Watchgas Bat-1 2 3 Breathing Air Quality Test Kit User Manual

USER MANUAL

WatchGas BAT-1, 2, 3
Breathing Air Quality Test Kit
FULL COMPLIANCE WITH BS EN12021

Safety Information

IMPORTANT!
Failure to perform the procedures detailed within this user guide may impair the performance of this equipment. For maximum safety and optimal performance please read and follow the following procedures and conditions. The volume flow and quality of the supplied air should be thoroughly tested at intervals as specified by a competent person after risk assessment.
The WatchGas BAT kit is to be used to test compressed air for; oil mist, water vapor, Carbon Monoxide (CO), Carbon Dioxide (CO2), Oxygen (O2), temperature, humidity,  flow, pressure, and odor in accordance with your local governing body (see section 2). Gases like NOx, H2S, SO2, NH3, PH3 can be detected with optionally available gas detector tubes.
The BAT kit should be checked on the correct flow every 6 months. This can only be performed by a trained and authorized person. How to perform the flow check can be seen in section 10.
Any attempt to repair components or to substitute components can cause an error and possible damage to components.
Only replace consumable items (Gas Detector Tubes + WatchGas PDM O2) with genuine components specified for use as a direct replacement for the BAT kit. The use of different components or attempts to repair components can cause an error and possible damage to components.
The quality of the air supplied to a breathing apparatus should be tested at least every three months and more frequently when the quality of the air supplied cannot be assured.
The regulators and flow restrictors are factory set to deliver the required flow rates specified by the manufacturers. Flow rates can only be adjusted by trained and authorized personnel.
Please use safety glasses when using the BAT-kit, safety glasses are not included.

ADDITIONAL WARNINGS CONCERNING THE USE OF THE WATCH GAS PDM O2:

• Before operating this device, please read the manual carefully.
• If calibration and self-test fail continuously, please do not use the device.
• For the O2 detector, perform calibration every 30 days in a fresh air environment, preferably outside.
• Before use, please check the activation date, and if the activation date is passed, please do not use the device. The PDM O2 has a life span of 2 years from start-up. A  countdown timer shows the remaining life of the PDM O2. At the end of the PDM O2 life, it automatically shuts off. Once the software shutdown is complete, discard the detector and contact WatchGas for a replacement.
• Clean detectors with a soft cloth and do not use chemical substances for cleaning.
• To maintain 24 months lifetime, avoid the below activities except the necessary cases to check events (Max/Min), lifetime/concentration, and alarm setpoints. Otherwise,  the frequent use of the button will deplete the battery life of fewer than 24 months. Do not push the button frequently without valid reasons.
• Normal Alarm Use 1 time and 2 minutes per day
• View the serial number on the label at the backside of the device.
• WARNING: Explosion Hazard – The PDM O2 contains no serviceable parts.
• WARNING: Substitution of components may impair intrinsic safety.
• WARNING: The PDM O2 contains a lithium battery that may leak or explode if the instrument is mistreated. Do not attempt to disassemble or dispose of in fire.
• Never cover or insert foreign objects into the alarm signal opening, the opening must remain clear and free of foreign objects, otherwise, any alerts made during an alarm state may not be heard or identified.

International Standards

Table 1

Technical Specifications

3.1 GAS DETECTOR TUBES

Optional. available on request

Table 2

3.2 MANIFOLD

Table 3

3.3 PRESSURE / FLOW REDUCER

Pressure 25 – 300 bar reducing to 4.5 bar

Table 4

3.4 HYGRO THERMOMETER

Table 5

3.5 FLOW METER

Flow range: 0.2 – 3 PM

Table 6

3.6 PDM O2 DETECTOR (AVAILABLE ON REQUEST)

Table 7

BAT layout

Table 8

Operating Instructions

5.1 PREPARING FOR MEASURING

Warning
First, follow these steps before performing the test in 5.2 or 5.3.
First, it is important to determine the detection limit of the oil type using table 9 below.
Determine sampling time according to the threshold value to be detected using table 10 below.

Table 9: Detection limits

Table 10: Measurement time for evaluated reference value

1. Clean the valve of compressed gas cylinders or charging connections of the compressor with a brief burst of air.
2. Chose and connect the adapter suitable for the prescript maximum pressure of the compressor charging panel (300 or 200 bars). When using the BAT kit on a gas cylinder, you can skip this step.
3. Insert and firmly fit the nozzle of the manifold on the pressure reducer as shown in fig. 5.

