Gasman

Personal Gas Monitor

User Manual

M07630
October 2008
Issue 7
Safety information:
• Read and understand all instructions
in the operation section of this manual
before use.
• Do not substitute components as this may
impair intrinsic safety and invalidate war-
ranty.
• Observe all warnings and instructions
marked on the unit and within this
manual.
• Observe site health and safety procedures
for gases being monitored and evacua-
tion procedures.
2. The equipment may be used in Zones 1
• Make sure you understand the screen
and 2 for flammable versions and Zones 0,
display and alarm warnings.
1, and 2 for toxic and oxygen versions, for
• If this product is not working properly, Group IIA, IIB, and IIC gases and vapours
read the troubleshooting guide or call for Temperature Classes T1, T2, T3 and T4
Crowcon.
3. The equipment is certified for use in
• Ensure qualified service personnel change ambient temperatures in the range –20°C
sensors and operating system. to +65°C (-4 to +149 F). The equipment
• Ensure maintenance and calibration are should not be used outside these ranges.
carried out in accordance with the proce- 4. Compliance with the Essential Health and
dures in the manual. Safety Requirements has been assured
by compliance with EN60079-0:2004
Instructions specific for use in hazardous + Amds 1 & 2, EN60079-1:2004 and
areas EN60079-11:2006, as certified by Baseefa.
The following instructions apply to equipment Compliance with gas detection perform-
covered by certificate number: ance standards EN50054, EN50057,
EN61779-1, EN50104 and EN50270 has
Baseefa04ATEX0383 Flammable Gas been certified by Lloyd’s Register.
Baseefa04ATEX0384 Oxygen or Toxic Gas 5. Repair of this equipment and gas sensor
The following information covers all relevant replacement shall be carried out by the
points listed in clause 1.0.6 of the EHSR’s of manufacturer or in accordance with the
the ATEX directive. applicable code of practice.
1. The certification marking is as follows: 6. If the equipment is likely to come into
contact with aggressive substances, then it
is the responsibility of the user to take suit-
able precautions that prevent it from being
adversely affected, thus ensuring that the
type of protection is not compromised.
7. The rechargeable battery must only be
charged in non-hazardous (safe) areas
by connection to the specified Crowcon
charger.
8. Only the following cell types may be fit-
ted in the battery compartment of the
non-rechargeable battery pack: CR2 of
the following brands only: Panasonic, GP,
Energiser and Maxell. Do not fit a Duracell
battery
 The cells must only be changed in a © Copyright Crowcon Detection Instruments
non-hazardous (safe) area. Ltd 2008.
9. The equipment is not certified for use in All rights are reserved. No part of the docu-
atmospheres containing more than 21% ment may be photocopied, reproduced, or
oxygen. translated to another language without the
prior written consent of Crowcon Detection
Area Classifications: - Instruments Ltd.
Zone 1: An area classified as Zone 1 is likely Publication number: M07630
to have ignitable concentrations of Seventh edition: October 2008
flammable gases, vapours or liquids
present under normal operating
conditions.
Zone 2: An area classified as Zone 2 is not
likely to have ignitable concentra-
tions of flammable gases, vapours
or liquids present under normal
operating conditions.

Crowcon Detection Instruments Ltd

2 Blacklands Way, Abingdon
OX14 1DY UK
Tel. +44 (0)1235 557700
Fax. +44 (0)1235 557749
www.crowcon.com
Email: [email protected]
Gasman
Personal Gas Monitor

Contents
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Quickstart guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Alarm indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fixing accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Flow sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance and calibration. . . . . . . . . . . . . . . . . . . . . 22
PC interface and software. . . . . . . . . . . . . . . . . . . . . . . 24
i-module replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Accessories and spare parts . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . 31
Appendix: Limitations of sensors. . . . . . . . . . . . . . . . . . 32
Gasman Unpacking

Gasman
Personal Gas Monitor
Thank you for purchasing the new Gasman Personal Gas Monitor.
Gasman has redefined portable gas monitoring and will give you years
of unparalleled service and reliability.

Please read the instructions carefully before use. Keep the manual for
future reference.

Unpacking
Remove the Gasman Personal Gas Monitor from the packaging. The
Gasman accessories will be located in the bottom of the box. Check the
contents are complete, you should have:
• Gasman unit with standard pocket clip;
• A configuration report detailing the sensor installed, alarm
settings and a calibration certificate;
• Calibration flow cap and tubing;
• User manual.
Optional battery chargers and other accessories will be packed in a
separate box.

Gasman units ordered with an Alligator clip will receive this clip in place
of the standard pocket clip.

Battery check
The Gasman Personal Gas Monitor has two battery options: Li-ion
rechargeable or non-rechargeable batteries.

Rechargeable units
Gasman uses a Li-ion battery pack and should arrive with sufficient
charge so that the unit can be used straight out the box. However, if
this is the first time you have used the Gasman unit, you may need to
charge the battery to attain the full operating time. (The actual operat-
ing time will depend on the types of sensor installed.) The flammable
Gasman will operate for at least 12 hours on a fully charged battery

Unpacking Gasman

Warning: rechargeable units

Do not attempt to recharge the rechargeable battery with any other
charger other than the Crowcon charger supplied with this unit. Failure
to comply could invalidate safety certification and may result in perma-
nent damage to the unit.

