GasCheck R2pc User Manual V1.6
Contents
1. 5 10 Table 1 Leak Detection thresholds Notes Each successive gas group number corresponds to a decrease in sensor responsivity by a factor of 10 A gas such as R32 is very readily sensed by the instrument hence it is placed in gas group 1 This means that the instrument is able to operate in contaminated background conditions when searching for R32 with minimal risk of interference from other fugitive gases 2 3 Battery data Note the energy storage capacity of batteries is affected by temperature The data in Table 2 is for an ambient temperature of 20 C 68 F WARNI NG GasCheck R2 Mk 2 includes a battery recharging and sensor heater control facility Never use the instrument its battery re charger in a hazardous area The GasCheck R2 can be used with primary disposable batteries There is a provision for the recharging of ISL batteries within the GasCheck R2 Do not substitute any lon Science parts within the GasCheck R2 Page 7 of 20 GasCheck R Manual V1 6 lon Science Ltd Number of batteries required 4 Battery type Nickel Metal Hydride Rechargeables size AA For other acceptable battery types see Table 2 Battery life hours Battery type ee Check R2 NMHi re chargable LR6 R6 n OS MN1500 4 Table 2 Average battery life without recharging 2 4 Charger plugs The charger plugs available are for single phase supply sockets in UK Europe and USA as shown below 2 5 Outputs Aud2. GasCheck R2pc User Manual V1 6 Part Number 19042 www ionscience com lon Science Ltd The Way Fowlmere Cambs SG8 7UJ U K f Tel 44 0 1763 208 503 Fax 44 0 1763 208 814 Advanced Gas Sensing Technologies Email info ionscience com Web www ionscience com GasCheck R Manual V1 6 lon Science Ltd Declaration of conformity Manufacturer lon Science Ltd The Way Fowlmere Cambridge England SG8 7UJ Product GasCheck R2pc Product description a handheld leak detector specifically designed for the detection and measurement of refrigerant and air conditioning gases Directives 89 336 EC EMC Standards BS EN 61010 1 2001 Safety requirements for measurement control amp lab equipment BS EN ISO 9001 2000 Quality management systems BS EN 61326 1 1997 EMC Equipment for measurement control and laboratory use the undersigned herby declare that the equipment specified above conforms to the stated Directives and Standards Signed By pt Name Mark Stockdale Position Technical Director Date 23 April 2007 Safety GasCheck R2pc 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 Page 1 of 20 GasCheck R Manual V1 6 lon Science Ltd Contents Page Introduction 4 Scope and definitions 4 Description 4 Principal of operation 4 Applications i i 5
3. 14 of 20 GasCheck R Manual V1 6 lon Science Ltd 4 4 Switching off the GasCheck When the GasCheck R2 is not required immediately but will be used again leave it switched off but still plugged in to the main power supply This is for recharging the batteries and heating the sensor ready for future use When the GasCheck is not going to be used again for an extended period switch it off to conserve the batteries 5 MAI NTENANCE 5 1 Inspect and clean the GasCheck CAUTION Do not clean the probe while it is attached to the GasCheck and do not try to clean the sample hole l Switch off the Gas Check 2 Refer to Figure 5 If the probe is fitted hold the probe 1 by its quick fit bayonet and gently twist it anti clockwise to remove it from the GasCheck R2 3 Inspect the GasCheck If the case of the Gas Check is cracked or dented we recommend that you do not continue maintenance but return the GasCheck to your supplier for inspection and calibration 4 Wipe the GasCheck with a clean lint free cloth moistened with a weak solution of detergent 5 Carefully wipe the outer faces of the probe to remove any small particles of dirt or debris 6 Use a gentle air flow to dislodge any particles within the probe but not done with the probe attached 7 Use a suitable tool to push any blockage out of the end of the probe and then wipe the outside of and the inner face of the wide part of the nozzle 8 Refit the required pr
4. Battery charging for optimum performance 6 Technical data F 5 General 6 Performance 7 Battery data 8 Charger plugs 9 Outputs 9 Installation A 10 Operation i 12 Control buttons 12 Display i 13 Recommended leak search procedure 15 Switching off the GasCheck 16 Maintenance i A 15 Inspect and clean the GasCheck 16 Replacing the batteries 17 Battery charging 18 Fault finding 18 Storage and disposal 18 Storage i 18 Disposal 19 Spares and Accessories s i 19 Introduction 19 Spares l 19 Accessories l l 19 Calibration l 20 Refurbish program 20 Page 2 of 20 GasCheck R Manual V1 6 lon Science Ltd 1 INTRODUCTI ON 1 1 Scope and definitions This manual provides installation operation and maintenance instructions for the Gas Check R2 You must use the Gas Check R2 as specified in this manual Read this manual before you install and operate the Gas Check Important safety information is highlighted as WARNING and CAUTION instructions you must obey these instructions The use of WARNINGS and CAUTI ONS is defined below WARNING Warnings are given where failure to observe the instruction could result in injury or death to people CAUTION Cautions are given where failure to observe the instruction could result in damage to the equipment associated equipment and process PLEASE ENSURE THE INSTRUMENT IS PLU