5.2 MEASURING ON COMPRESSED GAS CYLINDERS
(for measuring on compressors go to 5.3)

1. Slowly open the cylinder valve.
2. The flow rate of air through each port of manifold can be confirmed if necessary by using the flow meter provided with the kit. (To measure the flow rate connect the tubing of the flow meter to the desired manifold port- Fig. 6)
3. Insert the detector tube holders in the manifold ports- Fig. 7.
4. Flush device for sufficient time to make the test device free from other gases if any.
   When the test device is clean and dry flush for 2 min. is sufficient. If the condition of the device is not known, or if during a previous measurement higher values were found than are permissible according to EN 12021, flushing at 2 l/min. must be continued. This must be done until 2 water vapor measurements, made at an interval of approx. 15 min., give identical results within the permissible measuring accuracy range. It then can be assumed that the test device is sufficiently clean for making measurements.
   Liquid/water (droplets) can only be removed from the test device through long flushing with dry, if necessary warm air. Observe the arrow on the detector tube. The arrow points in the flow direction of the test air; therefore, after inserting the tube, the arrow must point away from the test device.
   Each outlet of the manifold is made for a particular detector tube. The flow has been engraved above each outlet on the blue manifold:

   • CO2	0.3 l/min
   • CO	0.3 l/min
   • H2O	1 l/min
   • Oil	2.5 l/min

   

5. Check the temperature and relative humidity of the breathing with the Hygro-Thermometer. Place the cone in one of the rubber tube holders of a 0.3 outlet. Hold the back of Hygro- Thermometer on the cone for 1.5 minutes. Write down the readings on the Air Analysis Form.
6. Break off the detector tube tips at the air exit side (see fig. 11) Put the detector tube into the correct tube holder, inserting broken-off end tightly into the holder side away from the test device.
7. Break off the other end of the detector tube (air entry side) and immediately insert the open tube tightly into the other end of the detector tube holder (close to test device). (see fig. 12).
8. Immediately thereafter start the timer to the time designated for the type of detector tube.
9. Remove the detector tube of CO, CO2, and H2O after 5 minutes from the tube holder and take the readings from the printed scale on the tube, on the Air Quality Analysis Form, and apply the relevant correction factor according to the manual of each gas detector tube, for temperature and humidity measured with the Hygro-Thermometer.
10. After concluding the sampling time remove the Oil detector tube from the sampling device and bend at the indicated point (between two arrowheads) to break the internal reagent-filled ampoule  (Caution: the ampoule contains concentrated sulfuric acid).
11. Allow the ampoule fluid to flow onto the indicator layer, apply pressure of the breathing air cylinder through regulator & manifold until the indicator layer is covered approx. 10 mm with the ampoule fluid.
12. Wait 1 minute before evaluating the indication. If no color change occurs, the oil content within the pressurized gas sample is below the detection limit of the detector tube and below the evaluated reference value of interest 0.1 mg/m 3, 0.3 mg/m 3, 0.5 mg/m 3 resp. 1.0 mg/m 3 .
13. To dismantle the BAT, close the valve of the breathing air cylinder to remove the pressure, and unscrew the regulator of the cylinder.
    Optional:
    When required to test NOx, O2, SO2, PH3, H2S, or NH3 please contact WatchGas for more information.

www.watchgas.com
5.3 MEASURING ON COMPRESSORS

• Switch on the compressor
• Wait until 200 or 300 bar is reached
• Switch off the compressor
• Slowly open the valve on the compressor
• Perform the test as described in 5.2

The water content that is measured in air from a compressor only corresponds to the water content of compressor gas cylinders simultaneously charged, or cylinders charged immediately after measuring if a pressure retaining valve is built into the compressor at the exit side of the drying cartridges. A prerequisite, however, is that the cylinders to be charged are dry.
The pressure retaining valve assures that the pressure inside the compressor drops only insignificantly from the maximum pressure of 300 or 200 bar when cylinders are being charged. With a  compressor that has no pressure retaining valve behind the filters, water from the drying cartridge can be released to the sudden decompression when the charging connection is opened. The air has then higher water content as was measured on the compressor charging panel.
To dismantle the BAT, turn off the compressor until the point that there is no pressure on the BAT anymore, and unscrew the regulator of the adapter, whereafter you can unscrew the adapter of the compressor. Place the BAT inside the suitcase.