Non-rechargeable units.
Gasman uses a CR2 battery which can be easily field replaced. Ensure
only the correct types of battery are fitted to maintain compliance with
certification.

Gasman IR CO2 Personal Detector

The Gasman IR CO2 personal detector uses a newly developed i-module
with an infrared gas sensor for CO2 detection. This version of Gasman is
not designed or certified for use in a hazardous area, and the safety cer-
tification data in Section X is non applicable. Operation and maintenance
of the Gasman IR CO2 is essentially the same as for other Gasman units
but with the following points to note.

CO2 is present in ambient air at a background concentration of just under 400ppm. In any
enclosed environment the ambient CO2 concentration will increase as a result of respiration and
if the room is poorly ventilated concentrations well in excess of 1000ppm (0.1%) can occur. CO2
levels in the outdoor air will also be enhanced by any emitted CO2 e.g. from vehicle exhausts or
boiler flues venting to atmosphere so it is normal to see fluctuating levels of CO2 on the display
whether indoors or outside.


Gasman Quickstart guide

Quickstart guide

1. Getting started
Review your Gasman unit

Gas
name
label Alarm
Gas LEDs
Sensor

Sounder
outlet

Operator Operator LCD

Button Display Screen

Switching on your unit

Gasman requires little setting up, follow these simple steps to get your
unit ready for use.
1. Ensure the unit is in clean air.
2. Switch on
Press and hold the operator button for H 2S

approximately 3 seconds until the red LEDs

flash.
The operator display screen will light up and
the unit will begin a warm up sequence.


Quickstart guide Gasman

Gasman warm up sequence LEDs Alarm test

a) The unit will test the alarm

Sounder
LEDs, sounder, vibration alerts, Alarm test H2S

and the operator display

screen. The sounder may
be silenced by pressing the
button. Vibrator Alarm test

b) The unit will continue through a warm up sequence as shown

below, this will take approximately 20 seconds.

0.0 OK
ppb
ppm ppm
vv/v

c) Autozero
If Autozero is enabled (default), the unit will display the Autozero
confirm screen: the display will alternate between ‘ZERO’ and
‘????’. Press the operator button with a single click to confirm
Zero. If the operator button is not pressed within the 10 second
time out, Gasman will proceed directly to Run mode without
performing Zero.
Autozero confirm Screen Icons
OK OK Warm up

OK Flashing
icon,
Gasman
No Autozero running
normally
OK
ppm AL - 1
Alarms
AL - 2
Battery

Run mode
Your unit is now ready to use. 0.0 Autozero
Familiarise yourself with the gas being
monitored in your unit and make sure you understand site health
and safety procedures in the event of alarm conditions.


Gasman Quickstart guide

Confidence signals
In normal Run mode, Gasman will emit a short beep accompanied by a blue LED flash every 10
seconds and the OK icon flashes to show operational health. These confidence signals can be
disabled using the PC software.

2. In the event of an alarm

Alarm signals
In the event of gas concentrations exceeding the alarm thresholds for the
gas being monitored, Gasman will activate the alarm signals.
Alarm signals
The red and blue alarm LEDs
will flash, the sounder will emit
a loud, fast series of beeps, the
H 2S
ppm
internal vibrator alarm will activate.
The operator screen will display
the alarm level and gas reading
alternately.
See the figure to the left.
AL - 1 — Alarm level one
AL - 2 — Alarm level two

1. When the gas level returns to normal, press the operator button.
This will reset your Gasman unit to normal Run mode. If the gas
level is still in alarm, the button will have no effect.

The Gasman alarm is set to latch by default. The unit will still continue in alarm mode even
when the gas level returns to normal, pressing the operator button will clear the alarm.

3. Switch off unit and storage

Switching off unit
1. Press and hold the button for 5 seconds until the display shows
OFF. The display will count down to switch off.


Quickstart guide Gasman

Storing conditions
In order to optimise sensor performance and lifetime, your Gasman unit
should be stored in a safe, non-hazardous area, 0-30°C, 10-90%RH.

4. Additional information
For battery recharging information go to section III.

For fixing accessories go to section V.

For sampling section go to section VI.

For calibration information go to section VII.

For troubleshooting guide go to section XII.


Gasman Introduction

I. Introduction
Thank you for purchasing the new Gasman Personal Monitor. Gasman is a
portable single gas detector, designed to be carried or worn by individuals
working in hazardous environments such as confined spaces. It is suit-
able for use in classified hazardous areas. Gasman monitors a single gas
and displays the reading on a display screen. Alarm warnings are given
through a combination of a loud audible alarm, a bright visual alarm of
blue/red flashing LEDs and an internal vibrator. Gasman can be fitted with
a wide range of modular, plug and play gas sensors. The sensor carries an
intelligent processor which contains calibration and sensor information.
Gasman is battery operated and is available with rechargeable batteries
or dry cell battery options. The dry cell battery option is only available for
toxics and oxygen Gasman units. A battery charger for single and multiple
Gasman units is available for rechargeable units, see section XI for more
information.
At Crowcon we recognised the need for a reliable and robust personal
monitoring system, which is both small, light and easy to use. Gasman
has a single operator button, and an intelligent user-friendly display with
automatic backlight. The gas level is continuously monitored providing
normal gas readings, peak readings and time weighted averages (TWA).
Gasman is available as a diffusion sampling instrument, see section XI for
sampling accessories. Configuration and data/event logging is handled by
Crowcon Portables PC software, the PC communication link is provided
as a link on the charger unit.
Gasman’s compact shape and design makes it comfortable to wear and
as non-intrusive as possible, with a non-slip grip for better handling. Extra
accessories, such as pocket clip, hard hat clip, alligator clip, shoulder strap
and chest harness, can be purchased.
Gasman has been designed from top to bottom to bring you a lighter,
compact design with single button operation for ease of use, mainte-
nance and extreme reliability. Through innovative and rigorous design
technology, we have introduced several new features.


