Sensit GOLD G3 User manual

851 Transport Drive • Valparaiso, IN 46383 (USA)

Phone: 219.465.2700 • www.gasleaksensors.com

INSTRUCTION MANUAL

Read and understand instructions before use.

For use with combustible gases and optionally available oxygen and toxic gases.

Intrinsically safe for use in:

Class I Div. 1

Groups C, D

Temp Classification: T4, IP64

Hazardous Locations

⚠ WARNING: To prevent ignition of

flammable or combustible atmosphere,

disconnect power before servicing.

710183

UL913

CONTENTS

SPECIFICATIONS ................................................................ 4

PRODUCT SPECIFICATIONS................................................. 4

HARDWARE AND SOFTWARE FEATURES.............................. 5

COMBUSTIBLE GAS SENSORS ................................................................ 5

ELECTROCHEMICAL SMART SENSORS..................................................... 5

FLEXIBLE WAND AND FLASHLIGHT.......................................................... 5

RECHARGEABLE BATTERY AND CHARGING STATION............................... 6

TWO-SPEED PUMP AND SAMPLING SYSTEM............................................ 6

LED DOME ............................................................................................ 6

WORK DISPLAY OPTIONS .................................................. 7

COMBUSTIBLE GAS SCALE AND RESOLUTION ......................................... 7

H2S RESOLUTION.................................................................................. 7

HCN RESOLUTION ................................................................................ 7

LEL DEFINITION ..................................................................................... 7

NON-STANDARD READINGS .............................................. 8

NSR...................................................................................................... 8

NSC ..................................................................................................... 8

CALIBRATION OPTIONS ..................................................... 8

GAS TYPE ............................................................................................. 8

METHANE CALIBRATION POINT ............................................................. 8

ALARMS ............................................................................ 9

WORK DISPLAY ALARMS ........................................................................ 9

LEAK SEARCH MODE ALARM (IF ENABLED) ............................................. 9

OPERATION AND USE ........................................................ 10

POWER-ON AND STARTUP SEQUENCE................................................... 10

BUMP TESTING AND CALIBRATION......................................................... 10

THE WORK DISPLAY............................................................................... 10

FILTER INTEGRITY AND FLOW BLOCK CHECK........................................... 11

READY FOR USE .................................................................................... 11

POWER OFF & BATTERY CHARGING ................................... 12

POWER OFF.......................................................................................... 12

BATTERY CHARGING ............................................................................. 12

CALIBRATION/BUMP TESTING............................................ 13

SMART-CAL ........................................................................................... 13

AUTOCAL .......................................................................... 14

MANUAL CALIBRATION...................................................... 15

MANUAL CALIBRATION: METHANE LEL 2.5 %VOL.................................... 15

CONTENTS

MANUAL CALIBRATION: CARBON MONOXIDE (CO) 100 PPM ................ 15

MANUAL CALIBRATION: HYDROGEN CYANIDE (HCN) 10 PPM ................ 16

MANUAL CALIBRATION: HYDROGEN SULFIDE (H2S) 25 PPM.................... 16

MANUAL CALIBRATION: METHANE TC 100 %VOL................................... 17

QUICK MENU TEST MODES................................................. 18

TICK ..................................................................................................... 18

BAR HOLE TEST...................................................................................... 19

CO TEST ............................................................................................... 20

PURGE TEST........................................................................................... 21

LEAK SEARCH MODE............................................................................. 22

STANDBY MODE ................................................................................... 23

PEAK MODE.......................................................................................... 23

INERT MODE......................................................................................... 24

USER MENU....................................................................... 25

SET TIME............................................................................................... 25

SET DATE .............................................................................................. 26

TIME ZONE........................................................................................... 27

GPS...................................................................................................... 27

BUMP TEST............................................................................................ 28