Interpreting Tube Readings

A When the end of the color change layer is flat, Read the value at the end of the layer. In this example, the reading should be 5%. B When the end of the color change layer is slanted. Read the value in the middle of the slant. In this exaggerated example, the reading should be 5%.

C When the demarcation of the color change layer is pale. Read the value in the middle between the dark layer end and the pale layer end. In this exaggerated example, the reading should be 5%.

6.1 OIL MIST TUBES

The reading is obtained directly off the tube in mg/m3.
NOTE: High water vapor levels can affect the accuracy of reading (see note below).
AMBIENT CONDITIONS DURING SAMPLING
The test result applies only to the sampled portion i. e. to the expanded portion of air. In order to validate the oil content of the total air in the compressed air system, variations in place and time resulting from surface adsorption and desorption processes must be taken into account. Such processes strongly depend on temperature. The measurement must be taken from the same system  (machine, compressor tube line, etc.) that will be placed in operation.
Temperature: 10 °C to 30 °C; 50 °F to 86 °F
Humidity: see table 8
Pressure: only for use with de-pressurized air
INTERFERENCES AND CROSS SENSITIVITIES
Vapors of many other organic substances will be indicated too. The sensitivity of indication is different.
OVERALL UNCERTAINTY
Due to the varying chemical composition within compressor oil types and ambient conditions, the indication shall be regarded only to semi-quantitative.
STORAGE AND TRANSPORT
Up to 25 °C (77 °F) and protected from light. Expiration date: see back of the package.
SAFETY ADVICE/DISPOSAL
For tubes contents the following indications of danger apply:
Indication of danger R: 20/21/22-35-37 Safety advice S: 2-24/25-28.1
Tubes must be kept away from unauthorized persons. For disposal of tubes as waste observe the legal regulations applicable in the individual country of use.

6.2 CARBON DIOXIDE TUBES

The reading is obtained directly off the tube in parts per million.
NOTE: High water vapor levels can affect the accuracy of reading (see note below).
AMBIENT CONDITIONS DURING SAMPLING
Detector tubes can be used between 10°C and 30°C (50°F and 86°F) and in the humidity range up to 8 g/m3 (90% RH at 10° C (50° F), 26% RH at 30°C (86°F).
INTERFERENCES AND CROSS SENSITIVITIES
No interference from:
– Hydrogen, Methane, Ethane, Propane, Carbon Monoxide, Mineralic oil (vapor and mist).
OVERALL UNCERTAINTY
Up to ± 15% in the range above 500 ppm.
Up to ± 25% in the range 100 ppm … 500 ppm. (expressed as relative standard deviation).
STORAGE AND TRANSPORT
Up to 25°C (77°F) and protected from light. Expiration date: see back of the package.
SAFETY ADVICE/ DISPOSAL
For tubes contents, the following indications of danger apply R: 20/21/22-34.
Safety advice S: 2-23-24/25-26-28 (water).
Tubes must be kept away from unauthorized persons. For disposal of tubes as waste observe the legal regulations applicable in the individual country of use.

6.3 CARBON MONOXIDE TUBES

The reading is obtained directly off the tube in parts per million.
NOTE: High water vapor levels can affect the accuracy of reading (see note below).
GENERAL INFORMATION AND CAUTIONS

• The white mist appearing at the air outlet of the detector tube during the measurement is caused by the emission of small droplets of sulfuric acid with the airflow. The amount is very slight. Any irritations will not happen.
• Used detector tubes without any color change cannot be used repeatedly.

INFLUENCE OF TEMPERATURE
Detector tubes can be used between 0 °C and 40 °C (32 °F and 104 °F) and up to 90 % rh (46 g/m3at 40 °C [104 °F])
INTERFERENCES AND CROSS SENSITIVITIES
No interference from:
Hydrogen, Methane, Carbon Dioxide, Mineral oil (vapor and mist).
OVERALL UNCERTAINTY
Up to ± 15 % in the range above 15 ppm. Up to ± 25 % in the range 5 ppm … 15 ppm. (expressed as relative standard deviation).
STORAGE AND TRANSPORT
Up to 25 °C (77 °F) and protected from light. Expiration date: see back of the package.
SAFETY ADVICE/DISPOSAL
For tubes contents, the following indications of danger apply R: 20/21/22-35-37-43. Safety advice S: 2–23-24/25-2628 (water).
Tubes must be kept away from unauthorized persons. For disposal of tubes as waste observe the legal regulations applicable in the individual country of use.