Introduction Gasman

i-module gas sensor

Gasman uses unique plug and play i-module sensor technology. Each sen-
sor unit incorporates its own intelligent processor holding sensor configu-
ration and calibration data. Different sensors can be purchased, and once
inserted, are immediately ready to run. Flammable units are only available
with rechargeable batteries. Plug and play will ease maintenance time and
cost, and the intelligent modular system will remove the need to calibrate
the sensor. Gasman can be reconfigured by purchasing additional pre-
calibrated i-modules from your local supplier.

Reliable, anti-shock mechanics and robust housing

The Gasman housing is built from resilient material, giving it strength and
flexibility to withstand the hardest of working conditions, water and dust
tight to IP65 and IP67, with a non-slip grip. If the unit is dropped, there
will be no disruption of power or function, ensuring reliability and service
for years to come.

Software
The internal software in Gasman has been designed and written in accord-
ance with the requirement of IEC 61508 to ensure quality and integrity
of operation. Gasman has been designed to give a truly reliable personal
gas monitoring system. The internal circuitry includes an independant
watchdog, the software monitors for any malfunction within the unit and
will display an error warning to the user should they occur.


Gasman Operation

II. Operation
2.1 Switch-on sequence
1. Ensure the unit is in clean air.
NB. For CO2 detectors see zeroing, Section VII.
2. Switch on
Press and hold the operator button for approximately 3 seconds
until the red LEDs flash.
The instrument begins with testing all the LCD segments on the
operator display screen, the red and blue alarm LEDs, sounder and
internal vibrator alert. The sounder may be silenced by pressing the
button. The unit enters a warm up mode and displays a sequence
of screens, see page 3 for more details. At the end of warm up,
the Autozero menu will be displayed.
The Autozero function can be disabled Battery check
or set to run automatically, without user
confirmation: Autozero will not appear.
! Use this time to check there
is sufficient charge in the bat-
See section VIII PC Interface and software. tery pack

Calibration check
During the warm up sequence, if the next calibration date is due in less than 31 days,
‘CAL - nn’ will be displayed, where nn is the number of days to the next calibration.
If the date has expired, the Gasman unit will display a warning message ‘CAL’. The
instrument can still function, but it is strongly recommended the unit is sent for
calibration as soon as possible.
Press the button to continue to Run mode.
Gasman can be set, using the Portables PC software, for the instrument to lock in the
event of the calibration date expiring, to prevent further operation of the instrument.

3. Autozero
Press the operator button with a single click to NB. If Autozero
confirm Autozero. Flammable and toxic units will fails, a warning
be set to read zero, and oxygen units set to read message will be
20.9%. If the operator button is not pressed within displayed.
10 seconds Gasman will proceed directly to normal
operation without performing a zero.
Switch off
To switch off the unit, press and hold the operator button for 5

Operation Gasman

seconds. The display will count down from 5, continue to hold the
button until the unit counts down to shut off.

2.2 Run mode

The Gasman unit displays the gas reading on the operator display screen.
A typical display is shown below:
Screen Icons
OK
ppm
Warm up

OK Flashing
icon,
Gasman
running
normally
The sensor channel will display the current value of the AL - 1
gas being monitored and units of measurement, the Alarms
AL - 2
‘OK’ symbol will flash indicating unit is working cor-
Battery
rectly. Familiarise yourself with the gas currently being
monitored in your unit. Ensure you understand site
health and safety procedures. For information on Peak
0.0 Autozero
and TWA readings, go to section 2.4.
Confidence signals
To reassure users the unit is working correctly, the Gasman unit will
emit a short beep accompanied by a blue LED flash every 10 seconds
and the OK icon will flash.

2.3 Display symbol guide

Battery
A full battery is represented by a battery icon showing
Full
a full three bars. A low battery charge will show 1 bar.

! When zero bars are shown the battery icon flashes and the
sounder will emit warning bleeps.
If the battery becomes too low, Gasman will switch off.

TWA alarm
Gasman will display the TWA alarm when the 15 minute or 8 hour time
weighted average alarm threshold is passed for toxic gases.
Gasman will display ‘LTWA’ and ‘STWA’. TWA alarms cannot be cleared.

10
Gasman Operation

2.4 Display options

Gasman provides four additional selectable displays:
Peak display
When Peak mode is selected the instrument shows the
highest value for flammable and toxic gases, or the lowest
value for oxygen since switch on or last Peak Reset. This is
useful for vertical entry checks where the whole instrument
can be lowered down the shaft rather than using a sampling
tube and for viewing peak exposure at the end of a shift.
TWA display
Shows the 15 minute or 8 hour time weighted average
(TWA), for toxic gases, monitored since last turn on.
Peak Reset
Before a Peak entry test is performed select this menu
option to clear any previously stored Peak value.