5. Minimum IP20 Page 5 of 20 GasCheck R Manual V1 6 lon Science Ltd 380 Length of long probe fitted to GasCheck R2 Figure 2 Dimensions of GasCheck R2 with short probe fitted mm 2 2 Performance Detector type Heated ceramic semi conductor oxide Gases Detected Most refrigerant gases and volatiles see Table 1 For effective leak measurement of a target gas gases are classed into one of four Gas Groups as shown in Table 1 Each group has a characteristic calibration curve assigned to it in the instrument s memory The table only lists refrigerant gases that have been tested by the manufacturer If the gas or gas mixture that you seek is not included in Table 1 select group III which delivers a large and therefore most conservative estimation of leak rate Minimum response time search mode About 2 seconds for 15 g year leak Recovery time search mode About 4 seconds for 15 g year leak Maximum signal measurable 30 g year or 2000ppm Flow rate through the Probe 15ml sec Smallest leak detection levels see Table 1 Page 6 of 20 GasCheck R Manual V1 6 lon Science Ltd Gas lower lower leak lower leak detection group detection detection limit limit gm yr limit ppm mbar L min R1305 1 010 16 17 PO R20 chloroform R30 dichloromethane Acetone 1 004 67 10 2 10 R33 p eo dq SS 1 m 3 X A Raon blend 4 562 9919
6. Recommended leak search procedure 4 3 1 General procedure When you use the GasCheck do not allow dirt or debris to enter the end of the probe If the probe is blocked the GasCheck will not operate correctly Ensure the part under test contains a reasonable percentage of a detectable target gas Turn instrument on allow to zero and activate Roaming mode by pressing the 1 key Press this key again if necessary to ensure H is displayed denoting high sensitivity 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 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 e Use L lower sensitivity in conjunction with Peak hold to pinpoint large leaks e If you want to zero the GasCheck move the end of the probe or nozzle away from any possible leak into a clean air zone then press the manual zero key refer to Section 4 1 Note that leak sensitivity depends on the ambient conditions If you want to accurately measure a leak compare the indicated leak with a calibration standard such as obtained with lon Science s CalCheck see Section 7 3 When the GasCheck indicates that a leak has been found move the probe back to determine the precise location of the leak The leak is located where the
7. largest leak bar indication is displayed and where highest frequency clicks and visual flashing rate are emitted by the GasCheck on the current range 4 3 2 Leak detection along seams Move the end of the GasCheck probe or nozzle along the length of the seam so that it just rests on the seam The speed at which you move along the seam will determine the size of the leak detectable e Ifthe leak is large you can move fairly fast along the seam at approximately 20 mm per second e Ifthe leak is very small move slowly along the seam at approximately 5 mm per second 4 3 3 Leak detection at pipe joints Use the same procedure as for leak detection along seams see Section 4 3 2 moving the nozzle at half the speed specified Refrigerant gases are heavier than air and also usually diffuse quite slowly into air so indicated leaks may be slightly displaced from their actual source 4 3 4 Leak measurement When a leak is found in Roaming mode withdraw the probe from the leak site and move to an ambient location Use the Peak mode key to activate Peak mode Allow instrument to zero Return the probe to the leak site and maintain it in position as the leak is registered This will usually take about 15 seconds and will be indicated by the permanent display of the peak icon Retract the probe from the leak The instrument will also display the peak leak registered by the instrument Press the zero key before repeating the procedure Page
8. switch off Software locked out Remove amp replace battery clip safely Battery symbol appears Battery state low Replace batteries safely Unit shows negative symbol Sensor not warmed up yet Ensure sensor left on if needed quickly Display appears blank dim Contrast control setting wrong Turn off amp on press amp hold contrast Numbers do not change Peak hold selected Press zero or change from Peak hold Range does not change Range not set in Auto range Press amp hold Range until Auto range Gas group is wrong Gas Group not set correctly Press amp hold Gas until shown OK Blocked probe Probe blocked Remove probe and clean Instrument readings noisy Test environment contaminated Move item under test into cleaner area Error E Zero symbol Detector not ready Charge to allow the sensor to warm up Error E Battery symbol Mains power off during charge Check power to instrument applied Table 5 Fault finding 6 STORAGE AND DISPOSAL 6 1 Storage If you will store the unit for a long time we recommend that you remove the batteries refer to Section 5 2 Refit the GasCheck in its storage case and store in dry cool conditions Unpack as described in Section 3 Page 17 of 20 GasCheck R Manual V1 6 6 2 Disposal lon Science Ltd Dispose of the GasCheck components and used batteries safely in accord