SMART SENSOR .................................................................................... 29

CALIBRATION........................................................................................ 29

CAL LOG .............................................................................................. 29

O2 TEST................................................................................................ 30

LED BRIGHTNESS................................................................................... 30

BAR HOLE LOG ..................................................................................... 31

CO LOG ............................................................................................... 31

SMART-LINK .......................................................................................... 32

NEXT DUE............................................................................................. 32

BARHOLE PURGE THRESHOLD ................................................................ 33

CO PURGE THRESHOLD ......................................................................... 33

NOTES............................................................................... 34

EU WASTE ........................................................................ 35

WARRANTY....................................................................... 36

SPECIFICATIONS

TYPE TECHNOLOGY RESOLUTION RANGE ACCURACY

LEL Semiconductor Variable: 0.1 % -

2.0% Increments

0-100% LEL ±10% or 1%LEL*

PPM Semiconductor 1ppm or 10ppm 0 - 50,000ppm ±10% or 500ppm*

%Gas Thermal Conductivity 0.1 % 5-100% Methane,

2.2-100% Propane

±5%

O2 Electrochemical 0.1 % 0-25% ±0.2% or 10%*

CO Electrochemical 1ppm 0-2,000ppm ±5ppm or 5%*

H2S Electrochemical 1ppm or 0.1ppm 0-100ppm ±2ppm or 5%*

HCN Electrochemical 1ppm or 0.1ppm 0-30ppm ±1ppm or 5%*

SO2 Electrochemical 0.1ppm 0-20ppm ±1ppm or 10% *

*whichever is greater

PRODUCT SPECIFICATIONS

SIZE L-13 x W-3 x D-3.2 in (330 x 76 x 81mm)

WEIGHT 2.3Ibs (1.0kg)

OPERATIONAL TEMP -4 to 122° F (-20 to 50° C)

STORAGE TEMP -4 to l 40°F (-20 to 60° C)

BATTERY LIFE >12hrs Continuous with Rechargeable

RECHARGE TIME/TEMP 5hrs Max/ 32°F to 104°F (0°C to 40°C)

INGRESS PROTECTION IP64

DISPLAY 2. 7” TFT LCD

HARDWARE AND SOFTWARE FEATURES

The SENSIT GOLD G3 has many different available features and custom settings, so that the instrument

can be configured to meet all customer requirements. A “setup sheet” is created at the time of order

that contains all settings that you choose, so that any additional instruments ordered in the future will

be setup the exact same way.

Many of these settings are in the “Expert Menu” and can be adjusted over the phone as well, if the

customers’ requirements change. See the Expert Menu section for a list of settings in the order they

appear in the menu. This section covers both the Expert Menu and settings that are in the Factory Menu

(generally only accessed by SENSIT) and are broken down into categories.

COMBUSTIBLE GAS SENSORS

All SENSIT GOLD G3 instruments incorporate a highly sensitive and uniquely designed metal oxide

semiconductor sensor. The function and accuracy of the sensor are monitored and controlled by

specialized circuitry and a microprocessor. The sensor is capable of measuring concentrations as low

as 1PPM methane, up to 100%LEL (5.0%VOL).

There is additional optional combustible gas sensor called the TC sensor that increases the capability

of the instrument to measure above 100%LEL, up to 100%VOL. This proprietary state-of-the-art thermal

conductivity sensor can measure high concentrations of gas quickly and accurately.

All gas readings are automatically switched between scales of PPM , %LEL, and %VOL (if enabled)

without requiring input from the operator.

ELECTROCHEMICAL SMART SENSORS

All other sensors in the SENSIT GOLD G3, if equipped, are “electrochemical” type sensors. Options

for these sensors are:

• Oxygen (O2), detectable range from 0-25% with a 0.1% resolution.

• Carbon Monoxide (CO), detectable range from 0-2,000ppm with a 1ppm resolution.

• Hydrogen sulfide (H2S), detectable range from 0-100ppm with either a 1ppm (default) or

0.1ppm resolution.

• Hydrogen cyanide (HCN), detectable range from 0-30ppm with a 0.1ppm resolution.

The maximum number of available “slots” for these sensors is 3. However, detection capability for all

4 is available (making the instrument a 5-gas detector), in which case the CO and H2S sensors will

be a combination sensor.

FLEXIBLE WAND AND FLASHLIGHT

The combustible gas sensor for the LEL range and Tick is installed at the end of the flexible wand

or “gooseneck”. This allows for extremely fast, near instantaneous reaction to gas, because there is

essentially no travel time for the gas sample. As soon as it is drawn in by the pump, the first thing it

hits is the sensor.

In addition, the wand in the SENSIT GOLD G3 is now equipped with a flashlight, made up of

individual LEDs installed on the sensor circuit board. This flashlight feature can be enabled or disabled

whenever the operator desires.

RECHARGEABLE BATTERY AND CHARGING STATION

The SENSIT GOLD G3 comes standard with a rechargeable battery pack. This battery pack is installed

in the handle of the instrument and secured with a captured Philips head screw. The battery pack can

be charged while installed in the instrument, or when removed, with the included charging station/

dock. This charging station can be semi-permanently mounted to a table or wall, in a vehicle, or just left

free standing without being secured. The station has a series of LEDs that indicate the charging status.