Zero
0.0 Performs Zero on your Gasman unit.

How to display the menu

1. To view the additional display Option menu, double-click the operator
button. The menu icons will appear on the screen, as shown.

0.0 OK Note: Only

ppm
instruments for toxic
H 2S gas monitoring will
display the TWA
0.0 OK
ppm

menu option.

2. Press the operator button with a single click to scroll across the
list. When the underscore appears under your choice, double-click
the operator button.
If Peak or TWA is selected, Gasman will display the icon on the
operator screen.
11
Operation Gasman

Peak test
When performing a Peak test, such as a vertical entry check,
previous readings can be cleared by selecting the Peak Reset menu
option .
1. Scroll 2. Select
Peak display
0.0 OK OK
ppm ppm

Zero
To perform Autozero, select the Zero function from the menu.
When Zero is completed, the instrument will return to normal Run
mode.

2.4 Logging
Gasman incorporates both data and event logging which can be
accessed using the RS232 communications link available with the
Single Way Charger Plus PC Interface (part No.C01940), using Crowcon
Portables PC software. See section VIII.

Data is recorded every minute (this rate can be adjusted using the PC
software). The log can record 900 hours of data at 1-minute intervals.

Gasman also records the time and date for a number of operating and
diagnostic events including:
• Switch on and switch off;
• Level 1, Level 2 and Time Weighted Average Alarms (TWA),
alarm on, alarm off and the peak level during the alarm;
• Zero, calibration and gas test with success or failure;
• Flammable sensor saver on and off;
• The battery condition is logged every switch on and switch off
while the instrument is operating, and certain configuration
changes are also logged;
• The Event log can record over 4800 events.

12
Gasman Batteries

III. Batteries

3.1 Rechargeable batteries

Recharge time for the Li-ion batteries is less then 6 hours (less, if they are
not fully discharged). Rechargeable batteries will typically last 12+ hours
for flammable units.

3.2 Gasman Charging Unit

There are 3 models of charging units available for Gasman; a sin-
gle way drop in charger unit, a single way charger unit with integral
PC Interface, and a multiway charger unit. The multiway charger unit
can accommodate up to 5 Gasman units. Note: the multiway charger
unit does not have a PC interface option.

The charger units are powered by a nominal 12 V dc input. Power

Supplies are available with UK, EUR or US pins, alternately a universal 90-
260 V power supply is available for any other configuration. The multiway
charger includes a universal power supply. A vehicle lighter socket lead
can also be supplied, please see section XI Parts and Accessories.

As a condition of certification, charging voltages must be limited to less

than 9 V. Communications are only permitted via Crowcon charger-inter-
face C01940.

Charging the batteries

1. Ensure you are in a safe area.
2. Plug the charger power supply into a mains socket, and connect to
the charger
H 2S

Power
Supply

Green LED
Red LED
charging
unit charging
complete
12 V dc

13
Batteries Gasman

3. To charge your Gasman unit, simply drop the Gasman into the
charger in an upright position with the screen facing outwards,
see diagram below:
The Gasman would normally be left switched off for charging.
During charging the red LED on the front of the charger unit will
be lit. When charging is complete the red LED is extinguished.
(Early units had a green LED illuminate on completion of charge).
During charging, the display will show the battery icon sweeping
from empty to full. (Early units only show this when the instrument
Is switched on.) On removing Gasman from the charger unit, if the
Gasman is on, the display icon will update in 20 seconds to show
actual charge state.

The charging time will be longer if the unit is switched on during charging.

When Gasman is fully charged and switched on the battery icon

will display three full segments.

Changing rechargeable batteries

It is recommended that rechargeable batteries should be changed by an
authorised Crowcon service centre.

3.3 Non-rechargeable batteries

Gasman uses a Lithium Cell battery pack which will give up to two years
of operation.

Always switch the Gasman off before opening the case to change the battery.

To replace the battery pack, ensure you are in a safe, non-hazardous area.
Remove the back cover and remove the battery pack. Replace the Lithium
Cell, then reinsert the battery into the instrument and replace and securely
fasten the back cover.

14
Gasman Alarm indications

IV. Alarm indications

Gasman provides two instantaneous alarm levels, designated level 1 and
level 2. For toxic gas sensors, there are also two time weighted average
alarms (TWA), one for short term exposure (STEL): based on a 15 minute
time weighted average, and the second TWA alarm is for long term expo-
sure: based on a 8 hour time weighted average.
Alarm configurations are set via the Crowcon Portables PC software.
The following settings can be made:

Alarm thresholds for each sensor: Level 1 and

level 2 alarms can be set for the gas sensor.
Alarm trigger: This can be set to rising levels of gas
concentration, or as falling. Oxygen units are set to falling for defi-
ciency monitoring.
Alarm latching: Alarms can be set to be latched or unlatched.
Latched alarms will require the operator button to be pressed in
order to clear the alarm. This is the default setting. Unlatched
alarms will clear automatically when the gas hazard has passed.
Alarm mute: The sounder can be set to mute for level 1 alarm
only; pressing the operator button during an alarm condition i.e.
presence of hazardous gas, will silence the sounder and stop the
vibration alarm. The alarm LEDs will continue to flash.
Alarm sounder tone: Different distinctive tones can be selected
for the each alarm condition to achieve the best performance for
the monitoring conditions available.
In the event of a Time Weighted Alarm (TWA)
In the event the 15 minute or the 8 hour TWA is triggered,
Gasman will go into alarm and display a TWA warning with
the toxic gas readings. The 8 hour TWA alarm cannot be
cleared.