9. GGED TO THE MAINS ADAPTER WHEN NOT IN USE The units of measurement used throughout this manual conform to the SI international system of units of measurement 1 2 Description Gas Check R2pc shown in Figure 1 below is a portable battery powered hand held refrigerant gas leak detector detecting the presence of refrigerants in air by means of their adsorption on a semi conducting surface The GasCheck R2 is suitable for leak detection of most refrigerants including R134a A comprehensive list of sensed gases is given in Table 1 on Page 4 There are provisions for sensor heating and battery charging within the GasCheck R2 Mk2 design enabling its immediate deployment when required Indications of a leak are shown on the digital display Figure 1 2 and are also given by a front panel mounted LED flasher 3 and as audible clicks from the rear panel loud speaker 6 The GasCheck R2 includes a convenient storage and carrying case together with a spare battery holder the mains powered 6V DC power supply and connection cord for battery charging and sensor regulation and a long flexible probe 1 3 Principal of operation When switched ON the GasCheck R2 automatically waits for the sensor response to stabilise in the ambient environment Then the instrument either enters Peak Mode for gas leak measurement or Roaming Mode for location of gas leaks and emissions according to which mode of operation last used In Peak Mode a clear t
10. ance with all local and national environmental safety requirements Some of the GasCheck carry case plastic material is recyclable 7 SPARES AND ACCESSORIES 7 1 Introduction Order spare parts from your local agent or distributor when you order please state for each part required e Serial Number stamped on your GasCheck refers to Figure 6 e Item Number and description of part 7 2 Spares Spare Rechargeable batteries 4 off Replacement battery holder Short Probe R2 Long Probe R2 Case Instruction Manual 7 3 Accessories Accessory Power supply for battery charger specifying UK mains plug specifying Euro mains plug specifying USA mains plug Portable reference leak specifying gas leak rate and pressure Item Number 1 BM 01 1 BH 01 A 19043 A 19045 28367C SPR2MAN Item Number 1 VS 09 1 VS 10 1 VS 12 Cal Check Page 18 of 20 GasCheck R Manual V1 6 lon Science Ltd 7 4 Calibration lon Science offer a calibration service including issue of traceable certification to National Standards 7 5 Refurbish program lon Science offer a refurbish service for all customer repairs Page 19 of 20
11. ction 4 2 3 The Gas Group number is shown at the lower left hand side of the display when the instrument is in Peak Mode Page 12 of 20 GasCheck R Manual V1 6 lon Science Ltd 4 2 2 Gas Measurement In Peak Mode a leakage is displayed as a bar graph and a single exponent for the range of the signal For example MNI x101 ppm Corresponds to a reading of 80 ppm 4 2 3 Other display symbols Small display indicators show zeroing peak hold low battery voltage signal conditioning gain and gas group setting Zeroing This symbol appears whilst the GasCheck is zeroing When cleared the 4l instrument is ready for use Peak hold When the Peak hold is flashing the instrument is ready for use When the F Peak hold symbol is shown on its own the reading is being held Low battery When the instrument is in use this symbol indicates that the battery pack is lower than required for use When the instrument is being charged the zd state of the battery is shown on the bar graph display Negative This shows the sensor is still conditioning Wait until this symbol has cleared before taking a reading EEA Hi sensitivity Sensitivity is at maximum gain Displayed only in Roaming Mode Low sensitivity Sensitivity at 1 16 maximum gain Displayed only in Roaming Mode Gas Group Indicates which Gas Group is selected in Peak Mode Gas Group 3 is shown i in the example here Page 13 of 20 GasCheck R Manual V1 6 lon Science Ltd 4 3
12. ge case and remove the GasCheck The GasCheck is supplied with the short probe fitted To interchange probes loosen the three screws S Figure 4 attaching the probe to the instrument Rotate the probe clockwise by a one eighth turn to release it from its fitting Replace with the alternate probe and reverse the procedure Figure 4 Probe replacement Position of one of three screws S is indicated and direction of removal of the probe CAUTION Do not bend the long probe through sharp angles as this will reduce its mechanical life A 45 degree bend at the end of the probe is all that is normally required Hold the bavonet connection when attaching or removing the probes to the instrument Page 10 of 20 GasCheck R Manual V1 6 lon Science Ltd 4 OPERATION Having assured that the instrument is fitted with the correct probe familiarise yourself with key operation described below 4 1 Control buttons E3 S J Refer also to Figure 4 overleaf for key operation The display panel is described in Section 4 2 2 POWER 1 Press this key to switch the GasCheck R2 on and off The instrument will be operable after between 15 and 120 seconds depending on when the instrument was last used and background contaminants in the air Ideally the instrument should be plugged into the battery charger when not in use This ensures that the sensor is retained in a stabilised condition ready for use ZERO 2 Press zero to re zero