6.4 WATER VAPOR TUBES 5-160 MG/M3
Available on request:

• in PPM range
• in a range of 2-200 mg/m3

The reading is obtained directly off the tube in parts per million.
NOTE: High water vapor levels can affect the accuracy of reading (see note below).
GENERAL INFORMATION AND CAUTIONS

• The measurement result applies only to the sampled portion i. e. for the expanded portion of air. In order to validate the water content of the total air in a compressed air system, variations in place and time resulting from surface adsorption and desorption processes must be taken into account. Such processes are strongly dependent on temperature.
• The white mist appearing at the air outlet of the detector tube during the measurement is caused by the emission of small droplets of sulfuric acid with the airflow. The amount is very slight. Any irritations will not happen.
• Used detector tubes without any color change cannot be used repeatedly.

INFLUENCE OF TEMPERATURE

• Detector tubes can be used between 0 °C and 35 °C (32 °F and 95 °F). The calibration scales on the detector tube are exactly valid if tubes have a temperature of 20 °C (68 °F) during measurement. If the detector tube temperature deviates from 20 °C (68 °F), multiply the reading (mg/m3) with the appropriate correction factor (see table 11 below). Normally, the detector tube temperature is equivalent to ambient temperature.

Table 11:

OVERALL UNCERTAINTY
Up to ± 15 % in the range above 50 mg/m3(5 l sample) resp. 20 mg/m3(10 l sample).
Up to ± 25 % in the range 20 mg/m3… 50 mg/m3(5 l sample) resp. 5 mg/m3… 20 mg/m3(10 l sample). (expressed as relative standard deviation).
STORAGE AND TRANSPORT
Up to 25 °C (77 °F) and protected from light. Expiration date: see back of the package.
SAFETY ADVICE/ DISPOSAL
For tubes contents, the following indications of danger apply R: 20/21/22-35-37. Safety advice S: 2–23-24/25-26-28 (water).
Tubes must be kept away from unauthorized persons. For disposal of tubes as waste observe the legal regulations applicable in the individual country of use.

Pressure Dewpoint

To establish pressure dewpoint, take the point where the water tube reading in mg/m3 intersects system pressure and read off pressure dewpoint from the vertical scale
NOTE: Pressure dewpoint is the temperature at which free water is likely to occur at system pressure, therefore this will be the minimum operating temperature of the system.
NOTE: The above graph is for a guide only and can be used to estimate dewpoint from reasonably high water level readings. These dewpoints are normally obtained in systems with little or no drying capability. Refrigeration dryers normally produce dewpoints around +3°C at 7 bar g. For desiccant systems dewpoints of better than -40°C can be obtained and the above graph should not be for calculating water at these low levels <250 mg/m3.

Service & Maintenance

8.1 GENERAL
In view of the significance of the accuracy of measuring results, the test device must be treated with care. Dirt must be avoided at all times, especially at the high-pressure connection. Flushing and cleaning of the test device must be made as described in para. 5.2. After measuring is completed, the test device shell is stored in the suitcase. The high-pressure regulator connection should be closed with the white protective cap. Function checks should be made every month, and if erroneous measurements are suspected. It is advised to do a full-service check and recertify the BAT kit at a  match as factory trained company every 12 months.

8.2 DISORDERS
If the handwheel of the test device cannot be loosened while it is connected to a compressed gas cylinder or compressor, check if the connection is under pressure. In this case, close the cylinder valve or compressor valve and release air from the test device.

• Leaks at the connection to the cylinder or compressor could be due to a defective gasket. In this case, replace the gasket.
• If the high-pressure regulator or the detector tube holder is defective, they must be replaced.
• In case of other disorders, the device should be returned for repair to WatchGas or any authorized service station.

Ordering & After Sales

PROVIDED BY:
WatchGas B.V.
Klaverbaan 121
2908 KD Capelle aan den IJssel
The Netherlands
+31 (0)85 01 87 709
[email protected]
www.watchgas.com

DISTRIBUTED BY:

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WatchGas BAT-1, 2, 3 Breathing Air Quality Test Kit
Full Compliance with BS EN12021
V1.4
10-01-2022