15
Alarm indications Gasman

In the event of a Flammable overange alarm

If flammable gas concentrations exceed 100% LEL
Gasman locks into alarm and displays ‘9999’ showing
an overange condition. Gasman will temporarily cut off
power to the sensor to prevent burn out and display a progress bar for
200 seconds. When the timeout is complete, either press the button to
continue or optionally switch your unit off and on to restart. This option
is programmable with Crowcon Portables PC software.

16
Gasman Fixing Accessories

V. Fixing Accessories

Clip Accessories
Gasman is supplied with a simple pocket clip, other clip options are:

Hard hat clip

Allows Gasman to be clipped to a hard hat, a method of wearing a port-
able gas detector preferred by many users.

Alligator clip
A strong alligator clip allowing the user to wear Gasman on a belt, sleave,
jacket lapel etc.

Universal harness plate

Crowcon provide a universal harness plate which can be used with either
a chest harness or a shoulder strap.

How to wear your Gasman unit

Chest harness
Shoulder/neck
Use the M3 fixing on the back connectors
of your Gasman unit to attach
the chest harness plate. Create
M3 nut
a chest harness by attaching one
strap to the top connectors, to go Waist
connectors
around the neck, and the other
to link around the waist using
the side connectors. Adjust the
lengths until the Gasman unit is in
a comfortable working position.
Chest harness plate
Shoulder strap
With the universal harness plate in place on the belt clip, attach the
shoulder strap accessory onto the top connectors. Adjust to a comfortable
working position.
See accessories, section XI, for full list.
17
Flow sampling Gasman

VI. Flow sampling

Attaching the flow cap

To perform manual sampling using Gasman, a flow cap must be fitted
onto the front of the unit, over the sensor. A flow cap is included with
your Gasman unit.

1. To fit the flow cap, slip the flow cap over the sensor on the front
of your Gasman unit, until the cap is tightly fitted into place.
2. Attach the sampling tube or flow accessory onto the gas inlet
nozzle.
3. Attach the aspirator bulb onto the gas outlet nozzle.
4. To remove the flow cap, gently tease the cap from the sensor and
lift the cap away from the instrument.
When using the manual aspirator kit, adopt a consistent style whilst using
the hand aspirator. Crowcon recommend squeezing once per second to
achieve a flow rate of approximately 0.5 - 1 litre/min. At least 10 pumps
per sample are recommended.
The sampling tube supplied is normally a 2m (6ft) length. Longer lengths of sampling tube
can be provided, but will increase the time taken to get a sample from the point of sampling
to the Gasman instrument. When using an extended length of tubing a response time test is
recommended. Gas of known concentration should be sampled along the full length of tubing
to be used and the time taken for the sensor reading to reach the known gas levels should be
noted. This time should be used as the minimum for sampling before readings should be taken.

18
Gasman Gasman gas test accessory kit

Gasman gas test accessory kit

The Gas Test Accessory is a gas testing kit designed to enable gas testing
and one button calibration of your Gasman gas detector using a specially
formulated, high stability long life single gas mix. It can be used with
Gasman units having sensors for Flammable, Oxygen, Carbon Monoxide
and Hydrogen Sulphide gases.

6.1 Gas testing

Gas testing checks the sensor is responding within set limits to an applied
gas of known composition. This can be performed as often as desired, but
would usually be carried out each time the Gasman is issued for use. The
Gasman itself will determine Pass/Fail status for the gas test.
In order to perform successful gas tests ensure:
• The gas used has the correct gas concentration, and that it is
within the validity date specified by the supplier.
• The gas flow path is leak tight. It is important to check that the
flow cap is properly fitted to the Gasman unit, and the outlet
tubing is not restricted in any way, nor additional tubing length
used.
The Gas Test Accessory Kit comprises a gas cylinder containing the gas, a
'Trigger' regulator with interconnect tubing, a magnet - used to activate
Test mode, a flow cap to attach to the Gasman, and a vent line. The kit is
supplied in a convenient carry case. The Trigger regulator can be operated
in two ways: (1) squeeze and hold - allows gas flow as long as the lever is
held in, or (2) by lifting the lever - the flow is locked on.

6.2 How to perform a gas test

1. Ensure your Gasman unit is switched on and in normal operation.
2. Fit the flow cap onto the front of the sensor and attach the hose
from the Trigger regulator.
Attach the outlet hose to ‘vent gas away’ - do not extend this
hose and do not restrict or allow kinks.
3. Touch the magnet, vertically aligned onto the case, to the left
hand side of the display. Your Gasman unit will activate the Gas
Test and show ‘TEST’ on the display.
19
Gasman gas test accessory kit Gasman

4. Gasman will display a progress bar. Apply the gas whilst the
progress bar is counting down.
Gasman will display ‘PASS’ or ‘FAIL’
In the event Gasman displays ‘FAIL’, please see the troubleshooting
guide in the first instance or contact Crowcon.
5. To abort the gas test press the button at any time whilst the test is
in progress.