13. ick will be heard on the audio every 10 seconds or so When the sample drawn into the detector contains traces of refrigerant gas then this will be displayed and the audio tick will rapidly increase in frequency The maximum response of the instrument relative to the previously registered background is converted into a leak measurement of either ppm as registered within the instrument or gm yr adjusted for the instrumental rate of sample gas intake Page 3 of 20 GasCheck R Manual V1 6 lon Science Ltd In Roaming Mode the sign leading the bar graph in the left hand side of the display will be seen to flicker on and off occasionally This indicates that the detector response to background gas is continuing to decrease and that the instrument is therefore re zeroing It will be particularly observed on power up and when the instrument is removed from a gas leak 1 4 Applications You can use the GasCheck R2 on many types of applications including those listed below e Manufacturing quality assurance testing on manufactured component seals e Industrial the detection of leaks from gas installations in cylinder receiving rooms from pipe assemblies and flanges the detection of leaks from stored gases in drums and vessels e Medical the detection of leaks from anaesthetic gas bottles pipe conduit and the integrity testing of membrane materials glove boxes 1 Probe 4 Key pad 2 Display 5 Power socket 3 LED flasher 6 Lo
14. io Fixed volume variable frequency blip from internal piezo speaker at rear of unit Visual Ten segment bar graph and direct reading with exponent and units on LCD display Indicators Flashing LED red light alert on keypad panel Alarm The alarm warbles at 15g year 0 5 oz per year The audio sounder and a flashing LED indicator are activated in positive response of the gas sensor and upon pressing operation keys Page 8 of 20 GasCheck R Manual V1 6 lon Science Ltd 3 I NSTALLATI ON Remove all packaging materials then open the storage case and inspect the equipment If the storage case or any other item is damaged notify your supplier and the carrier in writing within three days state the Item Number and the Serial Number stamped on rear case of the GasCheck together with your order number and your supplier s invoice number Do not use the GasCheck 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 Description Check GasCheck R2 Mk2 Long probe Spare battery holder with 4 batteries l 8 Power plug if ordered Table 3 Checklist of items in the storage case 1 Long probe 3 Spare battery holder 2 GasCheck R2 4 Power plug if ordered Figure 3 Items in the storage case Page 9 of 20 GasCheck R Manual V1 6 lon Science Ltd Open the stora
15. obe to the GasCheck refer to Section 4 4 9 Place the GasCheck and the long probe separately in the storage case Store the case in suitable conditions refer to Section 6 1 Page 15 of 20 GasCheck R Manual V1 6 lon Science Ltd 5 2 Replacing the batteries WARNING Replace the batteries in the GasCheck R2 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 lon Science Recommended parts for the rechargeable batteries The recommended batteries are specified in section 2 3 Battery Data Note A spare battery holder is supplied with the GasCheck Use of rechargeable batteries reduces effort 1 Refer to Figure 6 Turn over the Gas Check so that the battery compartment is at the top see detail A 1 Catch 3 Battery compartment 2 Battery compartment cover 4 Serial number Figure 6 Replace the batteries 2 Usea small coin screwdriver or your fingernail to press the catch 1 on the battery compartment cover 2 then pull up and remove the cover see detail B 3 Remove the battery holder from the GasCheck If required you can carefully unplug the battery holder so that you can detach the holder from the GasCheck 4 Remove the old batteries 4 from the battery holder Dispose of the batteries see section 6 2 5 Inspect the inside of the battery compartment and battery holder If the batteries have leaked use a cloth dampened with a weak soluti
