years after activation or 2 yearsafter the “Must Be Activated By”date, whichever comes first

Mighty-Tox90 days after activation or 90 daysafter the “Must Be Activated By”date, whichever comes first

Mighty-Tox 2Prorated credit is given towards repair or purchase of a newunit of the same type.

0 – 6 months of use 100% credit6 – 12 months of use 75% credit

12 – 18 months of use 50% credit18 – 24 months of use 25% credit

IQ Systems, Series 3000, Airpanel, Travelpanel, ZoneGuard,Gas Chek1 and Gas Chek4 One year from the date of purchase

Battery packs and chargers, sampling pumps and othercomponents, which by their design are consumed or depletedduring normal operation, or which may require periodicreplacement

One year from the date of purchase

Sensor Warranty PeriodsInstrument(s) Sensor Type(s) Warranty Period

O2, LEL**, CO, CO+, H2S& Duo-Tox 2 YearsPhD Plus, PhD Ultra, PhD5, PhD Lite,

Cannonball3, MultiVision, MultiPro,ToxiVision, ToxiPro, Ex Chek All Other Sensors 1 Year

CO, CO+, H2S 2 YearsToxi, Toxi/Oxy Plus, Toxi/Oxy Ultra All Other Sensors 1 YearAll Others All Sensors 1 Year

** Damage to combustible gas sensors by acute or chronic exposure to known sensor poisons such as volatilelead (aviation gasoline additive), hydride gases such as phosphine, and volatile silicone gases emitted fromsilicone caulks/sealants, silicone rubber molded products, laboratory glassware greases, spray lubricants, heattransfer fluids, waxes & polishing compounds (neat or spray aerosols), mold release agents for plastics injectionmolding operations, waterproofing formulations, vinyl & leather preservatives, and hand lotions which maycontain ingredients listed as cyclomethicone, dimethicone and polymethicone (at the discretion of BiosystemsInstrument Service department) void Biosystems’ Standard Warranty as it applies to the replacement ofcombustible gas sensors.

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ToxiProType O2 H2S SO2

CO CO-H CO+NH3 Cl2 ClO2

NO2 HCN PH3

SO2 HiSoftware Version _____

Vibrating MotorDataloggingBelt Clip

Serial Number ____________

MFG Date _____/_____/_____