6.3 How to perform a one button

calibration test
To perform a one button calibration test, you must first perform a Zero
on your Gasman unit.
1. Ensure you are in clean air.
Double click the button and select Zero from the Options menu.
Gasman will perform a Zero.
To perform a one button Calibration, complete the next steps within 15
minutes of completing the Zero.
2. Follow steps 1 to 3 given in 6.2, Gasman will display ‘CAL’
and ‘????’ alternately. Press the button to confirm one button
Calibration.
If the button confirmation for calibration is not made within 10
seconds then the process will revert to test as in 6.2.
3. Apply calibration gas following step 4 in 6.2.
4. To abort the Calibration test press the button at any time whilst
the test is in progress.
Your Gasman unit will adjust the value for the gas channel to match the
stored calibration gas value within the sensor i-module.
If your Gasman unit does not calibrate successfully, Gasman will display
‘FAIL’. Your Gasman unit must be sent for re-calibration.
Gas Test ‘pass’ and ‘fail’, and calibration ‘pass’, ‘fail’ and values are stored
in the Event log.

20
Gasman Gasman gas test accessory kit

6.4 Gas test/calibration troubleshooting

Symptom Possible Cause Action

No response to gas Gas cylinder empty Check gauge, replace
cylinder as needed
Hose blocked or kinked Ensure no restriction to
flow
Gasman fails gas Gas cylinder empty Check gauge, replace
test cylinder as needed
Gas cylinder out of date Check date and replace as
needed
Hose blocked or kinked Ensure no restriction to
flow
Calibration drifted Calibrate Gasman
Gas flow not started Repeat test, starting gas
immediately immediately
Gasman fails Gas cylinder empty Check gauge replace
calibration bottle as needed
Gas cylinder out of date Check date and replace as
needed
Hose blocked or kinked Ensure no restriction to
flow
Calibration drifted Calibrate Gasman
Stabilisation time too short Reset using PC software
Gasman passes gas Menu Zero not performed Select Zero from menu
test but will not Gasman not field calibration Send for re-configuration
enter calibration version
mode

Note: Remove regulator from gas cylinder when not in use over a pro-
longed period.
For parts list, see section XI.
One button Calibration will check for small drifts of stored calibration
value, but Crowcon recommends Gasman is sent for full certified calibra-
tion at six monthly intervals.

21
Maintenance and Calibration Gasman

VII. Maintenance and Calibration

Gasman is designed to operate almost maintenance free under most
conditions. However, some small items of routine maintenance are rec-
ommended.

General
To keep the display panel and operator button free from dirt build up,
regularly wipe over your Gasman unit with a damp cloth.

Filter
Inspect the front filter at regular intervals for dirt or damage. Clean as
necessary.

Zero and calibration

Gasman is supplied with an Autozero function on start-up. This function
can be configured to operate automatically, on user confirmation (see
quick start guide), or can be disabled. This configuration can be set with
the Crowcon Portables PC software, see section VIII. Gasman also has a
Zero function in the menu. See section 2.4.
Crowcon recommends, as a minimum, a monthly gas test to confirm sen-
sor operation. A test gas of known composition, needs to be applied, to
verify sensor response and alarm function, see section 6.1.
Instrument calibration of sensor should be performed at 6 month regular
intervals.

Calibration method
Gasman calibration can be performed using the Gas Test Kit as per 6.3,
or with Crowcon Portables PC software and calibration gas mixtures.
Appropriate certified calibration gases should be used. Calibration gas is
applied using the appropriate flow cap. Refer to Crowcon Portables PC
software help file for further information.

22
Gasman Maintenance and Calibration

Gasman IR CO2 Personal Detector

A properly zeroed Gasman IR CO2 monitor will read 0.04% in uncontami-
nated ambient air.
Zeroing in air usually means going outside into clean air well away from
a building or any CO2 emissions, and holding the unit well away from the
breathing zone of the operator – i.e. at arm’s length. When Gasman IR CO2
is zeroed in fresh air it automatically sets the CO2 baseline level to 0.04%.
Gasman IR CO2 can also be set to zero in nitrogen using the PC interface
and Portables PC software. This is in effect a zero point calibration rather
than a normal zero. To do this, after uploading the instrument configura-
tion file, note the existing calibration gas level, then set the calibration
value to 0.00%, apply nitrogen gas and click the Calibrate button. After
this zero point calibration is completed remember to re-set the calibration
gas level to its previous level.
Nitrogen for zeroing should be provided from a suitable gas bottle at a
regulated flow of 0.5 l/min (1 SCFH), connected to the standard flow cap
clipped over the sensor aperture. Recommended calibration gas is 2%
CO2 in a background of nitrogen.
Care should be taken to vent the nitrogen flow away from the operator
and not allow nitrogen flow for longer than necessary to complete the
zeroing. If indoors it is recommended to vent gas out of a window or into
an extracted fume cupboard.