16. of 100 gm mol 1 ppm 8 6 x 10 g yr PEAK MODE 6 This key activates Peak Mode enabling a measurement of leak rate On pressing the key the instrument enters 4 sequential states State Description Display 1 Zeroes instrument as per Zero key Sequential bars 2 Seek response Flashing Peak icon 3 Peak measurement retain probe at leak As 2 with changing bar display location and audio signal 4 Register peak Fixed bar display Peak icon Page 11 of 20 GasCheck R Manual V1 6 lon Science Ltd Note that key operation is only possible in Peak Mode states 2 and 4 Upon the sequence Peak mode state 4 Roaming mode Peak mode the reading obtained in state 4 is recovered In Peak mode the Peak mode key is only active in state 4 causing a return to state 1 Finally note that the audio output reproduces the actively detected signal even when the signal falls below the stored peak hold value 1 Power Lt 2 Zero 3 Roaming Mode t2 4 2 Display 4 2 1 General GAS CHECK R2 f 4 Gas 1234 1234 5 ppm gm year 6 Peak Mode Figure 5 Control keys for Gas Check R2 The display indicates the leak rate and instrumental status including user changes to the settings The upper portion of the display is allocated for representation of the leak rate by incremental bars see Section 4 2 2 Instrumental status appears in the lower portion see se
17. on of detergent to clean the battery compartment and battery holder Page 16 of 20 GasCheck R Manual V1 6 lon Science Ltd 6 Fit four new batteries in the battery holder Ensure that you fit the batteries in the correct orientation To reduce the risks of incorrectly connecting the battery clip remove one battery before you refit the battery holder to the GasCheck You then add the fourth battery into the clip before pushing it home 7 Refit the battery compartment cover 2 and ensure that the catch 1 is engaged Switch on the Gas Check If the display remains blank when you switch on the GasCheck refer to section 5 3 5 3 Battery Charging Battery charging can be carried out with the instrument turned on or off If the instrument is turned off upon plugging the battery charger into the instrument display will illuminate indicating the progressive degree of battery charging that has taken place If the batteries are severely depleted the sensor circuitry is automatically switched off to ensure maximum charging capability It is recommended instead to routinely attach the battery charger whereupon the instrument is automatically trickled charged whilst maintaining the sensor in an activated condition ready for immediate use when the charger is removed 5 4 Fault finding Fault symptom Diagnosis Action Unit will not switch on No dead batteries fitted Try another battery set safely Unit will not
18. the instrument due to a drift in background response incurred for example on relocating the instrument from one room to another In Peak mode pressing the zero button will return the instrument to State 1 In Roaming mode the instrument display is immediately zeroed to the registered instrument response ROAMING MODE and TOGGLE 3 This is a mode key allowing for dynamic and continuous instrument response in search of leaks or location of emissions of the target gas From Peak mode activation of this key enters the instrument into either the high or low sensitivity setting previously selected Additional key presses toggle between high and low sensitivity as indicated by the instrument display showing L or H The sensitivity changes by a factor of 16 between H and L ranges GAS 1234 SELECTION 4 Operable only in Peak mode Use this to change the Gas Group setting The most recently used gas group setting is recovered on power up See Table 4 for Gas Group selection ppm gm yr TOGGLE 5 Operable only in Peak mode Use this to switch between ppm and gm year settings when needed The default is gm yr and is not displayed only ppm is displayed when active When Peak Mode is recovered by turning the instrument on or pressing the Peak Mode key the most recently selected units ppm or gm yr are recovered The instrument s calibrated responses are referenced to ppm of gases Conversions are then made to gm yr assuming a molecular weight
19. udspeaker Figure 1 The GasCheck R2 Mk2 Page 4 of 20 GasCheck R Manual V1 6 lon Science Ltd 1 5 For optimum instrument performance If instrument is to be used for ultimate noise free leak detection then the following is recommended When not in use it is the instrument should remain plugged into the mains adapter with the instrument switched off This is recommended as it applies constant power to the sensor to keep it in a clean state and ready for immediate use If the instrument is stored with the batteries removed or not plugged into a mains adapter with power applied for a length of time then it is recommended that the instrument be put on permanent charge as above for a period of time prior to use The recommended time would be hours to days in the off state if stored in heavily contaminated environment else can be foreshortened as the need dictates Therefore if the instrument is left in the off state for 7 days then charge for 7 hours If it is left for 50 days charge for 50 hours 2 TECHNI CAL DATA 2 1 General Operating temperature range GasCheck R2 0 to 50 C 32 to 122 F Storage temperature range 25 to 70 C 13 to 158 F Materials of construction Storage case PPE polyester foam insert GasCheck R2 Polyurethane casing Dimensions Storage case 420 x 320 x 97 mm 16 5 x 12 5 x 3 75 GasCheck R2 see Figure 2 Mass Including storage case 1 6 kg 3 5 Ib GasCheck R2 0 5 kg 1 0 Ib Ingress ratings
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