TWO-SPEED PUMP AND SAMPLING SYSTEM

All SENSIT GOLD G3 instruments are equipped with a powerful and efficient pump that has two

speeds, depending on what mode of operation the instrument is in. While in BARHOLE or LEAK

SEARCH mode, the pump runs in the “high” speed (0.4 – 0.5 L/MIN), to make leak investigation

quicker and more efficient. When in the work display or any other test mode, the pump runs in the

“low” speed (0.3 L/min) to conserve power.

A hydrophobic dirt and water filter at the end of the gooseneck (sensor cap) protects the pump and

internals of the instrument from foreign material. There is an additional internal micron filter that also

helps to protect the pump from damaging debris. If the sampling system is compromised, a flow

blocked message will be displayed.

⚠ WARNING: Operating the SENSIT GOLD G3 without a sensor cap or damaged/

altered sensor cap can cause damage to the instrument and void the warranty.

LED DOME

The LED dome on the SENSIT GOLD G3 displays different colors and patterns to alert the operator of

various conditions. See the chart below for information on each.

COLOR INDICATION

Solid Green “Ready” indication. No current alarm condition

or failure.

Blinking Green 1. Low battery indication. The work display will

also give an indication on screen to alert the

operator.

2. Conned space mode. By default, the LEDs

will blink off every 30 seconds (adjustable).

Solid Amber / Yellow “LOW” or “HIGH” alarm condition (depending

on configuration) for combustible gas. The

default setpoint for this is 5.0%LEL.

Solid Red “HAZ 1 & 2” conditions for combustible gas.

Both will also be indicated on the work display.

“HAZ1” is triggered at ≥10%LEL

“HAZ2” is triggered at ≥25%LEL

Blinking Red 1. Any alarm conditions. How fast the LEDs blink

is determined by the alarm level (low, high, or

high-high). For combustibles, this is a “HAZ

3” alarm.

2. Sensor failure.

3. Flowblocked

WORK DISPLAY OPTIONS

COMBUSTIBLE GAS SCALE AND RESOLUTION

The combustible gas reading will be automatically displayed in one of three scales on the SENSIT

GOLD G3: PPM, %LEL, and/or %VOL. By default, the reading starts in the %LEL scale (from 0.0%LEL)

and will automatically switch to %VOL at ≥100%LEL (equal to 5.0%VOL by default, see the section on

LEL Definition), if equipped with a TC sensor.

If the %LEL option is disabled, the G3 will display in %VOL through the entire scale (either up to 5%VOL

if the TC sensor is not equipped, or up to 100%VOL if equipped).

If the PPM option is enabled, the G3 will instead start at 0ppm, and automatically scale to either %LEL

(if enabled) or %VOL at the specified upper limit. By default, this is 2,000ppm. Other options are

5,000ppm, 10,000ppm, or 50,000ppm. If set to 50,000ppm, the G3 will not scale to %LEL even if it

is enabled, because at the highest LEL Definition, 50,000ppm is equal to 100%LEL.

In addition, the display resolution for the PPM and %LEL scales are customizable. The default display

resolutions and options for each scale, while on the work display, are listed below.

DEFAULT RESOLUTION

PPM Disabled 1ppm or 10ppm

%LEL 0.1%LEL 0.1% - 2.0%LEL

[0.1% increments]

%VOL (FOR TC UNITS) <5.0%VOL: 0.01%VOL

≥5.0%VOL: 0.1%VOL

Not adjustable

%VOL (FOR NON-TC UNITS) Disabled

H2S RESOLUTION

If the SENSIT GOLD G3 is equipped with a hydrogen sulfide (H2S) sensor, it will have a resolution of

1ppm by default (0-100PPM range). There is an optional Expert Menu adjustment for this to increase

the resolution to 0.1ppm.

HCN RESOLUTION

If the SENSIT GOLD G3 is equipped with a hydrogen cyanide (HCN) sensor, it will have a resolution of

0.1ppm by default (0-30ppm range). There is an optional Expert Menu adjustment for this to decrease

the resolution to 1ppm.

LEL DEFINITION

By default, the SENSIT GOLD G3 defines the lower explosive limit (LEL) as 5.0%VOL methane and

2.2%VOL propane. This is factory adjustable between 4.0% and 5.0% for methane and 1.8% and

2.2% for propane, in 0.1% increments,

based on company or industry

requirements. This will affect how the

instrument displays the %LEL scale.

For example, if the LEL definition is

4.0%VOL, 2.5%VOL methane will

display as 62.5%LEL. Reference the

methane/natural gas chart below.

NON-STANDARD READINGS

When equipped with the optional TC sensor, the SENSIT GOLD G3 has two “non-standard” readings

available: NSR (non-standard response) and NSC (non-standard combustible). These can be triggered

on the work display, leak search or in barhole mode.