23
PC interface and software Gasman

VIII. PC interface and software

Gasman can be connected to a PC using the single way charger unit with
optional PC interface. The charger unit is fitted with a D-type 9 pin RS232
socket which is located at the rear of the charger, see diagram below. The
PC requires Crowcon Portables PC software. A USB-RS232 adaptor is also
available from Crowcon.

H2S

RS 232
link

The software provides the user with access to reconfigure alarm levels,
operation, run calibrations, print reports and to access data and event
log files.

Set-up
1. Install Portables PC software on PC and attach the RS 232 cable to
the charger and PC.
2. Switch on the Gasman unit and drop it into the charger unit
ensuring it is upright and the display is facing forward.
3. Open the Portables PC software and either use the Wizard or the
Engineer’s Form, select Gasman and upload the configuration.
For more information on using the Crowcon Portables PC software, see
installed help file.

24
Gasman i-module replacement

IX. i-module replacement

Installing or replacing an i-module

1. Ensure you are in a non-hazardous (safe) area, with suitable ESD
protection.
Switch off the unit
2. Remove the back cover by unscrewing the four M2.5, 12 mm Torx
screws as shown the in the drawing, point . Do not touch the
charging elastomer connector with your fingers.


i-module

3. Place the Gasman unit face down on a surface.

4. Unclip the i-module from its retaining support clip. Ease one side out
at a time. Ensure the elastomer which is retained within the body of
the support clip remains in place.
5. Unwrap the i-module from any packaging, ensure the sensor is
fully seated on the module board.

If replacing an i-module with one of the same type, instrument specific configuration will be
retained. If replacing with a different i-module its default configuration will be loaded.

25
i-module replacement Gasman

6. Ensure the gasket is in place on the sensor, slip the sensor onto
the sensor housing. Click the quick release fixings around the
i-module board, ensuring the i-module is held in place firmly and
the sensor is still tightly located on the module board.
7. Replace the back of the Gasman case.
8. Switch on the Gasman unit. The new i-module will be automatically
recognised.
9. Crowcon advise carrying out a calibration check when any new sensor
is fitted.

26
Gasman Specification

X. Specification
Dimensions 90 x 48 x 24 mm (31/2 x 1.9 x 1 inches)
Weight 130 g flammable
105 g oxygen
90 g toxic
Housing, degree of protection Ingress protection IP65 (NEMA 4) & IP67
Operating temperature -20°C to +55°C (-4°F to +131°F)
Humidity 0-99% RH, non-condensing for continuous
operation
Display Custom LCD with backlight. Starburst charac-
ters for number and text display, plus screen
icons for status and mode.
Warm up time 11/2 minute maximum
Response time (typical) (T90) : approx 20 seconds for most toxic and
flammable sensors, 10 seconds for oxygen.
Audible Alarms 95 dBA Multiple alarm sounds allow selection
of distinctive tones for different alarms.
Visible Alarms Dual colour red/blue flashing LEDs in gas hazard.
Vibrating Alarm Internal vibrating alarm.
Repeatability ±2% FSD, 6 months
Explosion protection Intrinsically Safe
ATEX Essential Health and Safety Requirement,
clause 15.9
Safety certificate no. BASEEFA04ATEX0383 Flammable Gas
BASEEFA04ATEX0384 Oxygen or Toxic Gas
IECEx IECExBAS05.0038 Flammable Gas
IECExBAS05.0039 Oxygen or Toxic Gas
Approval codes
Europe: ATEX II 1G Ex ia IIC T4, (Tamb -20°C to +65°C)
Toxic/Oxygen
ATEX II 2G Ex ia d IIC T4, (Tamb -20°C to +65°C)
Flammable
USA: Class I Division 1, Groups A, B, C and D
Canada: Class I Division 1, Groups A, B, C and D

27
Specification Gasman

Standards
Safety: EN60079-0, EN60079-1, EN60076-11, 94/9/EC
USA: UL913
Canada: CSA22.2, 152
Operation EN50270, EN50271, IEC61508, EN61779

28
Gasman Accessories and spare parts

XI. Accessories and spare parts

Accessory list
Crowcon
part number Description

Single way chargers

C01941 12 V DC input single way charger
C01942 Single way charger with 230 V UK style power supply
C01943 Single way charger with 230 V EUR style power supply
C01944 Single way charger with 110 V US style power supply
C01945 Single way charger with 90-260 V in line power supply
C01297 Vehicle lighter socket lead
C01940 Single Way Combined charger and PC interface
C01947 Single way charger/interface with 230 V UK style power supply
C01948 Single way charger/interface with 230 V EUR style power supply
C01949 Single way charger/interface with 110 V US style power supply
C01950 Single way charger/interface with 90-260 V in line power supply
Multiway charger
C01951 5 way Multicharger with 90-260 V in line power supply
i-modules:
S011424 0-100% LEL methane
S011436 0-100% LEL propane
S011437 0-100% LEL pentane
S011439 0-100% LEL butane
S011440 0-100% LEL ethylene
S011460 0-100% LEL hydrogen
S011423 0-25% oxygen
S011422 0-500 ppm carbon monoxide
S011421 0-100 ppm hydrogen sulphide
S011425 0-10 ppm sulphur dioxide
S011429 0-1000 ppm hydrogen
S011426 0-10 ppm nitrogen dioxide
S011428 0-5 ppm chlorine
S011432 0-1 ppm ozone
S011430 0-25 ppm hydrogen cyanide
29
Accessories and spare parts Gasman

S011435 0-100 ppm ammonia

S011438 0-1000 ppm ammonia
S011431 0-5 ppm phosphine
S011434 0-1 ppm fluorine
S011433 0-10 ppm hydrogen fluoride
S012015 Gasman IR CO2 i-module
Sampling accessories:
M02340 Alligator Clip
M04851 Flow cap
C01937 Aspirator Assembly
Calibration gas contact Crowcon
- required gases depend on sensor combination
Carrying and wearing:
C01952 Harness Plate
C01843 Shoulder Strap
C01844 Chest Harness Straps
C01953 Hard Hat Clip
Communications:
E07532 PC Interface Lead
C01832 PC Software
C02097 USB to RS232 adaptor
Spares / consumables:
M04856 Rear Moulding
M04973 Gasman IR CO2 Front and rear case assembly
C03329 Metal Clip
E01918 Disposable Battery
E07621 i-module Elastomer
E07620 LCD Elastomer
M04682 Sensor Sealing Ring
MO3705 Clip retaining nut M3
MO3793 Case screw
MO5910 Crowcon domed label
EO1535 Power supply for charger 230 V for UK only
EO1536 Power supply for charger 230 V for EUR only
EO1537 Power supply for charger 110 V for USA only
E01552 Power Supply for charger - 230 V No plug
E01553 Power Supply for charger - 115 V No plug
CO1979 Power supply for charger Universal 90-260 V
30
Gasman Troubleshooting guide

XII. Troubleshooting guide

Symptom/ Cause Action

error message
Instrument won't switch on Flat battery Recharge or replace battery.
No confidence beep Function disabled Reconfigure with PC software.
Gas reading when no gas Zero drifted Restart instrument in clean
present air.
Unstable/inaccurate gas Sensor failure Do not use; exit hazardous
reading area immediately. Return
instrument for recalibration
or sensor replacement.
Autozero failed Zeroing in Switch off and restart in
contaminated clean air.
atmosphere
Cannot Autozero due to Zeroing in Switch off and restart in
alarm contaminated clean air.
atmosphere
Calibration expired The calibration Send for calibration.
due date has
passed
Display shows empty Battery depleted Charge or change as
battery symbol on appropriate.
switch on

31
Appendix: Limitations of sensors Gasman

Appendix: Limitations of sensors

Sensor limitations
The sensors used in Gasman have limitations common to all such gas
sensors, and users should be aware of the points listed below. Crowcon
can advise on particular situations and suggest alternative sensors if the
instrument is likely to experience extreme conditions.
Gasman Flammable uses a catalytic gas sensor, which measures the flam-
mability of the gas. For this reason, readings displayed on the unit will be
unreliable over concentrations of approximately 120% LEL. Oxygen is nec-
essary for catalytic sensors to operate. A 'pellistor saver' is used to discon-
nect power to the pellistor sensor in the event of over-range to prevent
burn out. This locks out for 200 seconds after which a button press will
reconnect power to the pellistor. If the sensor power is reconnected when
the unit is exposed to an over-range gas concentration there is a risk of
damage to the pellistor sensor. Restart should be carried out in a known
fresh air environment. Depleted oxygen levels can reduce the flammable
gas reading, and if oxygen levels are below safe breathing limits it should
be assumed that the flammable reading is low.
Electrochemical gas sensors, toxic gases or oxygen, contain chemicals.
Extreme levels of humidity can also cause problems. The sensors are rated
for an (average) ambient of 15-90% R.H. However they are used from the
tropics to deserts to tundra without this normally being a problem.
Water should not be allowed to collect on the sensor as this may impede
gas diffusion.
Persistent exposure to high levels of toxic gas will shorten the life of toxic
sensor. If the high level gas is corrosive (e.g. hydrogen sulphide) damage
may occur over time to metal components.
Sensors may be cross sensitive to other gases. If unsure, contact Crowcon
or your local agent.

32
UK Office USA Office
Crowcon Detection Instruments Ltd Crowcon Detection Instruments Ltd
2 Blacklands Way, 21 Kenton Lands Road,
Abingdon Business Park Erlanger,
Abingdon Kentucky 41018-1845
Oxfordshire OX14 1DY USA
United Kingdom Tel: +1 800 527 6926 or
Tel: +44 (0)1235 557700 1-800-5-CROWCON
Fax: +44 (0)1235 557749 +1 859 957 1039
Email: [email protected] Fax: +1 859 957 1044
Web site: www.crowcon.com Email: [email protected]
Web site: www.crowcon.com

Rotterdam Office Singapore Office

Crowcon Detection Instruments Ltd Crowcon Detection Instruments Ltd
Vlambloem 129 Block 194 Pandan Loop
3068JG, Rotterdam #06-20 Pantech Industrial Complex
Netherlands Singapore 128383
Tel: +31 10 421 1232 Tel: +65 6745 2936
Fax: +31 10 421 0542 Fax: +65 6745 0467
Email: [email protected] Email: [email protected]
Web site: www.crowcon.com Web site: www.crowcon.com