NSR

NSR stands for “non-standard response”. In the case of NSR, the gas is likely not combustible. If the

G3 gas type is set for natural gas (methane), NSR likely indicates a gas that is heavier than air such

as carbon dioxide, and if the gas type is set for propane, NSR likely indicates a gas that is lighter than

air such as helium.

NSC

NSC stands for “non-standard combustible”. In the case of NSC, the gas is likely combustible. If the G3

gas type is set for natural gas (methane), NSC likely indicates a combustible gas heavier than air such

as propane, butane, gasoline vapors, etc. If the G3 gas type is set for propane, NSC likely indicates a

combustible gas lighter than air such as natural gas, naturally occurring methane, or hydrogen.

CALIBRATION OPTIONS

GAS TYPE

The SENSIT GOLD G3 supports two different combustible gas types: natural gas (methane) and

propane. The combustible gas reading will show which is currently set. This can be adjusted in the

User Menu (Gas Type). The GAS TYPE setting only affects what calibration is applied,how the display

reading is shown and how NSR/NSC are handled. It does not limit what gasses the 2611 (LEL) sensor

will respond to.

NOTE: Currently only natural gas (methane) is available as a GAS TYPE option.

METHANE CALIBRATION POINT

The default calibration point for methane is 2.5%VOL. This setting can also be set to 2.2%VOL.

ALARMS

The SENSIT GOLD G3 has audible and visual alarms to warn the operator when hazardous conditions

are being sensed. There are alarm setpoints specific to the work display, leak search mode, and

confined space mode. The LED dome on the G3 changes color based on alarm conditions. See the

following sections for information on each.

WORK DISPLAY ALARMS

WORK DISPLAY ALARM

SETPOINTS

DEFAULT

LEL 50.0%LEL

PPM 0PPM

CO 35PPM

O2 - DEPLETION 19.5%VOL

O2 - ENRICHMENT 23.5%VOL

H2S 10.0PPM

HCN 4.7PPM

SO2 2.0PPM

NO2 3.0PPM

UEL SETPOINTS DEFAULT

NAT 17.0%VOL

PRO 12.0%VOL

LEAK SEARCH MODE ALARM (IF ENABLED)

The LEL alarm, and UEL set points, outlined above in the work display section are active while in leak

search mode. There is also an additional alarm specific to leak search mode. By default, this alarm is

set to 50 PPM (unless otherwise noted on the setup sheet).

OPERATION AND USE

⚠CAUTION: Always start/zero any SENSIT GOLD G3 in a gas free environment.

NOTE: Fully read and understand this section of the instruction manual before using your SENSIT

GOLD G3.

This section of the manual outlines the operation and use of the SENSIT GOLD G3 by general

categories. Due to the many custom options available, and many different applications the instrument

can be used in, there is not one comprehensive sequential set of instructions for using the instrument. For

a quick list of instructions to get up and running, see the Quick Start Guide in the Safety Manual. Use

this Operation and Use section for more detailed instructions and use the sections that cover the Quick

Menu and User Menu for more specific instructions for each test mode and menu.

POWER-ON AND STARTUP SEQUENCE

Before powering on the SENSIT GOLD G3, ensure that you are in a gas free environment, and that

you have a charged battery pack installed and secured with the retaining screw.

Press and hold the Abutton until the SENSIT logo appears on the display and the LED dome

illuminates. There are many custom settings available in the G3 that may change what appears during

the startup process.

The instrument will not be ready to use until it reaches the work display, and both a successful autozero

and flow block check have been performed. The startup process will take less than 45 seconds , but

can take up to a maximum of 5 minutes depending on the outputs of the sensors.

BUMP TESTING AND CALIBRATION

To verify the accuracy of any SENSIT GOLD G3, it must be exposed to a known concentration of test

gas that will test the sensor combination included in your model. This is known as “bump testing”. This

can be done either by exposing the instrument to gas from the work display or using the bump test

feature which specifically tests each sensor and gives a pass or fail message. For more information, see

the Bump Test section in this manual.

A bump test should not be substituted for a calibration and does not update the calibration due date.

Full calibration is required to reset the calibration due dates for each individual sensor.

A calibration past due message will be displayed during startup if calibration has not been performed

per your company specified interval. Any time it is suspected that the SENSIT GOLD G3 is not working

properly, check calibration.

THE WORK DISPLAY

After the startup process, the work display will be shown. This is the main working screen of the

instrument, and what will be used most of the time when detecting gas. The live readings are shown on

screen simultaneously for all sensors installed in the instrument.

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